3/9/10. Found 4 specific areas of concern: Ergonomics / Safety (Machine) Efficiency / Cost (Process) Information (People) Simplification (People)

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Thomasina Sherman
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Eric Albanese Project Manager, Industrial Engineer Theresa Ambrose Mechanical Engineer Okechikere Ekeada Industrial Engineer Jeremy Gray Industrial Engineer Jesse Wykstra Mechanical Engineer The aim

1 Eric Albanese Project Manager, Industrial Engineer Theresa Ambrose Mechanical Engineer Okechikere Ekeada Industrial Engineer Jeremy Gray Industrial Engineer Jesse Wykstra Mechanical Engineer The aim of this project is to improve the meat marinade tumbler transport in the Wegman s Culinary Innovation Center. Currently, meat is marinated in 2000 lb. capacity tumblers, dumped into lb capacity vats, and then transferred into a vacuum pack machine. The current process suffers from many efficiency and ergonomic issues. The overall outcome of the project is to identify and implement process improvements in order to increase efficiency and safety of the workers. 2 1

2 3 Found 4 specific areas of concern: Ergonomics / Safety (Machine) Efficiency / Cost (Process) Information (People) Simplification (People) 4 2

3 Total Risk Rating Customer (Wegman s Importantance Ergo Analysis) (Maximum) Pounds per labor hour Percentage of workers knowing daily production schedule Square Feet of open space Customer Requirements 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 Less strain when moving washing hose 9 X Easier to push vmag vats 9 X Better/less stressful cleaning methods for carts 9 X Better way to push tumbler loader- vmag vat elevators 9 X Easier method to load carts into elevator 3 X Consistent wokery scoop sizes (some heavier than others) 3 X More reliable turkey dumping system 1 X More room to push carts around 3 X Less clutter in the marinade room 3 X Better place to put used carts (less clutter) 3 X Investigate necessity of long conveyor 3 X Contingency plans for cutting beef 1 X More visible and simple picklist with communication 3 X Clearer communication on daily production 3 X Eliminate excess species changeovers 3 X System that encourage workers to follow picklist 1 X Less Labor required to load products into multivac 9 X Less labor to wipe down drippings on multivac 9 X Clean vacuum seals on multivac 1 X 5 Projects Included: Kaizen of Marinade Room Conveyor Replacement Dump Table Proposal Column Dumper Proposal Vemag Retrofit Proposal 3

More room to push carts around Less clutter in the marinade room Better place to put used carts Investigate necessity of long conveyor 7 Simplification Customer Weight Interactions Weighted

4 More room to push carts around Less clutter in the marinade room Better place to put used carts Investigate necessity of long conveyor 7 Simplification Customer Weight Interactions Weighted Importance Space Used Open Space Target Solutions More room to push carts around Better place to put used carts (less clutter) Space taken by carts ft ft 2 Space taken by carts ft 2 Kaizen Project slide 9 Less clutter in the marinade room Investigate necessity of long conveyor Space taken by other clutter ft 2 80 ft 2 Space taken by conveyor ft 2 0 ft 2 Conveyor Project slide 15 Extra Clutter Shelves, Excess Garbage Cans, Tumbler Vats, Elevator, Dump tables Number of Dump tables 14 total Number of Vmag Carts 24 total 8 4

5 Project 1 - KAIZEN # of vemag vats(24) # of dumptables in queue(14) 5

6 KAIZEN - SCHEDULE KAIZEN RETURN ON INVESTMENT Cost data removed per Wegmans request 6

KAIZEN - IMPLEMENTATION PLAN Discuss changes with workers before event Start Kaizen at the Start of the shift Start with 7 less vemag vats and observe what happens

7 KAIZEN - IMPLEMENTATION PLAN Discuss changes with workers before event Start Kaizen at the Start of the shift Start with 7 less vemag vats and observe what happens Create a visual signal for dumptables Monitor progress and get feedback throughout day Follow up in upcoming days to check sustainability KAIZEN - RISK ASSESSMENT 7

