Wegmans: Flip-Label Project
P10715
20093/20094
Advisor: John Kaemmerlen (ISE)
Customer: Wegmans
Championed by Chris Isaacson
Problem Statement
Team Members:
The Flip-Label project goal is to reduce direct labor requirements for the
flip/label meat package process sequence in the Wegmans Culinary
Innovation Center. Currently an operator is needed to manually flip and
align meat packages to enter the x-ray inspection machine. One or more
operators are needed to label packages after they exit the inspection
machine depending on product type and process speed.
Objectives
•Implement devices to flip and arrange meat packages in optimal
configuration on conveyor for inspection by x-ray scanner
•Reduce direct labor needed to label packages at current takt
Key Business Goals/Project Deliverables
•Implement devices to automatically flip and align packages
•Remove ergonomic risks
•Devise quicker labeling process
System Hierarchy
Flip
Align
X-Ray
Label
Brandon Sbordone (ME), George Kilger (EE),
Ben Bouffard (EE), Ian Baker (ME),
Charlie Nicolosi (ME), Helen Jervey (ISE)
Layout offered minimal impact to room layout, while managing to
maintain required product flow without undesirable equipment
purchases.
Concept Selection
*Only top 3 options are shown
Selected Concepts
• The flipper mechanism is the first component encountered
in the system, it is required in-order to put product in an
orientation that improves labeling accessibility. It was
critical that flip motion be controlled and that it repeatability
dispenses product onto variable speed belt system for
aligning.
• The aligning solution had to offer complete
product support with minimal change-over time
between products. Precision feedback systems
offered exact control over product location on
belt surface, and simple user interfaces allows
employees to easily select product on the line,
which will in-turn recalibrate entire system.
• Due to concerns about getting the other project
sections implemented before moving forward with the
fully automated labeling system, a label assist system
was employed in the interim period. This system was
designed to increase labeling speed and reduce strain
on workers.
Recommendations for Future Work
• Implementation of automated labeling system would further reallocate labor
resources.
• Implementation on the second production line doubles the benefits.
• Automated package handling following labeling process.
• Improvements to Multi-Vac system to meet maximum capacity of automated
conveyor system.
Customer Needs Hierarchy
•Need 1: Product & Process are safe.
•Need 1.1: Product integrity is maintained.
•Need 1.2: Equipment satisfies USDA Regulations as well as the AMI
Checklist.
•Need 1.3: OSHA Safety requirements are met.
•Need 1.3A: Remove ergonomic issues and concerns.
•Need 2: Reallocate Direct Labor.
•Need 2.1: Reallocate direct flipping labor.
•Need 2.2: Reallocate direct alignment labor.
•Need 2.3: Reallocate direct labeling labor.
•Need 2.4: Camera labeling system is low priority.
•Need 3: Improve Processing Time.
•Need 3.1: Maintain or decrease takt time.
•Need 3.2: All packages get scanned by the x-ray at desired belt speed.
•Need 3.3: Control flow to scaling operation. (Control flow-rate variance)
•Need 3.3A: Packages must flow in a format that works with the X-ray.
•Need 4: Control orientation and flow-mechanics.
•Need 4.1: Packages are in the proper orientation.
•Need 4.1A: Label is in proper orientation position relative to the
package.
•Need 4.1B: All packages are centered in the x-ray beam.
•Need 4.1Ba: Packages are conveyed in single-file.
•Need 4.2: Keep allocation of floor space constant.
Design Specifications and Test Results
5
N 1,2
FDA/USDA Specs
5
Pass/Fail
Marginal
Ideal Value
Value
Pass
Pass
6
N 1,2,15
AMI Sanitary Design Checklist
5
Pass/Fail
Pass
Pass
7
N 1,3
OSHA Safety Specs
5
Pass/Fail
Pass
Pass
10
N 6,7
Direct Flip/Align Man Hours
5
hours
<75% Current <50% Current
11
8
9
N1
N 9,12
N 4,8
Keep Product Integrity
Flip
Belt Speed (X-Ray)
5
4
4
Pass/Fail
Pass/Fail
m/s or ft/s
Pass
Pass
Current
10
N5
Direct Label Man Hours
4
Hours
<75% Current <50% Current
12
1
4
2
3
13
N 15
Ergonomic Risk
N 4,13
Flow Rate
N 9,12
Label Orientation
N 9,10,12,13,14 Pc. Alignment
N 9,12
Pc. Perpendicularity
N 11,14
Flow Rate Variance
4
3
3
2
2
1
CIC Risk Assess units
pc/min
Deg
in from center
Deg
% of Rate
Current
7
85-95
TBD
85-95
+/- 25-50%
Metric Need Met
Description
Imp. Units
Acknowledgements
Pass
Pass
Current
<24
>7
90
0
90
+/- 0-25%