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Process Innovation Track R10002

Process Innovation Track R10002. Eric Albanese Helen Jervey Barret Zeinfeld Josh Monsees. Process Innovation Track. Recent past 8 projects, 5 companies Dresser Rand Gleason Works Wegmans Cooper Vision Parlec Looking forward 5 projects, 2 companies 3 Wegmans 2 Dresser Rand.

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Process Innovation Track R10002

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  1. Process Innovation TrackR10002 Eric Albanese Helen Jervey Barret Zeinfeld Josh Monsees

  2. Process Innovation Track • Recent past • 8 projects, 5 companies • Dresser Rand • Gleason Works • Wegmans • Cooper Vision • Parlec • Looking forward • 5 projects, 2 companies • 3 Wegmans • 2 Dresser Rand R10002 Process Innovation

  3. Project Status Update • Cooper Vision • Decided not to have a MSD project • Wegmans • Increased from 2 to 3 winter start projects • Dresser Rand • Expressed interest in 2 winter start projects • 2nd project overview meeting is November 11 R10002 Process Innovation

  4. Wegmans Project Roadmap R10002 Process Innovation

  5. Wegmans Intellectual Property Considerations • Layout currently available to public • Recipes and labor rates are confidential • Employee identities confidential • Capacity is confidential • Other intellectual property concerns will be addressed as needed R10002 Process Innovation

  6. P10711Wegmans Meat Tumbler Process Improvement Eric Albanese

  7. Mission Statement • Product Description /Project Overview • 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 600-1200 lb capacity vats, and then transferred into a vacuum pack machine (Multivac). The current process suffers from many efficiency and ergonomic issues. The overall outcome of the project is to identify and implement process improvements or changes in order to increase efficiency and safety of the workers.  • Key Business Goals/Project Deliverables • The implementation of a new system to safely move the meat from the tumbler to the vacuum packaging line.  In the situation where multiple items need to be fabricated, a prototype is sufficient.    R10002 Process Innovation

  8. Project Relevance • Primary Customer /Project Opportunities • Wegmans Corporation (Scott Young & Chris Issacson) • Opportunity to save money on required labor • Reduce the high cost of injuries • Secondary Market /Project Opportunities • RIT • Develop future projects with Wegmans • Employees • Benefit from a safer work environment (morale) • Meat Product Customers • Potential higher quality or less expensive product • RIT Students • Opportunity to work on an open ended, interesting project R10002 Process Innovation

  9. Staffing Requirements • Project Lead (Eric Albanese) • IE Student – Ergonomics • IE Student – Lean Engineering • IE Student – Ergo/Process Integration • ME Student – Transport/Cart Design • ME Student – Transport/Cart Design R10002 Process Innovation

  10. Current Process ~1000 lbs R10002 Process Innovation

  11. Preliminary Work Breakdown Structure R10002 Process Innovation

  12. Required Resources • People: • RIT – John Kaemmerlen (Faculty Guide) • RIT – Dr. Matthew Marshall (Faculty Consult) • Wegmans – Chris Isaacson • Wegmans – Scott Young • Wegmans – Culinary Center Employees • Environment: • RIT – Senior Design Center • Wegmans – Culinary Innovation Center • Equipment: • RIT – Computer Labs • RIT – Manufacturing Labs R10002 Process Innovation

  13. Affinity Diagram R10002 Process Innovation

  14. Objective Tree – Why Does the Customer Need Help? R10002 Process Innovation

  15. Function Tree – What does this product need to do? R10002 Process Innovation

  16. House of Quality R10002 Process Innovation

  17. House of Quality Priorities • Standardize process • Standardize flow • Reduce number of hazards R10002 Process Innovation

