RIT SENIOR DESIGN PROJECT – P10711WEGMAN’S MEAT TUMBLER PROCESS IMPROVEMENT

Eric Albanese – Project Manager, Industrial EngineerTheresa Ambrose – Mechanical EngineerOkechikere Ekeada – Industrial EngineerJeremy Gray – Industrial EngineerJesse Wykstra – Mechanical Engineer

PROJECT PURPOSE

The aim of this project is to improve the meat marinade tumbler transport in the Wegman’s Culinary Innovation Center. Our primary goals were to: Fix ergonomic issues Address safety concerns Reorganize layout Reduce waste

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Customer RequirementsCustomer

Importance

Total Risk Rating (Wegman’s Ergo

Analysis)Square Feet

of open space Less back pain when loading multivac 9 X  

Less shoulder pain when loading multivac 9 X  

Easier to grab meat when table almost empty 9 X  

Less back/shoulder pain when pushing tables 9 X  

Less shoulder pain when scooping bulk foods 6 X  

Easier to push vmag vats 9 X  

Better/less stressful cleaning methods for carts 9 X  Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat 9 X  

Easier method to load carts into elevator 3 X  

More room to push carts around 3   X

Better place to put used carts 3   X

Investigate necessity of long conveyor 3   X

TRANSLATING NEEDS TO METRICS

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PROJECT METRICS AND GOALSCustomer Requirements

What we're

measuring

Customer Importanc

eCurrent Values

Marginal Values Ideal Values

Solved by Proposal #

Ergonomics Primary Risk Risk Rating Current

Risk Rating Target

Risk Rating Ideal

Less back pain when loading multivac Dumptable 9 Very High 72 24 1 3Less shoulder, wrist, and elbow pain when loading multivac Dumptable 9 Very High 72 24 1 3

Easier to grab meat when table almost empty Dumptable 9 Very High 72 24 1 3

Less shoulder and wrist/elbow pain when scooping bulk foods Dumptable 6 Very High 72 24 1 3

Less back/shoulder pain when pushing tables Dumptable 9 High 36 24 1 3

Better/less stressful cleaning methods for carts Dumptable 9 Very High 8 24 1 3

Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat

Column Dumper 9 Very High 26 24 1 4

Easier to push vemag vats Vemag 9 High 3 24 1 5Easier method to load carts into elevator Vemag 3 Low 3 24 1 5

Simplification Space Used Space Used Target

Space Used Ideal

More room to push carts around Space taken by carts/vats 3 301 ft^2 150 0 1

Better place to put used carts Space taken by carts/vats 3 301 ft^2 150 0 1

Better utilization of conveyor space Space taken by conveyor 3 546 ft^2 273 0 2

PROJECT 1 - KAIZENGoals• Reduce # of VEMAG vat usage on the floor.• Reduce dumptable inventory in front of

Multivac station.

Problems addressed• Excessive # of VEMAG vats• Too much full dumptable inventory

Used lean implementation tool, Kaizen to identify and eliminate waste.

Used process signals to establish a pull system.

KAIZEN RESULTS

Reduced amount of space taken up by vemag vats From 85 ft2 to 56 ft2

Reduced amount of space taken up by dump tables. From 190 ft2 to 82 ft2

Established a pull system by implementing process limits between stations, reducing inventory.

PROJECT 2 – MEAT CONVEYOR Goal of the project is reduce the space

taken up the meat flattening progress

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With the possibility of other tumbler process being moved into this room (estimated at least additional 32 sqft), better space utilization is a necessity

• Wegman’s had smaller conveyor in Brockport, NY facility that was transported to the CIC

• New conveyor is 18’ long, old one was 26’ long• Worked to optimize the space use of the new machine

• Reworked layout to minimize amount of ‘dead space’.• Completed ergonomic study to ensure safety

CONVEYOR – RESULTS Process converted

successfully to smaller sized conveyor

Space taken reduced Production capacity

determined to

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Customer Requirements What we're measuring Previous Value Marginal

Value Ideal Values Actual Value

Simplification Space Used Space Used Target

Space Used Ideal

Better utilization of conveyor space Space taken by conveyor 546 ft^2 273 ft^2 0 ft^2 270 ft^2

PROJECT 3 - DUMP TABLE

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Project Goals:• Reduce the amount of

bending/twisting required to unload the dump table at the multivac station.

• Improve the overall maneuverability of

the dump tables.• Simplify the dump table

cleaning process. Results: A spring loaded UHMW plastic insert greatly reduced the

amount of bending/twisting that the employees have to perform while unloading the dump table at the multivac station.

The maneuverability of the dump table will be improved by adding a new caster design.

The cleaning process will be improved by adding a removable drain bucket.

