Abstract:
A method and layout for loading food and beverages onto a plurality of trays. The method includes, for each tray in the plurality of trays, performing tray-loading method that includes the steps of selecting a tray from the plurality of trays; and loading the tray with food and beverages, to form an individual, customized tray. Each step in the tray loading method is performed at a different station in a plurality of stations. A path of travel extends alongside the plurality of stations. The first step in the tray-loading method is executed at a starting point in the plurality of stations. The path of travel includes a starting point adjoining the first station. The last step in the tray-loading method is executed at a last station in the plurality of stations. The path of travel includes an end point adjoining the last station. The end point and the starting point in the path of travel are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to perform in the first step of the tray-loading method on the next tray at the first station.

Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates in general to a system and a method for assembly of trays, and more particularly to an ergonomic food and tray assembly layout for a single operator, for use in health care or other institutional setting.  
         BACKGROUND OF THE INVENTION  
         [0002]    Many systems are known for preparing large quantities of trayed meals and like. A common example is the preparation of meals for airlines. These are usually carried by specialized catering companies, who supply fully replenished carts or trolleys directly to aircraft for use.  
           [0003]    However, preparation of meals for airlines has some unique characteristics. At least for regular or economy meals, the total number of items is limited; for most items passengers are not given any choices, e.g. salads, desserts, etc. Commonly, passenger may be given a choice between two main dishes. These main dishes are often prepared and stored separately from the trays themselves, so they can be readily rethermalized, so that the basic tray layouts are all the same. Consequently preparation of such trays is readily achieved on a production line set up.  
           [0004]    Preparation of meals in hospitals and institutional settings poses entirely different problems. Firstly, there may be a selection from as many as 35 to 40 items, giving many different combinations. All of these items must be stocked. Many such large institutions require meals or food to be prepared in large quantities and for this food to be individually delivered to many people. This commonly arises in hospitals and institutions for caring for elderly or chronically ill people. Traditionally, such institutions would have a kitchen on site and the meals would be prepared and immediately delivered from the kitchen by a cart to the patients. More recently and traditionally, for such institutions it has been recognized that there are advantages to preparing trayed meals or food in a more systematic way, using a local or external facility. Such external facilities often use an assembly line process, which increases the speed at which trays may be loaded. These assembly line facilities can typically provide loaded trays at a much higher rate than less systematized processes. However, assembly lines suffer from a number of disadvantages.  
           [0005]    Patients in hospitals or residents of nursing homes often have specific dietary needs and wants. Thus, there is a need to customize each tray based on the dietary requirements of the person receiving the tray e.g. diabetic diet, liquid diet, etc. In an assembly process, it is often the case that no one individual has ownership, or is accountable, for each completely assembled tray as it is delivered to the patient. Where trays containing the wrong food or beverage items are delivered, it will be difficult to hold specific operators accountable, and thus difficult to correct the problem. Also, in such arrangements, the staffing requirements can be relatively high, leading to inefficiencies and low rates of productivity, due to constant imbalance of workload for each of the assembly line workers.  
           [0006]    Accordingly, there is a need for a method and system for loading individual customized trays that is both systematic and efficient, while enabling responsibility and accountability for each tray to be assigned.  
         SUMMARY OF THE INVENTION  
         [0007]    In accordance with the first aspect of the present invention there is provided an improved tray assembly layout for loading food, condiments, wares, cutlery, and beverages (or at least some of these) onto a plurality of trays. The tray assembly layout comprises a plurality of stations for performing, for each tray in the plurality of trays, and a path of travel for an operator to follow to reach each station in the plurality of stations. The tray-loading method includes the steps of selecting a tray from the plurality of trays; and, loading the tray with food and beverages. The plurality of stations includes a first station for performing a first step in the tray-loading method and a last station for performing a last step in the tray-loading method. The path of travel extends alongside the plurality of stations, and includes a starting point adjoining the first station and an end point adjoining the last station. The starting point and the end point are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to performing the first step of the tray-loading method on the next tray at the first station.  