  18. Target Specifications • Primary Goals • Safety • Reduce the risk of existing safety incident/near miss from using cart • (Year to date: 3 incidents, Goal: 0 incidents) • Reduce meat transport bin movement ergonomic issues to within OSHA recommended levels • Reduce meat transport bin unloading ergonomic issues to within OSHA recommended levels • Utilization • Through process improvements, work to reduce the number of labor hours needed • (Current per day: 55.02 hours, Goal: TBD) • Develop new product flow to keep workers utilized in a more constant, level manner • (Current utilization: 52.5% (OEE), Goal: TBD) • Improvements above must not slow down process • Secondary Goals: • Reduce meat tumbler loading ergonomic issues to within OSHA recommended levels • Reduce the number of labor hours needed for Multivac • (Current per shift: 128.38 hours, Goal: TBD hours) R10002 Process Innovation

  19. Risk Assessment R10002 Process Innovation

  20. P10713Wegmans Batch Prep Project Josh Monsees

  21. Mission Statement • Product Description /Project Overview • The batch prep process currently takes place in the Central Kitchen and is where the ingredients for soups and sauces are batched and prepped for cooking. Currently there are capacity constraints that exist and Wegmans has no room to expand the current facility. • Key Business Goals/Project Deliverables • Develop Rate of Expectancy (RE) in lbs/hour for each product to assist in scheduling needs • Develop standard work procedures • Develop a layout to facilitate standard work procedures • Analyze and make necessary improvements to ergonomic issues to meet OSHA recommended levels R10002 Process Innovation

  22. Project Relevance • Primary Market /Project Opportunities • Wegmans Corporation (Scott Young & Chris Issacson) • Opportunity to increase capacity of current process • Create a safer work environment for all employees • Secondary Market /Project Opportunities • RIT • Develop future projects with Wegmans • Wegmans Employees • Benefit from a safer, more productive work environment • Soup and Sauce Customers • Higher availability of product • RIT Students • Opportunity to work on an open ended project for a Fortune Magazine number 5 best company R10002 Process Innovation

  23. Staffing Requirements Project Lead - (Josh Monsees) IE Student – Ergonomics IE Student – Lean Engineering ME Student – Layout/Tool Design ME Student – Layout /Tool Design R10002 Process Innovation

  24. Preliminary Work Breakdown Structure R10002 Process Innovation

  25. Required Resources • People: • RIT – John Kaemmerlen (Faculty Guide) • RIT – Dr. Matt Marshall (Faculty Consult) • Wegmans – Chris Issacson • Wegmans – Scott Young • Wegmans – Culinary Center Employees • Environment: • RIT – Senior Design Center • Wegmans – Culinary Innovation Center • Equipment: • RIT – Computer Labs • RIT – Manufacturing labs R10002 Process Innovation

  26. Affinity Diagram – Batch/Prep Process R10002 Process Innovation

  27. Objective Tree – Why Does the Customer Need Help? R10002 Process Innovation

  28. Function Tree – What does this product need to do? R10002 Process Innovation

  29. House of Quality – Batch prep R10002 Process Innovation

  30. House of Quality Priorities • Increase capacity per shift of overall process • Increase productivity of workforce (lbs/hr) • Improve process flow R10002 Process Innovation

  31. Target Specifications • Primary Goals • Develop Rate of Expectancy (RE) for each product to assist in scheduling • Develop standard work procedures to help increase capacity to meet peak customer demands • Develop a Layout to facilitate standard work procedures • Analyze and make necessary improvements to ergonomic issues to meet OSHA recommended levels • Secondary Goals • If full implementation is not feasible, develop a proposal to implement ideas • Develop safety procedures to limit the risk of long term injuries R10002 Process Innovation

  32. Risk Assessment R10002 Process Innovation

  33. P10715Wegmans Flip Label Process Improvement Helen Jervey

  34. Mission Statement • Product Description /Project Overview • The goal of this project is to reduce labor requirements for the flip package/label meat 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 • One or more operators are then needed to weigh the product. • Key Business Goals/Project Deliverables • Implement machine to automatically flip and align packages • Devise quicker labeling process • Control package accumulation at scaling operation R10002 Process Innovation

  35. Project Relevance • Primary Customer /Project Opportunities • Wegmans Corporation (Scott Young & Chris Issacson) • Reduce direct labor costs • Maintain or increase throughput • Secondary Market /Project Opportunities • RIT • Develop future projects with Wegmans • Employees • Improved work tasks and work environment • Meat Product Customers • Potential for higher quality or less expensive product • RIT Students • Opportunity to work on multidisciplinary, practical project R10002 Process Innovation

