© 2004 kraft senior design project improvements to juice work cell team members: jessica vastola -...
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© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Improvements to Juice Work Improvements to Juice Work CellCell
Team Members:Team Members:
Jessica Vastola - ISEJessica Vastola - ISE
James Hildick - MEJames Hildick - ME
Molly Kearns - ISE Molly Kearns - ISE
Michael Leiston - MEMichael Leiston - ME
Laura Pleten - MELaura Pleten - ME
Michael Russell - MEMichael Russell - ME
Nicole Verley - MENicole Verley - ME
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
AgendaAgenda BackgroundBackground Needs AssessmentNeeds Assessment Concept DevelopmentConcept Development Feasibility AssessmentFeasibility Assessment Design SpecificationsDesign Specifications Analysis & SynthesisAnalysis & Synthesis Conclusion & Next StepsConclusion & Next Steps QuestionsQuestions
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
BackgroundBackground
Kraft Lunchables with juice pouchesKraft Lunchables with juice pouches Movie clipMovie clip
Scope - Juice SupplyScope - Juice Supply 10-packs10-packs Current ergonomic risk factor Current ergonomic risk factor Current toolCurrent tool
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Needs AssessmentNeeds Assessment
Project Mission StatementProject Mission Statement Product DescriptionProduct Description Scope LimitationsScope Limitations Key Business GoalsKey Business Goals Financial ParametersFinancial Parameters
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Critical Performance Critical Performance ParametersParameters
Order QualifiersOrder Qualifiers Reduce ergonomic risk Reduce ergonomic risk
factorfactor Maintain line speedMaintain line speed Reduce required number Reduce required number
of passes of passes Meet safety regulations Meet safety regulations
and industry standardsand industry standards Weigh less than 10 Weigh less than 10
poundspounds Measure less than Measure less than
16”x10”x12”16”x10”x12”
Order WinnersOrder Winners Open four 10-packs at Open four 10-packs at
onceonce Clean & sanitize easilyClean & sanitize easily Consist of off-the-shelf Consist of off-the-shelf
materials for easy materials for easy replacement partsreplacement parts
Maintain juice pouch Maintain juice pouch integrityintegrity
Require one operatorRequire one operator Assist operation via Assist operation via
pneumaticspneumatics
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Concept AlternativesConcept Alternatives ““THE WEDGE”THE WEDGE” Handheld ToolHandheld Tool Stationary ToolStationary Tool
0
1
2
3
4T1
T2
E1
S1
S2
S3R1
R2
R3
R4
R5
Wedge
Handheld
Stationary
Baseline
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Concept DevelopmentConcept Development
Baseline concept – Kraft toolBaseline concept – Kraft tool Desire to open box in one Desire to open box in one
passpass Toggle designToggle design Tested required force for Tested required force for
openingopening PneumaticsPneumatics Desire to open one bundle Desire to open one bundle
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Feasibility AssessmentFeasibility Assessment
Design FeasibilityDesign Feasibility Materials FeasibilityMaterials Feasibility Fabrication FeasibilityFabrication Feasibility Cost FeasibilityCost Feasibility Ergonomic FeasibilityErgonomic Feasibility
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Design SpecificationsDesign Specifications Generates 300 lbs of Generates 300 lbs of
forceforce Operates with 110 psi Operates with 110 psi
plant pressureplant pressure Trigger ActuatedTrigger Actuated Desired weight < 10 lbsDesired weight < 10 lbs CompactCompact Build with food grade Build with food grade
materialsmaterials
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Analysis & SynthesisAnalysis & Synthesis
Force Force measurements & measurements & calculationscalculations
Pneumatic cylinder Pneumatic cylinder calculationscalculations
Estimated Estimated ergonomic risk ergonomic risk factorfactor
