Marble Cake Process Improvement – Final Review

Aaron DelahantyArwen SharpBenson Yu

Kenyon ZitzkaRyan Norris

Presentation OutlineMentality – As a team we have invested a lot into this project and have unavoidably

become attached. Despite this, the goal for this final review is to asses our progress up to present, our current project state, and future work in an honest and clear way that provides the most value to our customer.

• Project Re-scope– Schedule– Customer Needs

• Current Status– Near future test plans

• Known Issues• Deliverables• Project Insights• Acknowledgements

Project Re-scopeDue mainly to a quickly approaching deadline, fabrication, assembly and testing of the system components critical for task completion have been major focus of the second quarter. 

Fabrication, assembly, and testing of the following system components has been halted:• Cart• Shielding• Gate Mechanism

Team resources have been allocated to:• Assembly / calibration of Machine Head• Development of test process (product line mock-up)• PLC / Controls integration

Project Re-scope – Further Justification

Option 1• Force the delivery of a under

tested, unproven system

Option 2• Deliver well developed

machine ‘head’ prototype• Spend more resources further

investigating primary mechanisms

• Better develop PLC logic• More time testing and revising• Provide Wegmans with more

thorough documentation (including complete system design)

Current Project Status

Completion of Motor Module

• Motor

• Gear Train

• Quick Disconnect

• Swirlers

Complete Assembly of Machine Head/Chassis

• Pneumatic Actuation

• Sensor Integration

Initial PLC programming complete

• Sensor / PLC integration

Development of a test stand

• Simulation of product line environment

Initial Motor Module Testing(out of chassis)Swirl performance:

Initial Swirlers provide satisfactory results

Further refinement of design could significantly improve swirl aesthetics  

 

Near future Test Plans

 Prototype capability:

• Full mock-up of bakery conveyor line, designed to test and debug PLC integration

• Complete sheet pan batter testing

• Quality• Repeatability• Process Cycle Time• Batter Drip

• Fatigue / Endurance Testing

Known Issues

Vertical Translation – Pneumatics / Guide Rails Design:• Root Cause – Design requires unrealistic precision given available

resources• Warping of box frames•  Low angular misalignment allowance• Even if consistently smooth translation achieved, must be

secured as well

Potential Solution: • Alternative linear bearings• Neutrally load the middle frame (Solutions 1 & 2, low cost,

easily implemented)• Stronger box frame• High precision machining• Investigation of alternative lift / alignment mechanisms

Signal communication between sensors, actuators, PLC • Root Cause – Poor schematic documentation• Temporary Test Set-up

Potential Solution: 1. Complete electrical schematic2. Cleaner wire routing

Known Issues

Inadequate Aesthetic Swirler Performance (unconfirmed):• Root Cause – Untested final swirler prototype

• Variability due to manufacturing

Potential Solution: • Further testing• Swirler redesign and remanufacture (Relatively low cost,

easily implemented)

Further Pan Alignment Calibration • Root Cause – Edge tolerances (Both inductance sensor and Swirler Maximum Radius Condition)

Potential Solution: 1. Development of auxiliary guide mechanism 2. Loosen Edge Tolerances (Sacrifice swirl area)

Summary of Deliverables 

• Complete functioning prototype

• PLC Logic

• Wiring Schematics

• Complete CAD library– Drawings– 3D models– Hierarchy

•BOMs

• Explanation of current design choices and recommendations for future work

General Insights / Recommendations for future work• Early communication with machinists

• Lack of PLC / ladder logic from either ME or EE RIT curriculum

• Make availability of resources known• PLC programming• Wegmans recommended parts and specs

• Manufacturability of Design

Acknowledgments

• Professor John Kaemmerlen

• Mike Least

• Gary Kittrell

• Rick Norder

• Tony Contrera and Dean Wight

• Professor Scott Bellinger and his class

And thank you to Wegmans for the opportunity.