Receiving Dock Automated Handling System

Overview

The key issue being evaluated in this project is how a kosher poultry processing company currently performs its unloading procedure of crates of live chickens. The current process involves a number of actions that lead the crew members to be more susceptible to injury. The DEPF Team was tasked with performing an analysis of the current system and providing a recommendation for changing the current procedure.

Objectives

The primary objective was to provide a recommendation for a new unloading procedure that would 1) reduce worker injury 2) reduce required labor and 3) provide opportunities for automation.

Approach

– Began by performing a site visit and evaluating, in detail, the current unloading procedure.

– Generated a series of concepts that would feasibly solve the problem.

– Performed a preliminary breakdown of ideas based on decision matrix and objectives to zero in on the best 3 ideas.

– Performed a robust analysis of each of the remaining 3 ideas under the lens of cost, safety, processing speed, and maintenance.

– Selected the best idea based on the concept evaluation.

– Assembled a final recommendation including updated process flow, materials to be purchased, downtime operations, and miscellaneous recommendations.

Outcomes

– The new, recommended solution will improve safety by reducing the CTD Risk Index from 2.559 to 1.071.

– The solution will eliminate the need for 1/2 of a worker’s time, generating cost savings of ~$20,000/year.

– The DEPF team also offered up additional recommendations on how to improve safety around the truck bed, adding weight capture to the process, and creating an additional set of exit stairs.

– There is room for improvement with future capstone teams to evaluate if a forklift could be removed from the process.