Wegmans Bread Tray Lift Assist

Senior Design Review

Andrew BeastenGreg FeatherAlex PhillipsBrendan Moran

Wegmans Bread Tray Lift Assist

Wegmans Bread Tray Lift Assist

• Goal:Improve ergonomics for operator during the task of stacking loaded bread trays at the Wegmans Bakery

Critical Needs• Enable good ergonomic practices in terms of

lifting and body position• Meet Wegmans safety requirements in terms of

mechanical operation and physical aspects (sharp edges, pinch points)

• Meet Wegmans requirements in terms of cleaning and food contamination risks

• Ease of use for operator• The unit should be durable and reliable

Specifications

• Minimize process time• Mechanical components are constructed from

food safe material• Allow for food to descend no closer to the

floor than ½ foot

Hold first and subsequent traysuntil dolly touchesfloor

Hold Trays

Reset Lift

Release from system

Constant force mechanism

Keep relatively horizontal

Mechanical reset

Continuous reset

Dolly slides off

Tray Slides onto dolly

Maintain loading at waist height

Lower each tray from waist level

Ramping mechanism

Keep dolly with trays

Functional Decomposition

Holding Trays

Lifting Trays

Remove from System

Reset Lifter

Position Tray

Collapse

Forks ClipsMagnet Flat base Hooks

Spring Weight Piston Rack Pinion Pulley Motor

Fall Push/Pull Lift Magnet

Pedal Switch Lever Button Pull Cord

Walls Guide Rail Slots/Grooves Rubber Stopper

Hinge Cotter Pin Screw Tab

wedge Magnet

Magnet

Manually

clips

Pugh Matrix Results For Lifting Trays

• Criteria Considered:Ease of use, resetability, durability, portability, cost, safety, storage, maintenance, simplicity, and input required

• Ranking system: 1-3

Pugh Matrix Results For Reset Mechanism

• Criteria Considered:Cost, feasibility, practicality, maintenance, safety, simplicity, endurance and adaptability

Why Not Electric• Skill set– Programming and Controls

• Safety– Eye wash station for battery– Cords are tripping hazard

• Maintenance• Source of power/Tethered • Less versatile • More complex

Proposed Design• Skeleton Frame• Sheet metal wrap

• Springs and Damper• Track guided system• Lockable wheels• Lock at bottom

position• Lever vs. foot pedal

Variation in Design • Side guard material• Overall material• Foot pedal release• Fork vs. plat form• Wall vs. leg support

Risks Design Risks:• Spring failure• Metal bending• Pinch points• Sharp edges• Fast movement/impact

risk• Trip hazards

• Design failure/product does not work

• Visibility• Incorrect guarding• Tipping/fall danger• Lubrication concerns• Metal shavings• Ergonomic failures• Unstable product

Project Plan

Questions and Comments