Egg.Inc Automation -- 2

Instructions SCENARIO – You work for a company that packages eggs for distribution across Ireland – for the purpose of this assignment will be known as “Eggs Inc”. The first section of the packaging process is automated; however, the second section is not. The current situation is that cartons containing one dozen eggs travel down a conveyor to a human operated station, once the first carton of eggs reaches the end of the conveyor it is detected by a sensor which stops the conveyor. At this station several operators carry out the following duties: - 1. Operator 1 manually unfolds a cardboard box from flat pack and tapes the bottom with a tape gun. He/she places 32 cartons of eggs into each box. As each carton is placed in the box it gets scanned into a computer by hand, while also being operator inspected for breakages, label issues and carton integrity. When the box is full the operator tapes the top of the box. He/she goes to a computer and prints a box label with the company’s details, the quantity of cartons in the box and their individual details (Traceability). 2. Operator 2 then takes the full box and transfers it to a pallet, each box that is placed onto the pallet gets scanned by hand. The pallet is stacked 3 x 3 boxes per row and 4 rows high. Once the pallet is completed the operator goes to a computer prints a shipping consignment label, applies it to the pallet and then film wraps the pallet by hand. 3. Operator 3 pulls the pallet with a manual pallet mover into an empty truck on the loading bay, as each pallet is placed on the truck it gets scanned on a computer and assigned to the truck number, which is scanned onto the system when the truck arrives. The truck can hold 24 pallets. Once the truck is full the operator generates the paperwork for the truck driver and the truck leaves. When the new truck arrives, the operator takes empty pallets back to operator 2. 4. At the end of his/her shift operator 3 walks to finance with the paperwork for each truck that has left. Finance then starts to send invoices based on this paperwork. 5. This process continues until all the eggs are packed. Eggs Inc. is supplied with eggs from 7 local farms. It is critical that the eggs get packed and shipped promptly to ensure a longer shelf life. The shift pattern at Egg Inc. is currently: - Days (8am - 4pm) & Evenings (4pm – 12am), Monday to Friday. PROBLEMS WITH EXISTING SYSTEM 1. Cartons with broken eggs are being reported from end customers. The transport company are denying any responsibility. Operator 1 is tasked with checking the final quality of the product by eye and says this is being done. No documentation is filed to prove this inspection so Eggs Inc. must bear responsibility for breakages. 2. The line stops during break times which backs up the automated section of the line and reduces productivity. 3. If an operator is off sick the output of the line is reduced as 2 operators now must work 3 stations. 4. Paperwork is frequently going missing between the production floor and finance meaning they are invoicing for less product than they are sending. 5. Stocks of consumables (boxes, tape and labels) frequently run low as people forget to order more from stores leading to downtime. 6. Downtime leads to a request for overtime on a Saturday. This is paid at a premium which reduces the profit margin of Eggs Inc. Also, they struggle to get people to work overtime which leads to good eggs being sold off at a big discount to pet food companies. Recently Eggs Inc. have signed contracts with another 5 farms and are expecting a surge in production levels beginning in 12 months’ time. As a mechatronics engineer on site, Eggs Inc. have assigned you the project of dealing with the task of automating the second section of the production line. This assignment will outline the steps to be taken from the beginning to the end of the project.