edge.rit.eduedge.rit.edu/edge/p10715/public/p10715 detailed design... · web viewreallocate direct...
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KGCOE MSD Technical Review Agenda
Meeting Purpose: Detailed Design Review for Wegmans Flip-Label Team
Materials to be Reviewed:Detailed Design Review Presentation R00Detailed Design Review Handout R00
Meeting Date: 2/12/2010
Meeting Location: Wegmans Culinary Innovation Center Chili, NY
Meeting time: 3:00 – 4:30 pm
Timeline:
Meeting Timeline
Start Time
Topic of Review Required Attendees
3:00 Introduction/Goals of Presentation Design Team, Chris, John3:05 System Design Design Team, Chris, John3:10 Design Updates Design Team, Chris, John3:20 Flipping Design Team, Chris, John3:35 Aligning Design Team, Chris, John3:50 Labeling Design Team, Chris, John4:05 Cal-Pak Design Team, Chris, John4:20 Next Steps Design Team, Chris, John4:30 Conclude presentation Design Team, Chris, John
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Flip Label P10715 Detailed Design Review Handout R01Customer Needs Hierarchy
Need 1: Product & Process are Safeo Need 1.1: Product integrity is maintainedo Need 1.2: Equipment satisfies USDA Regulations as well as the AMI Checklist
o Need 1.3: OSHA Safety requirements are met Need 1.3A: Remove ergonomic issues and concerns
Need 2: Reallocate Direct Laboro Need 2.1: Reallocate direct flipping labor
o Need 2.2: Reallocate direct alignment laboro Need 2.3: Reallocate direct labeling labor
o Need 2.4: Camera labeling system is low priority Need 3: Improve Processing Time
o Need 3.1: Maintain or decrease takt time
o Need 3.2: All packages get scanned by the x-ray at desired belt speedo 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
o 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-fileo Need 4.2: Keep allocation of floor space constant
Ranked Customer Needs
Need The Product Needs to Imp.
N 1.1 Product integrity is maintained Meet specifications 5
N 1.2 Equipment satisfies USDA Regulations as well as the AMI checklist
Meet specifications 5
N 1.3 OSHA Safety requirements are met Meet specifications 4
N 2.1 Reallocate direct flipping labor Decrease man-hours 4
N 2.2 Reallocate direct alignment labor Decrease man-hours 4
N 2.3 Reallocate direct labeling labor Decrease man-hours 4
N 2.4 Camera labeling system is low priority Control project scope 4
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Flip Label P10715 Detailed Design Review Handout R01N 3.1 Maintain or decrease takt time Decrease processing
time 4
N 3.2 All packages get scanned by the x-ray at desired belt speed Scan all packages 3
N 4.2 Keep allocation of floor space constant Fit within specified area 3
N 3.3 Control flow to scaling operation(Control flow-rate variance)
Minimize variance 3
N 4.1A Label is in proper orientation and position relative to the package
Be aligned 3
N 4.1B All packages are centered in the x-ray beam Scan entire package 3
N 3.3A Packages must flow in a format that works with the X-ray Meet specification 2
N 4.1 Packages are in the proper orientation Be aligned 2
N 4.1Ba
Packages are conveyed in single-file Meet specification 2
N 1.3A Remove ergonomic issues and concerns Minimize risks 1
Importance Scale: 5 = Most Important, 1 = Preference Only
Engineering Metrics
MetricNeed Met Description Imp.UnitsMarginal
ValueIdeal Value
5 N 1, 2 USDA specs 5 Pass/Fail Pass Pass6 N 1, 2, 15 AMI Sanitary Design Checklist 5 Pass/Fail Pass Pass7 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%