8 More room for other operations in room Simplification Customer Weight Weighted Importance Space Used Space Lost Space Used Marginal Space Used Target Ideal Target Better utilization of conveyor space Space taken by conveyor ft^2 110 ft^2 0 With the possibility of other tumbler process being moved into this room (estimated at least additional 32 sqft), better space utilization is a necessity 15 Remove conveyor and replace with tables Have yet to see actual conveyor in use, mostly used as tables in process Employees say that sometimes up to a dozen people use, however labor is tight and not the ideal process Modify workstations to be allowed to fold down Could be very difficult because the length of the workstation is longer than the height off the ground, would need to make additional hinges Make workstations easily removable/attachable Held on by just 4 bolts, can use a pin system Remove some/all of workstations Better position conveyor to free up more space in center of room 16 8

Idea Name Free Space Gained (ft) More Open Center Area (ft) Cost Difficulty to Implement Work to Maintain Idea Name 1 Remove Conveyor, Replace w/ Movable Table 208 FT 75 FT Low TBD Low Remove

High High Low Modify Conveyor, 2x Foldable Workstations 4 Modify Conveyor, 1x Foldable Workstation, Remove 1x Workstation 66 FT 75 FT Med High Low Modify Conveyor, 1x Foldable Workstation, Remove 1x

9 Idea Name Free Space Gained (ft) More Open Center Area (ft) Cost Difficulty to Implement Work to Maintain Idea Name 1 Remove Conveyor, Replace w/ Movable Table 208 FT 75 FT Low TBD Low Remove Conveyor, Replace w/ Foldable Table 2 Remove Conveyor, Replace w/ Solid Table 125FT 75 FT Low TBD Low Remove Conveyor, Replace w/ Solid Table 3 Modify Conveyor, 2x Foldable Workstations 66 FT 0 FT High High Low Modify Conveyor, 2x Foldable Workstations 4 Modify Conveyor, 1x Foldable Workstation, Remove 1x Workstation 66 FT 75 FT Med High Low Modify Conveyor, 1x Foldable Workstation, Remove 1x Workstation 5 Modify Conveyor, Remove 1x Workstation 33 FT 75 FT Low Low Low Modify Conveyor, Remove 1x Workstation 6 Modify Conveyor, 2x Attachable Workstation 66 FT 0 FT Low Med Med Modify Conveyor, 2x Attachable Workstation 7 Modify Conveyor, 1x Attachable Workstation, Remove 1x Workstation 66 FT 75 FT Low Med Med Modify Conveyor, 1x Attachable Workstation, Remove 1x Workstation

10 Cost data removed per Wegmans request 19 Testing Plan Be in attendance during first uses of setup Work beforehand to set up area and perform test run to work out any issues Discuss further ideas for improvement with employees 5S Working area to reduce excess materials Risks Flattened Chicken process needs conveyor Choose alternative that keeps conveyor in room or redesign process Employees don t understand purpose of change Work with to accommodate concerns and explain future space concerns 10

11 Less back/shoulder pain when loading multivac Easier to grab meat when dump table almost empty Less back/shoulder pain when pushing dump tables Less back/shoulder pain when pushing Vmag Vats Less shoulder pain when scooping bulk foods Less strain when moving washing hose Better/less stressful cleaning methods for carts Better way to push vmag -loader vat elevators Easier method to load vmag carts into elevator Consistent wokery scoop sizes (some heavier than others) More reliable dumping system from tumblers

12 Ergonomics Customer Weight Weighted Interactions Importance Less back pain when loading Multivac multivac Load Less shoulder pain when Multivac loading multivac Load Easier to grab meat when Multivac table almost empty Load Less shoulder pain when Multivac scooping bulk foods Load Consistent wokery scoop sizes Multivac (some heavier than others) Load Less back/shoulder pain Dumptable when pushing tables Push More reliable turkey dumping system Better way to push tumbler loader- vmag vat elevators Better/less stressful cleaning methods for carts Dumptable Push Primary Risk Risk Rating Current Risk Rating - Target Very High High Elevator Push Very High Dumptable Clean Very High 8 24 Easier to push vmag vats Vmag Push High 3 24 Easier method to load carts Vmag Push into elevator Load Low 3 24 Solutions Dump Tables, slide 24 Dump Tables, slide 24 Column Dumper, slide 31 Dump Tables, slide 24 VMAG Vats, slide Customer Needs Customer Importance Primary Risk Risk Rating Current Risk Rating - Target Less back pain when loading multivac Multivac Load 9 Less shoulder pain when loading multivac Multivac Load 9 Very High Easier to grab meat when table almost empty Multivac Load 9 Less shoulder pain when scooping bulk foods Multivac Load 6 Less back/shoulder pain when pushing tables Dumptable Push 9 High Better/less stressful cleaning methods for carts Dumptable Clean 9 Very High

