Wegmans Bread Tray Lift Assist
• Goal:Improve ergonomics for operator during the task of stacking loaded bread trays at the Wegmans Bakery
Needs
• Enable good ergonomic practices in terms of lifting and body position
• Meet Wegmans safety requirements in terms of mechanical operation and physical aspects
• Meet Wegmans requirements in terms of cleaning and food contamination risks
• Ease of use for operator• The unit should be durable
and reliable
Specs
• Maintain a loading height at 33 inches
• Allow for food to descend no closer to the floor than ½ foot
• Allow max load of 5 trays at 115 lbf
And
Lift Tray Cart
Features:• V groove wheels• Redesigned as
skeleton• Cotter Pin• End Caps • Gussets• Double Support Bar• Locating Wedge
Problems and Solutions from Last meeting
• Dolly Sliding off• Hand Guarding• Piston Failure• Foot being crushed
by forks
• End Caps on Forks• Brush Guard System• Removable forks
(use in place)
• Hard stop at 2 inches (normal use leaves 2.75 inch clearance)
Updated Risks Updated Mitigations
• Springs failing• Materials not arriving
on time/correct material
• Air drop installation• Air piston damper
failing• Not used correctly
or at all
Designed with factor safety
BOM finished and ready to order
Verify with MikeDesigned with factor
safety involvedAsked operators what
they want/expect
Ergonomic Analysis
• NIOSH Lifting Equation:– When setting tray on ground: 1.7– With Bread Tray Lift Assist: 1.4
» Analysis of only 36 inch and below
• Percent improvement:
»17.6%
Ergonomics Continued
• Release button height: 45 inches from floor– Height based up elbow height for 95th percentile male
according to ANSUR database• Tray stack height: 30-36 inches from floor– Based upon height of hand at rest calculated from ANSUR
database• Reduces bending at waist– Lower risk of back strain
• No detriment to higher lifts• Additional suggestion: add anti-fatigue mat to floor
where operator stands
Safety Features
• Bright colored forks for visibility– Powder Coated Yellow
• Hard stop for forks at 2 inches above floor– Prevent foot from being crushed in a failure
situation• Removable forks removes collision hazard
when device is not in use