System Design MSD I Phase II Hilltop Bottle

System Design MSD I - Phase II Hilltop Bottle Club

Agenda ● ● ● Functional Decomposition Benchmarking Analysis Current State Analysis System Alternatives Next Phase

Functional Decomposition ● Please refer to the handout

Benchmarking ● Two different recycling processes were investigated: ○ ○ ● ● Monroe County Recycling Center (Waste Management) Tomra automated self-service machines (found at Wegmans locations in the greater rochester area) Benchmarking consisted primarily of online research Goal is to compare these processes with the current Hilltop process and specify how functions are performed across each process.

Benchmarking - Monroe County Recycling Center ● ● Note that this facility is single-stream, so containers are processed alongside other paper/plastic products Recyclables are picked up curbside at customer locations Pre-sort to remove trash, then fully automated sorting process until bale pickup See graphic in handout

Benchmarking - Tomra Self-Service Bottle/Can Return ● ● Separate machines for glass, plastic/cans Automated back-end processes sort and compact containers Customer receives deposit by taking receipt to attendant Non-returnables will be rejected by machine

Benchmarking - Concept Development

Key Findings from Benchmarking ● ● Both Hilltop and Monroe County processes use a manual pre-sort step where trash is removed. For the Tomra reverse vending machines, non-returnables and trash are simply not accepted by the machine. Both Monroe County and Tomra processes containers further by crushing/compacting them ○ ● This makes container size less critical Computerized counting and/or display screen for customer is used in both other processes and could be beneficial at Hilltop

Current State Analysis - Floor Plan

Current State Analysis - Time Study Process and Standards Purpose: To capture average container processing time and variation for pre-sort, and count functions, as well as any perceived inefficiencies. Information tracked: ● Function ● Type and Size of Container ● Number Processed ● Time Taken ● Process Location ● Any notable events that took employee away from primary function.

Time Study Data and Analysis Containers Processed Per Minute Function Avg. Containers / Minute Std. Dev. / Avg. Pre-Sort 30. 34 17. 08 56% Count 28. 69 5. 81 20% Sort 11. 71 7. 57 65% Sort/Count 5. 45 0. 53 10% Main Takeaways: ● High variability ● Glass bottles have the highest opportunity for productivity improvement (Sort/Count)

Time Study Data and Analysis Time Spent Outside of Primary Function Time Spent Outside Function (min) Tot. Time Studied (min) Outside Function / Total Pre-Sort 26. 37 61. 37 43% Sort 46. 91 113. 44 41% Count 15. 66 78. 07 20% Sort/Count 10. 97 15. 04 73%

Time Study Data and Analysis Time Spent Outside of Primary Function Activity Time (min) Frequency Top Sub-Groups Activity Time (min) Bagging/Boxing Activity 53. 05 75 Removing Bags 24. 51 Left station 22. 65 20 Fixing ripped bags 10. 82 Paused at station 9. 53 57 Emptying liquid 2. 19 Writing 5. 21 23 Recording count all Customer interaction 3. 60 6 Give deposit 1. 87 Computer entry 3. 04 6 Entering total all Talking 2. 82 4 Asked about unknown container 2. 03 99. 91 191 Grand Total

Morphological Chart Purpose: 1) To break down individual functions and brainstorm isolated ideas for those functions. 2) Combine isolated function solutions to form different system concepts

Morphological Chart

System Alternative 1 1. 2. Customer dumps bags onto sorting counter or drops them off with a tag Initial sort is done a. 3. Containers are sorted into vertical racks with colored-coded, slotted shelves based on size and brand. a. b. c. d. e. 4. 5. Finished bags are put in appropriate hopper in main building Shelf slots are pre-sized and have only enough slots for the assigned count based on the container type. Once the shelves fill up, the count is known and the whole rack can be emptied, eliminating the need for a separate counting process Requires as many shelves as there are discrete size/brand combinations - as many bins as there are currently. Containers are placed in shelf slots with the aid of demonstration labels and color coding Foot-pedal release device that drops containers out of shelf and into bag After bags are counted, they are put in a pre-staging shelf in the main building based on size/brand. When pre-staging shelf is filled, cart is used to transfer to truck or staging area in warehouse depending on if the appropriate truck is there Risk Assessment ● New Container Type - Process for creating a new vertical rack for the new container type ● Vertical Rack Breakdown - Process to fix/replace wheels or shelves on rack

System Alternative 2 1. 2. 3. 4. Customer puts containers on conveyor belt or drops off tagged bags Initial sort is done into mobile bins Once mobile bin is filled, it is rolled to the sort process Containers are sorted as they are now, in the case of an “I don’t know”, a barcode scanner is used and flashes a color, corresponding to appropriate bin a. 5. Bins have IR counter around lid that automatically counts containers as they are dropped in. Once the display reads out the appropriate number, the bag is replaced. This eliminates the need for a separate counting process. When a bag is done, it is put in a cart in the main building. When that cart is filled, it is moved to the Hutch Risk Assessment ● New Container Type - Process for adding new container to barcode scanner database ● Conveyor Belt/IR Counter Malfunction - Manufacturer documentation for each device, plans to work around device during downtime, setup process for each device ● Employee Safety - Create safety documents and signs for where not to place hands/product on conveyor belt

System Alternative 3 1. 2. 3. Customer dumps bags onto sorting counter or drops tagged bags off Initial sort is done and full bags are put in staging hopper before being sorted Containers are sorted as they are now, in the case of an “I don’t know”, a barcode scanner is used and flashes a color, corresponding to appropriate bin a. b. 4. Bins have mechanical turnstile that automatically counts containers as they are dropped in. Once the display reads out the appropriate number, the bag is replaced. This eliminates the need for a separate counting process. When a bag is done, it is put on a shelf in the adjoining warehouse before it is placed on the truck with a cart Risk Assessment ● New Container Type - Process for adding new container to barcode scanner database ● Mechanical Turnstile - Manufacturer documentation for device, plans to work around device during downtime, setup process for each device ● Employee Safety - Create safety documents and signs for potential injury on turnstiles

Concept Selection (Pugh Chart)

Systems Architecture

Designs and Flowcharts

Updated Gantt Chart

Schedule Structure You Are Here

Plans for Next Phase ● Complete description of process design prior to the building and testing portion of the project ● Detailed design for high and medium technical risks ● Develop a test plan ● Risk assessment, mitigation plans and triggers ● Collect clear evidence that our design will meet the requirements ● Consider rapid experiments as preparation for build and test

Questions?