Drain Design: Removable Bucket Fixed Drain Criteria Importance Weighted Weighted Materials Cost 4 3 12 4 16 Ergonomics Improvement Ease of Implementation 5 5 25

8 4 16 Ergonomics 5 5 25 1 5 Improvement Ease of 3 4 12 3 9 Implementation Durability 4 3 12 4 16 Aesthetics 1 3 3 3 3 60 49 Handle Design: One End Both Ends

Implementation Durability 4 3 12 3 12 3 12 Aesthetics 1 3 3 3 3 3 3 53 56 49 Bottom Design: Flat Wheel Design: Four Swivel Wheels Weighted Criteria Importance

16 Aesthetics 1 4 4 4 4 49 61 Two Swivel Wheels Weighted Materials Cost 4 3 12 4 16 Ergonomics 5 4 20 1 5 Improvement Ease of 3 3 9 3 9 Implementation

13 Drain Design: Removable Bucket Fixed Drain Criteria Importance Weighted Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics Grate Design: Spring Loaded Fixed Gate Criteria Importance Weighted Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics Handle Design: One End Both Ends All 4 Sides Criteria Importance Weighted Weighted Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics Bottom Design: Flat Wheel Design: Four Swivel Wheels Weighted Criteria Importance Angled Criteria Importance Weighted Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics Two Swivel Wheels Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics Drain Bucket: Item # Description Qty 1 Caster 4 2 Cart 1 3 Fixed Post 4 4 Slider Post 4 5 Spring 4 6 Grate 1 7 Drain Bucket

Customer Needs Customer Importance Primary Risk Risk Rating Current Risk Rating - Target Less back pain when loading multivac Multivac Load 9 Less shoulder pain when loading multivac Multivac Load 9

14 Customer Needs Customer Importance Primary Risk Risk Rating Current Risk Rating - Target Less back pain when loading multivac Multivac Load 9 Less shoulder pain when loading multivac Multivac Load 9 Very High Moderate Easier to grab meat when table almost empty Multivac Load 9 Less shoulder pain when scooping bulk foods Multivac Load 6 Less back/shoulder pain when pushing tables Dumptable Push 9 High Low Better/less stressful cleaning methods for carts Dumptable Clean 9 Very High Low Cost data removed per Wegmans request 28 14

15 Test Plan: Implement/test spring mechanism on existing dump table before making an entirely new dump table. Perform trial run to make sure the springs react the way they were calculated to. A prototype could be created from standard steel to minimize the material costs. (roughly half the price of stainless steel) Install new casters and measure the updated force required to push the dump table. (compare against previous measured values) Install drain bucket, receive feed back from workers about whether or not it improved the ergonomics during the cleaning process. 29 Risks: Materials/spring may not be received from supplier in time to test out the dump table concept. Springs could jam and cause the grate to stop raising while unloading meat from the dump table. Springs may not be the correct stiffness, which would result in the meat not collecting near the unloading end of the dump table. New casters may not show a significant ergonomic improvement. Drain bucket may not show a significant ergonomic improvement during the cleaning process

16 Ergonomics Better way to push tumbler loader- vmag vat elevators Easier method to load carts into elevator Customer Weight Primary Risk Risk Rating Current Risk Rating - Target Elevator Push 9 Very High Vmag Push Load 3 Low 3 24 Four Swivel Casters Conveyance Gripping Vemag Vat Clip Ball Casters Motorized Wheels Grip Tape Handle Latch Chain Hook Criteria Importance Weighted Weighted Weighted Weighted Weighted Weighted Weighted Materials Cost Ergonomics Improvement Ease of Implementation Durability Aesthetics

COLUMN DUMPER GRIPPING SOLUTION Temp Range: -20 to 150 Will not rotate once applied Closed cell vinyl

Specifications: Temp Range: -20 to 200 Stainless Steel Polypropylene Durometer 75 Shore D Bolt Hole

