Project Review P09711- Automation/Improvement of Wegmans Cookie Line Packaging Project Team: Stephanie Rager (IE), Bruno Coelho (ME), Mark Voss (ME), Chukwuma.

Project ReviewP09711- Automation/Improvement of

Wegmans Cookie Line Packaging

Project Team:

Stephanie Rager (IE), Bruno Coelho (ME), Mark Voss (ME), Chukwuma Morah (IE), Brian Duffy (EE), Benjamin Powell (EE)

Project Overview

Project Description: Wegmans bakes and packages all of their mini cookies at their bakeshop

located here in Rochester on Brookes Avenue. Currently the packaging is done by six or seven people standing around a conveyor and pull the cookies into the clam-shell packages.

The mini-cookie package calls for 397 grams worth of cookies but employees sometimes package up to 450 grams.

This project will look into building an automated prototype that will separate the cookies into the correct amount by weight, which the employees can then package.

Economic Potential

Yearly Savings ($)

$0

$20,000

$40,000

$60,000

$80,000

$100,000

$120,000

$140,000

Eliminating packages with2 or more extra cookies

Eliminating packages with4 or more extra cookies

Eliminating packages with6 or more extra cookies

Total Yearly Savings ($)

$0

$50,000

$100,000

$150,000

$200,000

$250,000

Eliminating packageswith 2 or more extra

cookies

Eliminating packageswith 4 or more extra

cookies

Eliminating packageswith 6 or more extra

cookies

All Minis

High Level Customer Needs

Must separate mini-chocolate chip cookies by weight

Must reduce the amount of excess mini-cookies in package

Must not substantially slow down process

Must not be considered a capital investment

Weight of cookie package Creates clear separation of product for packaging

Percentage of packages with excess (2 or more) cookies (currently at 95%)

Throughput

Cost

Key Target Metrics

More needs and metrics were developed but it was decided that these would be the focus of the prototype.

Proposed Prototype Design

Sifting Bar:• Need 4.2• Metric 7

Push-Rod:• Metric 6

Weigh Station:• Need 1.1 & 2• Metric 1 & 2

Final Prototype System Design

Final Prototype System Design

Final Prototype System Design

Documentation for Implementation

List of Normal & Abnormal ConditionsStart Up ChecklistList of Questions for Developing a

Maintenance PlanVisualsDesign for Pulling Stick

These can be used as a basis for creating documentation for the implementation of the final

prototype concept.

Results and Conclusions

Move cookies into lineRe-designed funnel system Eliminated the need for the sifter bar

Move cookies onto weigh stationFlow down drop chuteHeight and angle of drop chute

Accurately weigh cookiesScales were accurate within 1 gramDrop chute accurately rotated

Move cookies off of scalePush rod moved groups off of scale quick enough

Results and Conclusions

Metric Marginal Target Ideal Target Our Result

Weight of Cookies 422 +/- 5 grams 397 +/- 5 grams Average of 409 grams

% with Excess Cookies (for a fully

implemented system)60% 0%

20% (still have packages with 2 extra cookies ≈ 25 grams)

Throughput

Full System: 1500 +/-2.5%

Prototype: 375 +/ 2.5%

6.25 packages per minute

Full System:1700 +/- 2.5%

Prototype: 425 +/- 2.5%

7.1 packages per minute

6.5 packages per minute

Clear Separation Yes Yes Yes

Cost of Prototype < $10,000 < $5,000 < $5,000

Future Work

Scale interface should be switched to EthernetImprove user interface by adding speakers, screen,

mouse and gui interfaceAlarm and lights for safetyTraining manualFull creation of the pulling stick designWith knowledge of full implementation materials, a

maintenance plan can be developed

Acknowledgements

We would like to acknowledge all of the people who have helped with this project:

Scott Young and Chris Isaacson, for all of their support they provided us with during the creation of this project

Professor John Kaemmerlen and Phil Bryan, for all of the guidance and advice they provided throughout the entire process from design to creation

Dr. Christopher Hoople, for all his help during the design stages of the project and presence at our design reviews

All the Wegmans employees who allowed us to observe them doing their job on the cookie line