SPRING-LOADED DUMP TABLE PROTOTYPE

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Item #

Description

Qty

1 Caster 42 Cart 1

3 Fixed Post 4

4 Slider Post 4

5 Spring 46 Grate 17 Drain Bucket 1

Item Description Price

1 .115” Stainless Compression

Spring

$299

2 .120” Stainless Compression

Spring

$299

3 0.75” OD Stainless Tubing

$107

4 1.25” OD Stainless Tubing

$372

5 0.25” OD Stainless Rod

$0.80

6 Stainless Sheet Metal

$29

7 Perforated Stainless Sheet

Metal

$60

8 1” OD Stainless Ball

$61

9 6” OD Stainless Swivel Casters

$480Total Cost: ~$1,708

DUMP TABLE RESULTS

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The spring-loaded grate mechanism was completed in the RIT machine shop.

The removable drain bucket will have to be completed by Wegmans.

The new casters will also have to be installed by Wegmans.

All of the new dump table features will have to be tested.

These new features will improve the ergonomics involved with unloading, transporting, and cleaning the dump table.

PROJECT 4 – COLUMN DUMPER

Goals Make column dumper require less force to

move Reduce the number of workers required to

load column dumper with VEMAG Vat and secure it

Problems addressed Ergonomic concerns workers have

(complaints of a stressed and strained body after a busy day)

Reduce waste involved with using two workers to properly secure VEMAG Vats

COLUMN DUMPER – SUGGESTED MODSSecondary Securing Mechanism: Upside – out of the

way Downside – install on

every vat Carabiner

Test the purchased casters Force Gauge Worker survey

Purchase suggested casters

Modify Column Dumper for 6” casters

PROJECT 5 – VEMAG VATS 3 Injuries:

Shoulder pain while working in the tumbling area

“A shooting pain” in hamstring from pushing a small empty vat out of the way

While pushing a full vat into the power lifter, shooting pain in shoulder

Loading into dumper: Very large push required for

vat to “click” securely in place

VEMAG HANDLE

VEMAG RESULTS Vat handle was constructed and attached

successfully Used round stainless steel tubing for easier

bending and welding 1/8” thick, 1” OD, same lengths

Ergonomic risk rating was reduced from 3 to 1 Still not a large risk, but the injuries related to

bending are going to practically disappear Initial feedback from team members and

machine shop staff is very positive Waiting on feedback from floor employees

RESULTS OF ALL PROJECTSCustomer Requirements

What we're

measuringCurrent Values

Marginal Values

Actual Values

Met Goals

Ergonomics Primary Risk Risk Rating Current

Risk Rating Target

Risk Rating Actual Yes/No

Less back pain when loading multivac Dumptable Very High 72 24 1 Expected

Less shoulder, wrist, and elbow pain when loading multivac Dumptable Very High 72 24 1 Expected

Easier to grab meat when table almost empty Dumptable Very High 72 24 1 Expected

Less shoulder and wrist/elbow pain when scooping bulk foods Dumptable Very High 72 24 1 Expected

Less back/shoulder pain when pushing tables Dumptable High 36 24 1 Expected

Better/less stressful cleaning methods for carts Dumptable Very High 8 24 1 Expected

Easier to maneuver Column Dumper/ One worker to secure VEMAG Vat

Column Dumper Very High 26 24 N/A NO

Easier to push vemag vats Vemag High 3 24 1 YesEasier method to load carts into elevator Vemag Low 3 24 1 Yes

Simplification Space Used Space Used Target

Space Used Ideal

More room to push carts around Space taken by carts/vats 301 ft^2 150 0 Yes

Better place to put used carts Space taken by carts/vats 301 ft^2 150 0 Yes

Better utilization of conveyor space Space taken by conveyor 546 ft^2 273 270 Yes

PROJECT WRAP-UP

SUCCESSES: ISSUES:

Issues with parts tracking and ordering

Discovered some overlap with existing Wegmans projects and had to modify plans

Could have used more test time with prototypes

Email communication could be better

Miscommunications between involved parties

Process inventory controlled and reduced

Opportunities for other process additions to marinade room

Discovered and reinforced existing issues

Carried designs from concept to completion

Created working prototypes for mass production

Got experience working as consultants in a multidisciplinary team

MOVING FORWARDSuggestions for Future MSD Projects: Collaborate with other MSD groups for parts

ordering/receiving Have large formal introduction meeting at

start where we meet everyone involved (management, parts ordering, operations, etc)

Less time should be spent on deliverables in MSD1 and more time spent on ordering, building, testing in MSD2

Keep standing meeting every week and cancel as needed

QUESTIONS?

THANK YOU!