P16702: ABVI fabric shredding process and facility design


Project Summary Project Information

Currently, Goodwill collects unsold textiles and sells them to other companies for revenue that goes directly to other projects and technology. This eliminates the possibility of generating additional revenue by processing the textiles in house, and then selling the newly shredded and sanitized material to companies for a higher revenue. Unfortunately, there is currently no facility or process in place where this is done.

The goals of this project are to increase the revenue stream by developing a facility layout, a rework process, and logistical plan that will allow to rework textiles and sell them to other companies. The expected end result would be to have an accurate simulation model of the overall system, which would include a facility design, and would eventually turn into reality. Some key constraints are that the new process is monetarily efficient, meaning that it there is a high return on investment and short payback period. Also, the new design must fit the ethical model of the company, create as many new jobs for the visually impaired and other disabled persons as possible, and maintain a safe working environment.

Project Name
Fabric Shredding Process and Facility Design
Project Number
Start Term
End Term
Faculty Guide
John Kaemmerlen
Primary Customer
Joyel Bennett
Joe Kells
Sponsor (financial support)
Goodwill of the Finger Lakes

Team Members

Team Members (from left to right): Burake Taye, Alexis Leshko, Steven Walton, Kristen Hennessey, Chris Haluszczak, Matthew Babcock

Team Members (from left to right): Burake Taye, Alexis Leshko, Steven Walton, Kristen Hennessey, Chris Haluszczak, Matthew Babcock

Member Role Contact
Chris Haluszczak Project Lead cwh7274@rit.edu
Kristen Hennessey Facility Design Manager kbh7318@rit.edu
Alexis Leshko Documentation Analyst acl4889@rit.edu
Matt Babcock Technical Specialist mjb8978@rit.edu
Burake Taye Simulation Manager btt9380@rit.edu
Steven Walton Financial Analyst sjw5378@rit.edu

MSD I Summary

Phase 1: Problem Definition - In this first phase, the team utilized the Project Readiness Packet and a meeting with Goodwill of the Finger Lakes to understand the scope of the problem. Customer and engineering requirements, a communication plan, a work breakdown structure, and a preliminary schedule were developed to ensure the team was aligned with the customer and guide.

Phase 2: Systems Design - In the second phase, each team member developed a function decomposition. Then, as a group, a finalized functional decomposition was developed and mapped to customer and engineering requirements. After it was ensured that each requirement was mapped to a subfunction, concept generation and selection was done. The four important areas that were chosen by the team for functional decomposition were packing, sorting, cleaning, and space requirements.

Phase 3: Subsystems Design - In the third phase, further research was completed on each subsystem. The identified subsystems were sorting, shredding, cleaning, and storage and movement of bales. For each subsystem, research and benchmarking were presented to Goodwill of the Finger Lakes.

Phase 4: Preliminary Detailed Design - The fourth phase gate was broken into two different mini-phase gates. The first (Scope Change Review), was conducted in order to determine a end product of the system. The team was running into difficulties during research and benchmarking with no end product. The result of this first phase was choosing, with the customer, insulation as an end product. The second (Cost Breakdown Tool Review), was conducted to give Goodwill of the Finger Lakes an update on the Cost Breakdown Tool. Using information provided by SMEs in Saunders College of Business and an accounting lecture from the guide, the team was able to present some updates to the tool.

Phase 5: Detailed Design - In the final phase gate of MSD I, the general process flow was developed for the new subsystems identified after choosing the end product of insulation. In this process flow, there are several different value streams the team identified, depending on the sorting method. A preliminary plan for the schedule and deliverables for MSD II was developed.

MSD II Summary

Phase 1: Build & Test Prep - In the first phase of MSD II, the team was able to begin working on the cost tool, simulation, and facility layout right away. Two team members working on the cost tool contacted subject matter experts. Two team members working on the simulation began mapping processes and the simulation. The final two team members began bench marking the space requirements for the facility, the material handling system, and labor requirements.

Phase 2: Subsystem Build & Test Prep - The second phase of MSD II resulted in changes for the three tools (cost tool, simulation, and layout). The two team members working on the cost tool were able to make updates to the tool after discussions with SMEs. After researching and benchmarking other companies' facilities, the two team members working on the facility layout were able to utilize machine specifications to develop a starting layout. There was also additional research into material transport and staffing requirements. The two team members working on the simulation were able to utilize material handling and staffing research with machine specifications to create a starting simulation.

Phase 3: Integrated Subsystem Build & Test Prep - The third phase of MSD II resulted in changes for the three tools (cost tool, simulation, and layout). The cost tool was updated through the addition of functionality such as varying revenue streams, number of shifts, and the purchase of raw material. Through the research of material storage (gaylords, pallets, and racking), the facility layout was updated to include the inbound and outbound space requirements. The simulation has also been created and updated several times based on calculations and research.

Phase 4: Integrated Subsystem Build & Test Prep with Customer Demo - In the fourth phase of MSD II, the team is nearing completion of the three tools. After a customer demo and a usability assignment with the overall team, the cost tool needs to go through a major change to include an additional baler. The simulation team has completed almost all experiments, but is working on the simulation for the automatic sorter. The facility layout team has completed the base layout, in addition to five additional. To complete the customer requirements, the two team members need to further research utilities.

Phase 5: Customer Handoff & Final Project Documentation - In this final phase, each subteam worked to the completion of the deliverables. For the facility layout team, a summary of the square footage, ceiling height, and floor requirements was developed and handed off to GFL. For the simulation team, the optimal scenario was ran and analyzed. And lastly, for the cost breakdown tool team, instructional videos along with final touch formatting was completed. Additionally, all team members worked on gathering and organizing all the needed information for a successful handoff to GFL.

Table of Contents


Project Management

Project Photos and Videos

Imagine RIT

Problem Definition

Systems Design

Subsystem Design

Preliminary Detailed Design

Detailed Design

Build & Test Prep

Subsystem Build & Test

Integrated System Build & Test

Integrated System Build & Test with Customer Demo

Customer Handoff & Final Project Documentation