           [0008]    In accordance with the second aspect of the present invention there is provided an improved tray assembly method for loading food, condiments, wares, cutlery and beverages onto a plurality of trays. The method comprises the steps of, for each tray in the plurality of trays, performing a tray-loading method. The tray-loading method includes the steps of (a) selecting a tray from the plurality of trays, and (b) loading the tray with food and beverages. Each step in the tray-loading method is performed at a different station in a plurality of stations. A path of travel extends alongside the plurality of stations. The first step in the tray-loading method is executed at a first station in the plurality of stations. The path of travel includes a starting point adjoining the first station. The last step in the tray-loading method is executed at a last station in the plurality of stations. The path of travel includes an end point adjoining the last station. The end point and the starting point are adjacent such that an operator can quickly move from performing the last step of the tray-loading method on a tray at the last station to performing the first step of the tray-loading method on the next tray at the first station. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]    For a better understanding of the present invention, and to show more clearly how it may be carried into effect, reference will now be made, by way of example, to the accompanying drawings which show a preferred embodiment of the present invention and in which:  
         [0010]    [0010]FIG. 1 is a plan view of a system in accordance with the present invention;  
         [0011]    [0011]FIG. 2 is an elevational sectional view along line DD of FIG. 1;  
         [0012]    [0012]FIG. 3 is an elevational sectional view along line EE of FIG. 1;  
         [0013]    [0013]FIG. 4 is a sectional view along line CC of FIG. 1;  
         [0014]    [0014]FIG. 5 is a sectional view along line BB of FIG. 1;  
         [0015]    [0015]FIG. 6 is a sectional view along line AA of FIG. 1;  
         [0016]    [0016]FIG. 7 is an elevational sectional view along D 1 D 1  of FIG. 1; and  
         [0017]    [0017]FIG. 8 is a perspective view of the system of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0018]    The system as a whole is intended to provide an ergonomic environment or station, to enable a single operator, or possibly more than one operator as detailed below, to assemble a complete food tray. Such a system is primarily intended for use in health care and other institutional applications, for preparation of selected, individual menus. A prime characteristic of the system is to arrange all of the elements as ergonomically as possible. This then enables an operator to assemble an individual tray quickly, efficiently and accurately. Having a single operator assemble each tray is believed to lead to greater efficiencies, and a greater degree of accountability and pride.  
         [0019]    Referring first to FIG. 1, this shows an overall plan view and the basic elements of the system. Thus, a basic configuration is a U-shape, and the overall system is indicated at  20 . A generally U-shape ribbed counter  22  runs around the inside of the system, and defines a path for a tray, and the ribbed counter  22  has a start end  24  and a finish end  26 . The ribbed counter  22  comprises a first straight part  28 , a first corner part  29 , an intermediate straight part  30 , a second corner part  31 , and a final straight part  32 .  
         [0020]    Together, the first straight part  28  and final straight part  32  define a path of travel  21 . The path of travel  21  runs between and roughly parallel to the first straight part  28  and final straight part  32 , first toward the intermediate straight part  30  and then back away from the intermediate straight part  30 . The first straight part  28  and final straight part  32  would typically be spaced about one meter apart, or in the range of 0.7 meters to 1.5 meters, to permit an operator to move easily between them and to minimize movement required to turn from one section to the other section.  
         [0021]    Immediately adjacent the start end  24  of the counter  22 , there is an ergonomic condiment section  40 . Behind and adjacent the first straight part  28  of the ribbed counter  22 , there is an ergonomic combination section  60 , for dairy products, juice, desserts and bakery items. Behind the intermediate straight part  30 , there is an ergonomic soup section  80 . Similarly, behind the final straight part  32 , there is an ergonomic entrée section  100 . Finally, to one side and adjacent the finish end  26  of the counter  22 , there is a beverage dispenser  120 . These individual elements or sections of the overall system  20  will now be described, in turn, together with their associated components.  
         [0022]    With reference to FIGS. 1 and 2, in known manner, the ergonomic condiment section  40  includes, a frame or stand  42 . As best shown in FIG. 6, this includes a vertical rear panel or frame, on which are hung a variety of condiment bins  46 . In known manner, these condiment bins can have a variety of sizes. Details of typical bin sizes are given below. Immediately below the bins, there is a work surface  48  on which is placed a stack of tray liners indicted at  49 . To one side, as part of the stand  42 , there is a series of compartments for holding cutlery, indicated at  51 . Typically, it is expected that cutlery will be provided presorted, e.g. knives, forks and spoons, for a chosen menu (for example, a soup spoon may or may not be required).  
