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Project Summary
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Project Information
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Wegmans desires that the cheesecake desserts
produced in their Rochester bakery can be easily
removed from the pans in which those cheesecakes
are baked and frozen. This process would have
minimal ergonomic concerns for the employees who
must arduously complete this task. Food quality
constraints would be met while keeping the
appearance of these cakes the same. Employees must
warm the cakes for approximately one minute and
slam the pan onto a working surface to finish the
removal process.
The goals of this project are to analyze the
current design and to simplify the removal process
as well as make it ergonomically friendly for the
employees. If any additional staff is required, an
ROI analysis must be done to show it makes sense to
add them to the line. The end result must not
involve repeated heating/freezing of the cakes, nor
affect the quality of the product. It must also
keep up with current production rate. Solutions
should not be capital intensive, as the budget is
to be determined.
For an detailed visual of the Wegmans cheesecake
depanning process, copy and paste the following
link into your browser:
www.youtube.com/watch?v=a0NnX3C_IcU
Wegmans Large Plain Cheesecake
Customer & Sponsor
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Project Name
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Cheesecake Depanning Improvement
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Project Number
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P15711
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Project Family
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Process Innovation
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Start Term
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20141
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End Term
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20142
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Faculty Guide
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John Kaemmerlen
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Primary Customer
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Jose Guzman, Shawn Hart, Eric MacCormack
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Sponsor (financial support)
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Wegmans Food Markets, Inc.
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Key Stakeholders
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Bill Holden, Dave Schneider, John Antinore, Paul
Adams
Team Members
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Member
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Role
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Contact
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Casey Bauman
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Mechanical Engineer
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email
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Garth Sinclair
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Industrial Engineer
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email
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Zachary Alsheimer
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Industrial Engineer
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email
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Matthew Gundrum
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Mechanical Engineer
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email
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Left to Right: Matt Gundrum, Casey Bauman, Garth
Sinclair, Zach Alsheimer
MSD I and MSD II Summary
Semester 1 Breakdown
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Weeks 3-6
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The teams focus during this time was conducting
initial testing and speaking with subject
matter experts for topics relating to the
project. These topics included ergonomics, heat
transfer, as well as previous experiences with
depanning frozen items. Along with this the
team also starting conducting initial testing
which included the vacuum effect test, the
mallet test, and also the gravity test. Along
with this the team also conducted its first
ergonomic assessment to get a baseline for the
current process. Most of the content from this
section of MSD I can be found here: Problem
Definition
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Weeks 6-12
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During this time the team continued to focus on
testing, running the first insert test. The
team also took advice from an ergonomist and
videotaped the process to more accurately
analyze each aspect of the process. Initial
heat transfer simulation was started using
computer software. There was also an expanded
focus upon the process as a whole, rather than
focusing simply on the depanning process the
team also started looked for additional
improvement areas. Most of the content from
this section of MSD I can be found here:
Systems
Design
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Weeks 12-15 Description
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During the final weeks of MSDI, the team
focused on continuing to test no cost
solutions. Multiple tests were conducted,
including the grease test, re-running the
insert test, and also the spatula test. From
these results, specifically the spatula test,
the team realized it had to adjust the focus of
the project to include side adhesion which had
been neglected originally. From this the team
started brainstorming possible ‘cookie
cutter’ solutions to eliminate side
adhesion. Another focus these last few weeks
were to develop an initial schedule for the
start of MSDII. Most of the content from this
section of MSD I can be found here: Detailed Design
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Semester 2 Breakdown
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Weeks 3-6
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The team's focus during this time was
conducting further, more complex tests. These
tests included a preliminary water-bath test,
stainless steel pan inserts and temperature
manipulations on the pizza oven. While also
conducting these tests, the team has also been
going in and collecting more data about the
time it takes to depan the cheesecakes. Over
the winter break, Wegmans switched the
cheesecake recipe to include Greek yogurt.
Information about the tests performed can be
found here: Build,
Test, Document
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Weeks 6-9
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During Weeks 6-9, the team ran a multitude of
tests. These tests included: Pizza Oven
Manipulation, Stainless Steel Inserts, Water
Bath Testing The team also created a problem
tracking table to aid the updated risk
assessment. During this time period, the team
sat down with Wegmans to discuss moving forward
to a stage where more cost-intensive solutions
might be considered. To see the most up-to-date
information, please visit the Build,
Test, Document page.
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Weeks 9-12
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During weeks 9-12, the team had 3 major
focuses: finishing up RIT deliverables, Imagine
RIT and getting ready to hand off the project
to Wegmans. In the final few weeks, the team
completed a larger scale test for the water
bath and switched over to aluminum for the
metal inserts. Those tests were completed and
presented to Wegmans. The team also completed a
return on investment analysis on the chance
Wegmans wanted to switch to a disposable pan,
similar to how the public purchases pies from
Wegmans. To see the most up-to-date
information, please visit the Integrating
Testing page. The team created a poster and
a final presentation for the MSD program. Those
can be found on the Publications
& Presentations page.
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Table of Contents
Acknowledgements
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Name
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Concentrations
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Affiliation
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Nancy Laurie
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Ergonomics
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Wegmans
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Beth DeBartolo
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Benchmarking
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RIT
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John Antinore
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Artisan (Mallet Greases)
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Wegmans
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Rob Stevens
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Heat Transfer
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RIT
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Home | Planning &
Execution | Problem Definition |
Systems Design | Detailed Design | Build, Test,
Document | Integrating Testing |
Publications
& Presentations | Project Management
