Wegman's Swirl Cake Process Improvement: Detailed Design Review Aaron Delahanty Ryan Norris Arwen Sharp Benson Yu Kenyon Zitzka Nov. 11th, 2011.

Wegman's Swirl Cake Process Improvement:

 Detailed Design Review

 Aaron Delahanty

Ryan Norris Arwen Sharp

Benson YuKenyon Zitzka

Nov. 11th, 2011

Overview• Actions Since SDR• Project Timeline • Risk Reassessment• Design

o Mechanical Swirler Cart Head/Chassis Gate

o  Electrical Overall System Logic Machine Logic Machine Control Unit Possible Sensor Locations

• Customer needs assessment • BOM/Budget • Questions

Actions  Addressing  Feedback from SDR

• Food safety should be prioritized in the risk assessment.o Use of stainless steel.o Components selected are food-service rated (i.e.

FDA or similar approval).• Mobility/Portability

o  Quick-connect ("Kitchen-aid" style) components used on swirling mechanism.

o We require your final input on mobility (cart, mounted directly to conveyor, etc).

• Consistency/Quality o  Prototype developed and tested.o Feedback received from Sharon Penta

Updated Timeline

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

Additional Risks Identified

• Parts/materials ordered are misplaced, damaged, or unusable. 

o Based on previous design team experienceso Set up a method to prevent loss of incoming parts

•  Unaware of ongoing production schedule  

o Caused delay in our schedule (~1 week behind)o Request that we are sent the schedule monthly

 • Possibility of only one prototype being developed

 o Mitigated by early prototype testing.

• Under swirled batter portion present in 1/2 sheet pans

Mechanical Design Overview

• Overall Form and Function overview

• Swirler Design o Prototype 2.0

•  Location and Mobility • Chassis / Motor Modules• Gate Mechanism

 Overall Form and Function

Overview

2nd Prototype Batter Testing: Results

2nd Prototype Batter Testing: Results

2nd Prototype Batter Testing: Results

2nd Prototype Batter Testing: Results

1. Rotational motion only will provide sufficient swirling  2. Effects of experimental variables: • Number of Contact Points

o More points will reduce time req'd to swirlo Too many points causes 'mixing'

•  Swirl Diametero Larger diameter moved batter further and made larger

swirl featureso Smaller diameter moved less batter but created thinner

more appealing marbling•  Swirler Angle

o Little to no effect on the depth of the swirl 3. 1/2 Sheet pan gap is present and must be addressed

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. 

o Proper nomenclature for this style connector?

Location /  MobilityCart 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.

Conveyor bracket

• Allows for quick disconnect and alignment

• Relies on stable conveyor wall

• Assumes access to conveyor wall

The Rail Debate

Mount directly to rail• Larger machine

footprint• Cantilevered machine

head

Remove rail• Plausible?• Consequences

Swirling Synchronization

Gate DesignA 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

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

Chassis / Motor Module Design

Overall Machine Summary

•    General Machine Dimensions:  o Footprint - ~42" x ~28"o Overall Height: ~59"

• Total Machine Weight (Approximation) =  ~110 lbs • Processing capabilities:

o Swirl process: 5 seconds (assuming 2 batter rotation)

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 

Electrical Design Overview

• Overall System Logic• Swirl Logic• Control Unit ("Brain")

o Motor Startero Relay / Contactor o Sensor / Other PLC Signal

• Safety Actions

Overall System Logic

Swirling Machine Logic

Power Conversion Logic

Control the power to gate

Control the power to pneumatics and motors

Motor Control Unit

Other Possible Controller

Electronics Components

• Starter Boxo Motor Startero Circuit Breakero Manual Starting Switch

• Relayso Solid State Relays vs. Programmable Relays

• Sensorso Photoelectric Sensors

SensorsSensor Locations:

1.  At the clamp2.  At the machine (Signals to Relay)3.  At the pan queue4.  Inside the machine (Signals to check if chassis back in starting position)

Electrical Safety Actions

• Circuit Breaker• Thermal Overload• NEMA Enclosure • Emergency Stop / Brake

Electrical Design Related Questions

 • Parts provided by Wegmans?• Sensors Communication ? • Professional Feedback on Components• Comments on Control Units / Other

Possibilities? • NEMA Enclosure?

Customer Needs AssessmentGreen - Feasibly achieved, as supported by current developmentYellow - Feasibly achieved, completion dependent on future developmentRed - Not feasibly achieved

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

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?

o Power?o Air?