Wegman's Swirl Cake Process Improvement: Detailed Design Review

1. Nov. 11th, 2011 Wegman's Swirl Cake Process Improvement:Detailed Design Review Aaron DelahantyRyan Norris Arwen SharpBenson YuKenyon Zitzka

2. Overview • Actions Since SDR • Project Timeline • Risk Reassessment • Design • Mechanical • Swirler • Cart • Head/Chassis • Gate •  Electrical • Overall System Logic • Machine Logic • Machine Control Unit • Possible Sensor Locations • Customer needs assessment • BOM/Budget  • Questions

3. Actions  Addressing  Feedback from SDR • Food safety should be prioritized in the risk assessment. • Use of stainless steel. • Components selected are food-service rated (i.e. FDA or similar approval). • Mobility/Portability •  Quick-connect ("Kitchen-aid" style) components used on swirling mechanism. • We require your final input on mobility (cart, mounted directly to conveyor, etc). • Consistency/Quality •  Prototype developed and tested. • Feedback received from Sharon Penta

4. Updated Timeline • We are ~1 week behind schedule discussed at system design review. •  Bill of Materials to be passed to purchasing by 18 Nov

5. Additional Risks Identified • Parts/materials ordered are misplaced, damaged, or unusable. • Based on previous design team experiences • Set up a method to prevent loss of incoming parts •  Unaware of ongoing production schedule • Caused delay in our schedule (~1 week behind) • Request that we are sent the schedule monthly • Possibility of only one prototype being developed • Mitigated by early prototype testing. • Under swirled batter portion present in 1/2 sheet pans

6. Mechanical Design Overview • Overall Form and Function overview • Swirler Design  • Prototype 2.0 •  Location and Mobility • Chassis / Motor Modules • Gate Mechanism

7. Overall Form and Function Overview

9. 2nd Prototype Batter Testing: Results

10. 2nd Prototype Batter Testing: Results

11. 2nd Prototype Batter Testing: Results

12. 2nd Prototype Batter Testing: Results • Rotational motion only will provide sufficient swirling  • Effects of experimental variables: • Number of Contact Points • More points will reduce time req'd to swirl • Too many points causes 'mixing' •  Swirl Diameter • Larger diameter moved batter further and made larger swirl features • Smaller diameter moved less batter but created thinner more appealing marbling •  Swirler Angle • Little to no effect on the depth of the swirl  3. 1/2 Sheet pan gap is present and must be addressed

13. Swirler Design • Based on feedback from Sharon     Penta from 2nd prototype test. • Variable diameter for maximum     coverage. • Yet to be designed: "Kitchen Aid" style quick-connectors for maintenance and cleaning. • Proper nomenclature for this style connector?

14. Location /  Mobility Cart justification • Permanently or temporarily mounted to the conveyor • Swivel feature allows permanent mount, still capable of removing machine from space above product line • Ergonomically design casters and handles allow for easy operator removal/set-up • Conveyor mounting bracket allows for quick alignment after initial bracket mounting.

15. Conveyor bracket • Allows for quick disconnect and alignment • Relies on stable conveyor wall • Assumes access to conveyor wall

16. The Rail Debate Mount directly to rail • Larger machine footprint • Cantilevered machine head Remove rail • Plausible? • Consequences

17. Swirling Synchronization

18. Gate Design A simple lever gate • Allows us to increase actuator stroke • Impact forces are seen by the lever and absorbed by the conveyor mounting point rather than actuator

19. Chassis / Motor Module Design • Mounting point for      "swirling modules" • Linear bearing for z-axis     motion. • .75" x .75" 304 Stainless     Steel box tubing • 1" x 1" T-bar for inner supports

20. Chassis / Motor Module Design

21. Overall Machine Summary •    General Machine Dimensions:   • Footprint - ~42" x ~28" • Overall Height: ~59" • Total Machine Weight (Approximation) =  ~110 lbs • Processing capabilities: • Swirl process: 5 seconds (assuming 2 batter rotation)

22. Safety • Sheet metal cover to prevent crush hazard and protect machine components. • Fail-safe considerations incorporated into logic controls.  • Appropriate safety labels to be applied to machine. • Water-tight enclosures for electric/electronic components. • On-board circuit overload protection • Emergency Stop • Center of gravity analysis for cart mobility safety 

23. Overall System Logic • Swirl Logic • Control Unit ("Brain") • Motor Starter • Relay / Contactor • Sensor / Other PLC Signal • Safety Actions Electrical Design Overview

24. Overall System Logic

25. Swirling Machine Logic

26. Power Conversion Logic Control the power to gate Control the power to pneumatics and motors

27. Motor Control Unit

28. Other Possible Controller

29. Electronics Components Starter Box Motor Starter Circuit Breaker Manual Starting Switch Relays Solid State Relays vs. Programmable Relays Sensors Photoelectric Sensors

30. Sensors Sensor Locations: •  At the clamp •  At the machine (Signals to Relay) •  At the pan queue •  Inside the machine (Signals to check if chassis back in starting position)

31. Electrical Safety Actions Circuit Breaker Thermal Overload NEMA Enclosure  Emergency Stop / Brake

32. Parts provided by Wegmans? • Sensors Communication ? • Professional Feedback on Components • Comments on Control Units / Other Possibilities? • NEMA Enclosure? Electrical Design Related Questions

33. Customer Needs Assessment Green- Feasibly achieved, as supported by current development Yellow - Feasibly achieved, completion dependent on future development Red- Not feasibly achieved

34. BOM • Independently sourced parts • Likely to change due to Wegmans part inventory • Current projected current cost $2,446.32

35. Questions • labels & paint? • parts warehouse? • Kitchen-aid interface? • non-ferrous materials are okay? • Solenoid vs pneumatic gate actuation? • how to deal with pan gap!?  • swivel desirable function? • Interfaces between PLC and the entire cart? • Power? • Air?