Current11 N 1 Maintain product integrity 5 Pass/Fail Pass Pass8 N 9, 12 Flip product 4 Pass/Fail Pass Pass9 N 4, 8 Belt speed (x-ray) 4 m/s or ft/s Current Current
10 N 5 Direct label man hours 4 Hours <75% Current<50%
Current
12 N 15 Ergonomic risk 4CIC Risk Assess units
Current <24
1 N 4, 13 Flow rate 3 pc/min 7 >74 N 9, 12 Label orientation 3 Deg 85-95 90
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Flip Label P10715 Detailed Design Review Handout R01
2N 9, 10, 12, 13, 14
Pc. alignment 2 in from center TBD 0
3 N 9, 12 Pc. perpendicularity 2 Deg 85-95 9013 N 11, 14 Flow rate variance 1 % of Rate +/- 25-50% +/- 0-25%
Importance Scale: 5 = Most Important, 1 = Preference Only
Projected System Cost
Subsystem Component Component Cost Subsystem Cost
Flipping
Parts & labor $2,600
Mounting TBD $2,600+
Aligning
Parts $2,100
Labor TBD
Conveyor TBD $2,100+
Camera
System TBD 2-18 TBD
Labeling
Cal-Pak TBD 2-18
Label assist $660 + enclosure
TBD
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Flip Label P10715 Detailed Design Review Handout R01Revised System Footprint
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Flip Label P10715 Detailed Design Review Handout R01System Isometric View
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Flip Label P10715 Detailed Design Review Handout R01Flipper Assembly
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Flip Label P10715 Detailed Design Review Handout R01Flipper Drawing
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Flip Label P10715 Detailed Design Review Handout R01Welded Flipper Assembly
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Flip Label P10715 Detailed Design Review Handout R01Displacement Under Loading
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Flip Label P10715 Detailed Design Review Handout R01
Flipping Bill of MaterialsPN Vendor Description Qty Cost TotalSSM-042.75-DW Bimba SS Bimba 3/4" Cylinder 2 $106.65 $213.30D-54565-SS Bimba SS Rod Clevis and Nut 2 $24.95 $49.90D-55203-SS Bimba SS Cylinder Pivot Bracket 2 $19.40 $38.80
4331K33 McMaster
Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI 1 $277.02 $277.02
9785K56 McMaster.104" 304SS 24x24 1 $163.21 $163.219785K36 McMaster.104" 304SS 12x24 1 $86.00 $86.008992K166 McMaster.125" 304SS 12x4 1 $14.12 $14.126620K62 McMaster.25" 304SS 6x6 1 $21.65 $21.658457K556 McMaster3/8" x 6' 304SS Tube 1 $32.89 $32.8998697A530 McMaster10-32 SS Weld Nut 10 Pack 1 $6.73 $6.7394912A330 McMaster10-32 SS SHCS, 5 Pack 1 $4.53 $4.53
6196K243 McMaster
Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC 1 $117.42 $117.42
1901K21 McMaster
Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe 4 $2.62 $10.48
5203K18 Polybutylene Manifold Swivel Tube Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT Thread 2 $12.26 $24.52
9066K31 McMaster
Corrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction 2 $20.60 $41.20
5390K31 McMaster3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear 20 $2.10 $42.00
5111K548 McMasterPolybutylene & Brass Push-to-Connect Fitting Wye for 1/4" Tube OD, Gray 4 $4.91 $19.64
Labor Process Part/Description Time Rate All labor is estimate only
Cut/Form Flipper Tray 5 $80.00 $400.00Welding Flipper Tray 2 $80.00 $160.00
Cut/Form Flipper Mount 3 $80.00 $240.00 Welding Flipper Mount 2 $80.00 $160.00 Machine Mounts 3 $80.00 $240.00 Build Pneumatics/Controls 4 $40.00 $160.00
TOTAL$2,523.41
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Flip Label P10715 Detailed Design Review Handout R01
