P12713: Wegmans Parbake Rounding Ergonomics

Detailed Design

Table of Contents


There was a design iteration process through 4 different designs:
  1. Mold with Rollers was deemed to not work since it could not tuck under the bread
  2. Ice Cream Scoop also could not tuck under but had a better tucking method
  3. Drop & Pinch could now tuck under but due to the fluidity of the dough would cause problems dropping it back on the conveyor
  4. Twister takes pluses from the previous designs and eliminates the dropping and tucking negatives

This table of Plus/Minus shows how we evaluated the designs and progressed onto the next.

Feasibility / Engineering Analysis

The group did feasibility talks throughout the design iteration process. A Failure Modes and Effects Analysis was also done for the Twister design to note possible failure points of the design. This will allow us to design in prevention and detection for these failures points.

Three types of Conveyor Belt material were also pilot tested to see which worked best at getting the necessary friction to grab and tuck the dough.

Bill of Material (BOM)

The materials required to build the Twister should cost no more than $5,000. The Bill of Materials will be purchased through Wegman's purchasing and is scheduled to be received early Spring quarter.

Test Plans

A set of Test Plans was created to make sure that all of the customer specifications are covered by the implemented design. Quality Specifications were collected to get a better understanding of what product gets rejected.

Then preliminary data was collected to find the reject rate of the current operation, automatic rounder once, and automatic rounder twice. This data went into the a two proportion t-test for reject rate which is what will be used as a baseline to test the design against. (A Sample Size of 200 was determined to be appropriate by Wegman's based on statistical power)

An Operator Survey will also be done to assure their willingness to accept and adopt implementation of the design.

An Ergonomic Evaluation will be completed by the team and the Wegman's Ergonomist to assess the ergonomic benefits of the design.

Finally, a Return on Investment calculation will be done to show the monetary benefits of using the design.

Risk Assessment

The Risk Assessment from the systems design was reevaluated to see where appropriate changes needed to be made based on new knowledge. The changes that we made were adding a risk for delays due to bad communication which is minimized by direct communication. Also, increasing the severity of not meeting the production rate to a 3 from 2. Finally, decreasing likelihood of parts not coming in on time and costing too much down to 1 from 2. The group still agrees that the largest risks are keeping the artisan look and keeping the operators on board with the project.

Detailed Design Review

February 17th, 2012 @ 9:00am

This meeting was held at Wegman's Bakery to critique the detailed designs, gain approval to move forward with purchasing and fabricating, and review the testing procedure for the design.

Meeting Agenda

Meeting Notes

February 29th, 2012 @ 3:30pm

This meeting was held at Wegman's Bakery to critique the detailed design and determine future involvement of Wegman's purchasing and fabrication.

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