  36. Staffing Requirements • Project Lead (Helen Jervey) • ME Student – Mechanics Design • ME Student – Mechanics Design • ME Student – Mechanics Design • EE Student – Sensor/Control Design • EE Student – Sensor/Control Design R10002 Process Innovation

  37. Preliminary Work Breakdown Structure R10002 Process Innovation

  38. Required Resources • People • RIT – John Kaemmerlen (Faculty Guide) • RIT – TBD (Faculty Consult) • Wegmans – Chris Isaacson • Wegmans – Scott Young • Wegmans – Culinary Center Employees • Environment • RIT – Senior Design Center • Wegmans – Culinary Innovation Center • Equipment • RIT – Computer Labs • RIT – Manufacturing Labs R10002 Process Innovation

  39. Affinity Diagram R10002 Process Innovation

  40. Objective Tree – Why Does the Customer Need Help? R10002 Process Innovation

  41. Function Tree – What does this product need to do? R10002 Process Innovation

  42. House of Quality R10002 Process Innovation

  43. House of Quality Priorities • Reduce flip labor • Reduce label error • Keep single piece flow R10002 Process Innovation

  44. Target Specifications • Primary Goals • Implement device to flip and arrange meat packages on conveyor • Reduce needed direct labor hours on line through process improvements • Current labor hours/day: 18.34 • Goal: 0 • Secondary Goals • Implement system or device to reduce direct labor hours associated with labeling packages • Current labor hours/day: 9.45 • Goal: TBD • Tertiary Goals • Implement system or device to regulate and control accumulation of meat packages at scaling operation R10002 Process Innovation

  45. Risk Assessment R10002 Process Innovation

  46. P10457Layout/Storage Improvement at Dresser-Rand Barrett Zeinfeld

  47. Mission Statement • Product Description /Project Overview • Because Dresser-Rand has such large amounts of capital in inventory, the storage and layout of the facility can cut cost dramatically. The team will be asked to explore any and all feasible options with the current layout of the inventory area to better the flow of product and improve tracking and storage of material. • 360 hourly employees/160 salary employees • Can pick anywhere from 5-500 parts for one process • 16000 parts in the inventory area • Key Business Goals/Project Deliverables • The team will be required to submit a layout proposal with accurate justification data, operation procedures on how to maintain new culture, inventory storage racking proposals (implementation if possible), and some sort of tracking system (ex. Supermarket). R10002 Process Innovation

  48. Project Relevance • Primary Customer /Project Opportunities • Dresser-Rand (Person of Contact: Holly Dunaway) • Enormous opportunity to save money by cutting inventory on site and by storing inventory and material more efficiently (2 day lead time to gather parts for workers) • Minimize travel cost/distance (200-300 feet/pick, over a mile a day of walking) • Ergonomically how do they handle such massive parts? (only have 1 jib crane) • Operation discipline is very weak • Secondary Market /Project Opportunities • RIT • Develop future projects with Dresser-Rand • Employees • Benefit from a more efficient work environment (morale, productivity) • Dresser-Rand Customers • Potential higher quality or cheaper product • RIT Students • Opportunity to work on an open ended, interesting project and opportunity for future employment R10002 Process Innovation

  49. Staffing Requirements • Project Lead IE – PM/Layout/Inventory Storage • IE Student – Layout/Inventory Storage • IE Student – Lean Engineering/Culture Change • Including standard operating procedures, visual aids, and kanban/supermarket types of systems • IE Student – Lean Engineering/Culture Change • ME Student – Material Handling/Shelving Design • ME Student – Material Handling/Shelving Design R10002 Process Innovation

  50. Intellectual Property Considerations • Layout is in house only but not confidential • Labor rates and part prices are confidential • Total amount of inventory ($) will be confidential • All Turbine production plans are confidential • No picture of the current Turbine can be taken R10002 Process Innovation

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