P09711 - Automation/Improvement of Packaging
on the Cookie Line
Sponsored by Wegmans
Stephanie Rager
Bruno Coelho
Automation/Improvement of Packaging on the Cookie Line
Line
Phase I
Phase II
Cookie Line
Automation
Automated
Scaling of
Cookies
Automated
Scaling of other
Products
Phase III Phase IV
Automated
Packaging for
Cookie Line
Integration of
Systems
Automation/Improvement of Packaging on the Cookie Line
Automation/Improvement of Packaging on the Cookie Line
Automation/Improvement of Packaging on the Cookie Line
Project Name
Automation/Improvement of Packaging on the Cookie Line
Project Number
P09711
Roadmap
R09710- Modern Food Processing and Bakery Technology for Lean Production Systems
Start Term
2008-2
End Term
2008-3
Faculty Guide
Professor Kaemmerlen (Industrial and Systems Engineering Department)
Primary Customer
Wegmans
Scott Young
Chris Isaacson
Automation/Improvement of Packaging on the Cookie Line
Project Summary
 Wegmans bakes and packages all of their mini cookies at their
bakeshop located here in Rochester on Brooks Avenue.
 Currently the packaging is done by six or seven people who stand
around a conveyor and pull the cookies into the clam-shell packages.
 Employees should be packing 398 grams into a package
 Employees are packing sometimes up to 450 grams of cookies
 This is a loss for Wegmans because customers are receiving more cookies
than they are paying for.
 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.
Automation/Improvement of Packaging on the Cookie Line
Mission Statement
 Create an automated prototype that will separate mini
cookies by weight, while preventing cookies from
moving on in the process until a specified weight is
reached. It will create a clear separation between the sets
of cookies that go into each package without
substantially slowing down the packaging process.
Project Stakeholders
Primary Customers:
 Wegmans Facility and Employees
 Scott Young, Manufacturing Engineering Manager
 Chris Isaacson, Industrial Engineer
Other Stakeholders:
 John Kaemmerlen, Faculty Advisor
 Mark Smith, RIT Senior Design
Automation/Improvement of Packaging on the Cookie Line
Key Business Goals/Project Deliverables
 Provide an effective design to minimize the packaging
wastes
 Research materials and sensors to be used in automated
prototype
 Produce an automated prototype
 Test/analyze effectiveness of prototype
 Present prototype to customer
Automation/Improvement of Packaging on the Cookie Line
Assumptions and Constraints
 Budget
 Wegmans’ engineering resources
 Scheduling of benchmarking/testing time due to
production goals
 Should not substantially slow down the packaging
process
Automation/Improvement of Packaging on the Cookie Line
Preliminary Customer Needs
1. Weights Product
1.1 Mini-Cookies
1.2 Mini-Muffins
1.3 Brownie Bites
2. Long Term Solution
2.1 Adjustable
3. Randomization
4. Waste Reduction
4.1 Reduces the amount of excess cookies in package
Automation/Improvement of Packaging on the Cookie Line
Preliminary Risk Assessment
 Cost/Budget
 Consequences- could not produce prototype
 Substantially slows down process
 Consequences- not useful in line, no implementation
 Technology- needed technology is not available
 Consequences- unable to produce effective prototype
 Reduce Quality- design effects cookies
 Consequences- design and prototype cannot be implemented
Automation/Improvement of Packaging on the Cookie Line
Staffing Requirements
Name
Discipline
Role
John
Kaemmerlen
Faculty Guide
Faculty Guide, will work closely with the team on an on-going basis to
facilitate success of project.
Stephanie Rager IE
Will serve as Project Manager. Assist in identifying the current process for
packaging. Perform analysis on current process to be used as a benchmark for
testing final prototype.
Bruno Coelho
ME
Will serve as Chief Engineer. Act as main point of contact from an
engineering standpoint. Assist in creation and production of an effective
prototype.
TBD
ME
Establish an effect engineering design for project. Research materials to be
used in prototype.
TBD
EE
Research sensors to use to collect the weight of the cookies. Program sensors
to be used in prototype.
TBD
EE
Research proper electronics to be used in mechanical system. Implement
electronics in system/prototype.
Automation/Improvement of Packaging on the Cookie Line Preliminary
Work Breakdown Structure
Person
Week 0-1 Tasks
Week 1-2 Tasks
Week 2-3 Tasks
Stephanie Rager – Project
Manager
Meet with Bruno to discuss specific
team assignments. Set up first
meeting before Friday. Conduct the
meeting, and provide each group
member with their assignments to be
completed by the next Fridays
meeting.
Organize a site visit to Wegmans for
entire team. Conduct a
brainstorming session with project
team to generate initial design ideas.
Review the project schedule with the
project team.
Compile research performed in
various fields by the project team.
Organize and conduct a team
meeting to monitor individual
progress. Address areas of conflict
with individual team members as
they apply to them.
Bruno Coelho – Chief
Engineer
Meet with Stephanie to discuss
specific team assignments. Assist in
conducting the meeting and provide
overview of project to team
members.
Conduct a brainstorming session
with the project team to generate
initial design ideas. Provide each
group member with their
assignments to be completed by the
next Fridays meeting.
Generate concept design of
mechanical system. Organize and
conduct meeting with team to
discuss individual concept designs.
Provide team members with their
assignments to be completed by the
next Fridays meeting.
ME
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible materials to be
used in the mechanical system.
Brainstorm some individual design
ideas.
Generate concept design of
mechanical system. Continue to
researching materials to be used in
mechanical system.
EE
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible sensors to use in
collecting weight. Brainstorm some
individual design ideas.
Generate concept design of
researched sensors. Continue
researching sensors to use in
collecting weight.
EE
Familiarize themselves with the
project by thoroughly examining the
project readiness package located on
the EDGE website.
Research possible electronics to use
in the mechanical system. Brainstorm
some individual design ideas.
Generate concept design of
electronics to be used in mechanical
system. Continue researching
electronics to be used in mechanical
system.