375 Caster Rig Type: Cold Forged Wheel Diameter: 6 Wheel Face: 1.5 Load Capacity (lbs.

17 COLUMN DUMPER GRIPPING SOLUTION Temp Range: -20 to 150 Will not rotate once applied Closed cell vinyl foam 4 ¼ length VEMAG VAT LOCKING SOLUTION 304 Stainless Steel Gate Latch 4 ¾ width 1 ¾ height Specifications: Temp Range: -20 to 200 Stainless Steel Polypropylene Durometer 75 Shore D Bolt Hole 1: 3 x 3 Bolt Hole 2: 2 x 5/8 Bolt Size: Caster Rig Type: Cold Forged Wheel Diameter: 6 Wheel Face: 1.5 Load Capacity (lbs.): 525 Overall Height: 7.5 Replacement Wheel: W-615-AZ-5/8 Swivel Offset: Top Plate: 4 x 4 ½ Weight (lbs.): 5 lbs Wheel Type: Aqualite Stainless Steel Caster w/ Aqualite Wheel 17

18 Stainless Steel Frame Hard Wheels Polypropylene Derlin Bearings Easy to clean Don t break in wet conditions Great for wash down environments Four swivel casters More maneuverability Tile Safe Large wheel diameter Higher rotational inertia Cost data removed per Wegmans request 18

19 Casters: Take another measurement of required force to move column dumper Install new casters and do a similar test Compare results and assess any improvement Handles and Latch Install, then survey employees to assess improvement Casters raise the column dumper s overall height too high Casters do not show ergonomic improvement Handles do not adhere well to column dumper and fall off Latch is too difficult to use (employees do not approve)/does not work well Latch breaks under the force of the Vemag vat 19

20 Ergonomics Need Primary Risk Risk Rating - Current Risk Rating - Target Easier to push VEMAG vat HIGH Easier to load vats into column dumper 3 Injuries: LOW Risk Rating - Ideal Notes: Shoulder pain while working in the tumbling area 3 injuries related to this issue over the past year due to bending, which causes back strain 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 Criteria Options: Non-Movable Handle Importance Weighted Telescoping Handle Weighted Spring Loaded Tension Rod Handle Weighted Folding Handle Weighted 1. Materials Cost Ergonomics - how well it solves problem 3. Ease of Implementation Durability Likelihood it can't be used elsewhere Aesthetics Without criteria # 5:

Ergonomics Need Primary Risk Risk Rating After handle retrofit Risk Rating - Target Easier to push VEMAG vat LOW 1 24 1 Easier to load

the risk is significantly lowered with the addition of a handle.

21 Ergonomics Need Primary Risk Risk Rating After handle retrofit Risk Rating - Target Easier to push VEMAG vat LOW Easier to load vats into column dumper LOW Risk Rating - Ideal Notes: The main concern is bending and putting strain on the employee s back, so the risk is significantly lowered with the addition of a handle. The bending strain has been eliminated, however a moderately high effort level is needed to make sure the vat latches into the column dumper, so the risk rating is still not going to be at the ideal value. 21

22 Cost data removed per Wegmans request Build a handle, weld to an existing VEMAG vat. Put to use on the floor! Get feedback from employees who used the modified vat Test model fails (during build or implementation): Depending on type of failure, design something new or build another test model more accurately Test model not well received by employees: Get suggestions on design changes or completely new designs 22

23 Member of team not available for a period of time RIT student or Wegman s employee Health or family issues/emergencies Contingency Plan: distribute work among remaining team members so as to stay on track Ordered parts don t arrive on time Contingency: order ASAP after the DDR to ensure arrival by MSD II in spring quarter Marinade room too busy for Kaizen implementations Contingency: run the schedule in advance by Wyatt and Chris. Have Wyatt discuss it the day of implementation at the morning meeting Will not be able to work on all issues discovered due to various reasons: Efficiency / Cost Wegmans has 2 smaller projects currently in process that will resolve a majority of the current problems Simplification Wegmans has new ERP system that will change production scheduling significantly 23

24 Order materials by end of next week Start prototype builds, modifications, and kaizens at start of spring quarter Test deliverables with documentation 24

Folding Shopping Cart Design Report

Folding Shopping Cart Design Report EDSGN 100 Section 010, Team #4 Submission Date- 10/28/2013 Group Image with Prototype Submitted by: Arafat Hossain, Mack Burgess, Jake Covell, and Connor Pechko (in