mission statement: the aim of this project is to improve the meat marinade tumbler transport in the...
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Mission Statement: The aim of this project is to improve the meat marinade tumbler transport in the Wegmans Culinary Innovation Center. Currently, meat is marinated in 2000 lb. capacity tumblers, dumped into 300-600 lb capacity vats, and then transferred into a vacuum packing machine. The current process suffers from many efficiency and ergonomic issues. The overall outcome of the project is to identify and implement process improvements in order to increase efficiency and safety of the workers.
Team:Eric Albanese – IETess Ambrose – MEJeremy Gray – IEOkechikere Ekeada – IEJesse Wykstra - ME
Sponsors: Chris IsaacsonWyatt NewbouldPaul Hickey
Advisor: John Kaemmerlen
Special Thanks to the Meat Tumbler Team!
Meat Tumbler Process Improvement
P10711 - Spring 2010
Proposal 2: Free wasted floor space
Proposal 3: Retrofit food dump tableProposal 4: Retrofit column dumper and VEMAG vats
Map Overall Process Flow
Concept Selection
Goals:• Improve ergonomics/safety and reduce risk of
work related injuries.• Reduce waste (i.e. remove unneeded items,
increase floor space, improve worker utilization)
Excess material handling equipmentsclutter the marinade room
Marinade room is in need of moreFloor space
High ergonomics/safety risk related to food dump table High ergonomics/safety risk related to column dumper and VEMAG vats
Fishbone Diagram
Proposal 1: Kaizen of Marinade Room
Results:
Additional Information can be found at: https://edge.rit.edu/content/P10711/public/Home
Before:
Concept:
Problems:• Excessive amounts of bending/twisting are
required for the employees to unload the dump table.• Hard to push/rotate the cart during transportation.• Cleaning process is very demanding, requiring the
employees to lift/flip the dump table over in order to drain it.Solutions:• A spring loaded grate design was added to the
dump table to greatly reduce the amount of bending/twisting required to unload the dump table
• Larger 6” diameter ,360° swivel casters were added to simplify the maneuvering of the dump table.
• The Cleaning process was simplified using a larger removable mesh drain, which eliminated the need to lift/flip the dump table over.
Before: Problems:
• Bending at the waist required to move vats.
• Incidents with shoulder pain from awkward angle of push, lower/mid-back pain from bending.
• Large force required to load vat into dumper, as well as to move dumper.
Solutions:• Raised handle
eliminates bending & awkward angle, adds place to properly grip vats.
• New casters make column dumper need less force to move it
• Vat latch requires only one worker instead of two
After:
Problems:• Excessive amount of VEMAG vats
taking up space on the floor• Too much inventory at the meat
packaging station
Solutions:• Used lean implementation tool,
Kaizen to identify waste and find ways to improve process.
• Use d process signals to establish a pull system, thereby reducing inventory in the packaging station and reducing number of VEMAG vats needed.
Problems:• Wegmans wants to add a separate
production line in the same refrigerated room as the meat tumbler.
• Existing chicken flattening process takes up approx 240 square feet due to poor space utilization.
Solutions:• Replace existing conveyor with a smaller,
more compact one• Rework layout to minimize amount of
‘dead space’.• Create standard work for higher outputs
• Reduced space utilization from 821ft2 to 408ft2 with kaizen events, layout optimization, and conveyor replacement
• Reduced ergonomic risks associated with pushing the VEMAG vats and column dumper to a safe level
• Reduced the ergonomic risks associated with pushing, unloading, and cleaning the dump tables to a safe level
Retrofit Dumptables
New Dumptables
Criteria Importance Score Wt Score Score Wt Score
Feasability 20 5 100 9 180
Cost 10 8 80 4 90
Difficulty to complete 10 8 80 5 90
Ergonomics 50 6 300 7 450
Process Impact (positive) 30 3 90 5 270
Totals: 650 1080
Tumbler1
receiving station
multivac station
V
V
Cart1
Cart3
Cart4
Cart6
Cart2
Cart7
cleaning station
VEMAG
conveyor
Elevator
Cart5
Identify and categorize different problems
Learn how the production room operates
Choose the best solutions based on different engineering metrics
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