1. Wegmans Bread Tray Lift Assist Design Review 2

2. Wegmans Bread Tray Lift Assist • Goal:Improve ergonomics for operator during the task of stacking loaded bread trays at the Wegmans Bakery

3. And Specs 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 • 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

4. Finished Design

5. Finished Design Continued

6. Lift Tray Cart • Features: • V groove wheels • Redesigned as skeleton • Cotter Pin • End Caps • Gussets • Double Support Bar • Locating Wedge

7. Deflection and Force Analysis Deflection seen by max force of Forks W Max Deflection: 0.0152 inch

8. Deflection and Force Analysis Deflection seen by max force of top bar F Max Deflection: 0.01477 inch

9. Problems and Solutions from Last meeting • End Caps on Forks • Brush Guard System • Removable forks (use in place) • Hard stop at 2 inches (normal use leaves 2.75 inch clearance) • Dolly Sliding off • Hand Guarding • Piston Failure • Foot being crushed by forks

10. Updated Risks Updated Mitigations • Designed with factor safety • BOM finished and ready to order • Verify with Mike • Designed with factor safety involved • Asked operators what they want/expect • Springs failing • Materials not arriving on time/correct material • Air drop installation • Air piston damper failing • Not used correctlyor at all

11. 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%

12. 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

13. 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

14. Simulated Floor Plan 30” 30” 18” 36” Operator

15. Bill of Materials

16. Next Steps • Procurement of materials • Regulator • Floor Location • Planning shop fabrication time • Receiving • Air Cylinder Maintenance • Build and Test