Flipper Controls Block Diagram
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Negative solenoidactivates for short time
Positive solenoid activates for short
time
Laser beam
reconnects
Laser beam broken
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Flip Label P10715 Detailed Design Review Handout R01
Aligning Proposed Solution
Flipper BOMPreliminary Bill of Materials to order from McMaster-Carr Rev-01
Item Part Number Qty
Unit Price Total
FDA-Compliant Rulon-Lined Guide Block, 1" Width
9728K3 4 $29.36 $117.44
13" Long Rail for 1" Width FDA-Compliant Rulon-Lined Guide Block
9728K62 4 $27.30 $109.20
Space-Saver Stacked Air Filter/Regulator Stainless Steel, 1/4" Pipe, 12 Max SCFM @ 100 PSI
4331K33 1 $277.02 $277.02
Body-Ported Solenoid Air Control Valve Dbl Solenoid, 4-Way, 2-Pos, 1 Cv, 1/4" NPT, 24 VDC
6196K243
1 $117.42 $117.42
Chemical-Resistant PVDF Tube Fitting Adapter for 1/4" Tube OD X 1/8" NPTF Male Pipe
1901K21 4 $2.62 $10.48
Polybutylene Manifold Swivel Tube 5203K18 2 $12.26 $24.52
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Flip Label P10715 Detailed Design Review Handout R01
Fitting 2 Outlets, for 1/4" Tube OD, 1/4" NPT ThreadCorrosion Resistant Air Flow Control Valve 1/4" Tube to 1/4" Tube Flow Control Direction
9066K31 2 $20.60 $41.20
3-A Sanitary White PVDF Tubing 1/8" ID, 1/4" OD, 1/16" Wall Thk, Semi-Clear
5390K31 20 $2.10 $42.00
General-Purpose Track Roller with Stud Stainless Steel, 89 lb Dynamic Load Capacity
60135K51
4 $36.65 $146.60
1' Rail for 89 lb Dynamic Load Capacity, SS General-Purpose Track Roller wth Stud
60135K521
1 $34.16 $34.16
7' 1.25"x1.25" 304 SS L-Channel, 3/16" Thick
8993K45 5 $67.49 $337.45
Multipurpose Stainless Steel (Type 304) #2B Mill Finish, .060" Thick, 24" X 36"
8983K33 3 $54.01 $162.03
18mm Dia Body Light Beam Sensing Switch NPN, DC Input, Object Reflecting with Male Plug
65845K22
2 $94.73 $189.46
Washdown Stainless Steel Air Cylinder 3/4" Bore, 6" Stroke Length
6239K115
2 $123.56 $247.12
Miscelaneous Stainless Steel Hardware (Panels, Bolts, Wasters…etc)
N/A 1 $200.00 $200.00
Materials Total Estimated Cost$2,056.
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Flipper Hour Estimates
Estimates for time requirements of human resourcesItem Qty Hours Total
Design 1 30.00 30.00Programming of Actuation System 1 10.00 10.00Diagnostics and Trouble Shooting 1 10.00 10.00Miscelaneous Welded Connections 1 6.00 6.00Conveyor System Modification 1 5.00 5.00Cover Box Assembly with Pivot Support Bridge
2 2.00 4.00
Pivoting Arm Assembly 2 2.00 4.00Miscelaneous Bolted Connections 1 2.00 2.00Mounting of Actuation System 1 2.00 2.00Actuator Support Brace 2 1.50 3.00
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Flip Label P10715 Detailed Design Review Handout R01
Actuator Mounting Bracket 2 1.50 3.00Pusher Plate Assembly 2 1.00 2.00Guide Rail Bracket 4 0.75 3.00Guide Rail Mounting 2 0.50 1.00 Total Estimated Time 85.00
System Integration and Occupancy
e
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Flip Label P10715 Detailed Design Review Handout R01
Pusher Side Profile
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Flip Label P10715 Detailed Design Review Handout R01
AppendixStress Analysis
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Flip Label P10715 Detailed Design Review Handout R01
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Flip Label P10715 Detailed Design Review Handout R01
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