FORCE:# Risk Factor RVF1 Two handed lift greater than 20lbs 2F2 Vertical travel distance of lift, greater than 60" 0F3 Horizontal lifting reach greater than 20" from the body 0F4 Two handed carry greater than 30 lbs 0F5 Horizontal carry distance of greater than 20 ft 0F6 Two handed horizontal push / pull greater 40 lbs 0F7 Two handed vertical push / pull greater than 25 lbs 1F8 Trunk rotation with a weight greater than 10 lbs 2F9 Wrist rotation while manipulating greater than 6 lbs 0F10 One hand horizontal palmer push greater than 15 lbs 0F11 Use of hand tool greater than 7 lbs 2
FORCE RF TOTAL= 7
POSTURE:# Risk Factor RV
P1 Trunk forward flexion greater than 45o 0
P2 Trunk extension greater than 20o 0
P3 Neck flexion or extension greater than 45o 0P4 Trunk or next side-bent plus twisted 0
P5 Shoulder abduction greater than 90o 0P6 Working with hands or arms behind the body 0P7 Full elbow extension with shoulder elevation 0
P8 Elbow flexion greater then 135o 0
P9 Wrist flexion or extension greater than 65o 0
P10 Wrist ulnar or radial deviation greater than 25o 0P11 Forced pronation or supination of hand & wrist 0
POSTURE RF TOTAL= 0
OTHER RISK FACTORS: (Note: Each "Y"=RV Value of 2)# Risk Factor YESO1 Unusually high tool or floor vibration NO2 Frequent ladder or stair climbing NO3 High exposure to direct pressure or mechanical stress NO4 Work with hands over shoulder level for greater than 50% of cycle NO5 Squat or kneel for greater than 50% of cycle NO6 Stand on one leg for greater than 50% of cycle NO7 Awkward / immobile body position for greater than 50% of cycle NO8 Greater than 6 thumb and or finger exertions with one hand N
OTHER RF TOTAL= 0ERF Total= 7
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Analysis & SynthesisAnalysis & SynthesisCylinder Mounting PlateCylinder Mounting Plate
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Analysis & SynthesisAnalysis & SynthesisMainframeMainframe
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Analysis & SynthesisAnalysis & SynthesisGuide Rod PlateGuide Rod Plate
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Analysis & SynthesisAnalysis & SynthesisRod PlateRod Plate
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Failure Mode & Effects Failure Mode & Effects AnalysisAnalysis
Actions Taken
Sev
Occ
Det
RPN
Juice pouch punctured
5 Tool inserted too far due to too much force
2 Guide plate 1 10 readjust guide plate, repeat air pressure/throttle testing
Operator Accurate guide plate
5 1 1 5
Open Boxes Tool uncomfortable
Ackward handle orientation
7 Insufficient Design 1 Prototype testing 1 7 Alter design of handles
RIT Senior Design Team
Design and testing
7 1 1 7
Unsatisfatory grips 4 Insufficient Material 1 Removable rubber grips2 8 Replace rubber grip
Operator Designed to be removable
4 1 1 4
8 1 1 88 Replace rods Operator Reapplication of Lubrication
Open Boxes Fatigue/stress on the rods
Tool inoperable 8 Bushing Failure 1 Lead Bushings, Graphite spray Lubrication
1
1 6 Reorient toggle Operator
1 12
Open Boxes Toggle rotating on end of rod
Boxes fail to open 3 Insufficient anti-rotation mechanism
2 generally durable
Operator 2 torsion springs added
4 3generally durable 1 Open toggle bolt manually
28
Function
Toggle opening Malfunction
Open Boxes Boxes fail to open 4 Toggle not spreading properly, spring strength
7
SEV
Potential Effect(s) of Failure
Potential Failure Mode
Detec
Current Design Controls
Occur
Potential Cause(s)/ Mechanism(s) of
Failure
Action ResultsResponsibility
& Target Completion
Date
Recommended Action(s)
RPN
© 2004 Kraft Senior Design Project© 2004 Kraft Senior Design Project
Conclusion & Next StepsConclusion & Next Steps One passOne pass Reduce Ergonomic RiskReduce Ergonomic Risk Maintain Line SpeedMaintain Line Speed Contingency PlansContingency Plans
Use same concept, open less than 4 boxesUse same concept, open less than 4 boxes Re-design current hand toolRe-design current hand tool
Address Recent Kraft RecommendationsAddress Recent Kraft Recommendations Build and Test Build and Test Conduct Feasibility Assessment on entire Conduct Feasibility Assessment on entire
workstationworkstation