Wegmans Culinary Center Tour Notes
Table of Contents
Eric notesTumber loading and unloading to the vacuum pack. Want improvements of:
Ergo - Accidents from moving smaller vats to tumbler, and dump tables to vacuum sealer. Concerned also with scooping meat from dump table into mutivac.
Flow/Throughput - Want to move product more efficient, and without losing any product. Multivac the bottleneck in the process. Tumblers and multivac run at different speeds. They have changeovers and usually 3-4 tables in queue. They get backed up when they try to handle tables individually. Can change size of unloads.
Deliverables: Want a finished design and/or prototype for loading multivac. Want new concept for loading tumbler (concerns with ergonomics and congestion)
Costing: Cost out the prototype, Wegmans has an approved list of vendors, and can cut purchase orders and buy directly through Wegmans.
Weekly meetings - Will set up weekly Friday meetings with Chris. Also will send out email updates about what we're doing, what will be done, roadblocks, and next steps to entire group.
For material use - no carbon steel, stainless steal best. Maybe can use certain plastics. Smooth edges.
Workers communicate with eachother by banging on windows
Multivacs too close to eachother to have 1 cart on each side of vac.
Theres not enough room to do stuff when using the vmag
The short dump tables are bad
Screens should be at the bottom to filter marinate somewhat but not always there
Tables that actually roll would be helpful.
Some of the old tables were too high and wide, chicken went over the end and marinade went all over
Scooping wokery food is the worst, hard on shoulders / back
Only use the vmag once a week, but do wokery 2-3 times
Some wokery food is heavier
Leaky packets get gutted and resent to vmag
The white hose they use to hose down the machines is very heavy
Usually get sore after 1 hour of work
Scooping is the hardest job, especially on the back
Some carts are significantly harder to move. Ones with new wheels are easy to move.
Put the wrong date on packaging.
- Notes repeated in Eric's section have been taken out
Single chicken breast Multivac operation
- 2 "loaders"
- 1 "wiper"
Pork tenderloin Multivac operation
- 1 loader only
Problems at Multivac station:
- can't load from both sides
- dump tables are too large & too deep
- thinner marinades cause puddles at the bottom of dump tables without grates
- dump tables are too heavy
- dragging the heavy dump tables
- having to repackage "leakers"
- Tumbler cleaning process takes too long. Gets hot after washing, so workers have to spend time cooling it to normal temperature.
- Tumbler workers cannot keep up with Multivac because of frequent switching of sauces and species
- order is not level
- The new tumblers take longer than the old tumblers
- Moved away from dry ice which cools the tumblers instantly
- Why are the carts so low?
- running out of space
- very congested on busy days
- food tables are laying around with no specific place to be
- Monday, Wednesday, Friday are pick days; Tuesday, Thursday are stock days
- New Tumbler
- much less physical process
- loading chute is very heavy and difficult to move around (very taxing on busy days)
- uses 30lb buckets of marinade
- great visuals on buckets make it easy to identify marinade type
- one bucket of marinade for small loads and 2 for normal loads
- material handling machine available
- moves the tumbler loading chute
- big and cumbersome
- workers prefer not to use it
- difficult to maneuver when busy
- would rather have a drive system built into the chute to not take up space (remote controlled)
- cleaning process
- takes too long
- the process is not too physical because of the new tumblers (workers say there has been much improvement)
- it would be better if they can run full loads because it would better utilize the tumblers (less overall cleaning time)
- too much cleaning raises the temp of the tumbler (because of the hot water) which spoils food (small window of time to put in a freezer to cool meat down)
- passes USDA inspection 100% of the time
- have to clean tumblers between each species/marinade change
- Old Tumblers
- in another room 70 paces away
- used for very small batches
- dangerous to load and takes much skill/experience
- faster because there used to be 6 of them (higher utilization)
- ergo/safety nightmare
- mostly phased out
- difficult to clean (depended on mood of the worker)
- passed USDA inspection only 80% of the time
- wasted resources due to the need to double check cleanliness
- very physically taxing
- only one remains
- Notes repeated in Jeremy's and Okechi's sections have been taken out
- 20-30 minute tumble time depending on marinade/species
- Approximately 8 minute tumble time for wokery items
- 20-30 minute cleaning time when switching between marinades/species
Additional observed problems
- Floor drain clogged
- The catch/basket in drain is very hard to remove
Worker proposed cart upgrades
- Larger/wider wheels to simplify pushing the carts
- Make carts easier to turn
- Better drain to simplify cleaning of the carts.
- Make all carts the same size