         [0023]    Two mobile carts are provided, there being one cart  52   b  for trays indicated at  50 . Another cart  52   a  is provided for dividers  54 , the purpose of which is explained below. The cart  52   a  for dividers is simply in the form of an open bin, and an operator simply reaches into the cart to select a divider  54 . For the cart  52   b , this is provided with a lowerator, so that the top most tray  50  of a stack of trays on the cart  52   b  is always approximately at the same ergonomic work height.  
         [0024]    In use, an operator stands at the position indicated at  56  in FIG. 1, selects a tray liner  49  and places it on the tray  50 . A divider  54  is then taken and placed in the middle of the tray, as shown in FIG. 1. The operator then selects desired condiments from the condiment bins  46  and cutlery from the cutlery compartments  51 . Depending upon the requirements of a particular operation, each of these selections can either be on the basis of a standard, set selection, or can be in accordance with choices indicated on a menu ticket. The operator would first select a menu ticket, to determine what items to select for the particular customized tray.  
         [0025]    The operator with the tray  50  then moves across to the first straight part  28  of the ribbed counter  22 . Behind this section, there is the combination section  60 , shown in the elevational view of FIG. 2, and also in section, in FIGS. 4 and 5. This combination section  60  has a main framework  61  and is accessible from the rear through doors  62 , as shown in FIG. 1. As shown in the sectional views of FIGS. 4 and 5, the combination section  60  includes various conventional elements of a refrigeration unit, such as a compressor  64 , circulation fan  65  and the like.  
         [0026]    The bottom part of the framework  61  defines a bottom compartment  66  for storage of crates for containers of milk types, juices and similar beverages. As shown, these crates indicated at  67  can be stacked and are accessible by providing a hinged open grate work top, in section  66   a , for the straight part  28  of the counter  22 . The grates have rails forming part of the ribbed counter  22 . This enables an operator, with the tray in one location, to reach through the open rail grate in an ergonomic fashion, to extract a refrigerated carton of milk or juice as required. The grates are hinged either at the front or the rear as desired, for loading the milk and juice crates.  
         [0027]    The upper part of the framework  61  includes a plurality of inclined shelves  69  for pans or containers of desserts, baked goods and the like, is a refrigerated section. Refrigerated air from the base of the main framework  61  is directed through the inclined shelves and returns through the open grates, indicated in FIG. 4.  
         [0028]    Various sections of the system are provided with suitable lighting, such as fluorescent fixture, task lighting with a vapor proof acrylic lens, as indicated at  58 . Also, as indicated at  59 , a communication operation and food safety board is provided, which can give standard safety and, hygiene or instructional information to an operator.  
         [0029]    The rear of stand  42  can be provided with various access doors, e.g. one or more bottom service doors with vent louvers for ventilation for a compressor coil, and one or more upper, insulated service doors, for sanitation and access. Where desired, front access doors can be provided. This configuration of doors applies generally to all the sections.  
         [0030]    Accordingly, in use, an operator reaches through one of the open grate sections  66   a  to select a desired drink and places it on the tray  50 . The operator can then select desired baked goods and desserts from the inclined shelves  69 . It will be understood that the order in which the operator carries out these two operations is not, usually, significant.  
         [0031]    The operator with the tray  50  then moves around to the first corner part  29 . Behind the corner part  29 , there is a mobile or wheeled soup bowl lowerator  81 . Accordingly, if the menu ticket indicates that soup is desired, the operator takes a soup bowl and places it on the tray  50 .  
         [0032]    The operator then moves with the tray  50  to the intermediate straight part  30 , in front of the ergonomic soup section  80 . This soup section  80  has a framework  82 . Again, the base of the framework  82  defines a compartment  83  with rear access doors  84   a , refrigeration equipment indicated generally at  85 , and front access doors  84   b . The intermediate straight part  30  runs across the front of the soup section  80 . At the rear of the soup section  80 , there are numerous soup containers  86  which can have different sizes and dimensions, as detailed below. In general, it is possible to anticipate what the demand will be for different soups, and provide greater quantities of soups that will be more popular and smaller quantities of the less popular soups. A counter weighted stainless steel protective cover  88  is provided. During the operator&#39;s coffee and lunch breaks or set up time, this can be lowered, to protect the soup. Immediately above the soup containers  86 , there is a rack  90  for supplements, e.g. packets of crackers and the like, commonly consumed with soup.  
         [0033]    Thus, in use, having already placed a soup bowl on the tray  50 , the operator would select the desired soup, fill the bowl, and select appropriate supplements from the top rack  90 . The operator then moves around to the second corner part  31 , the outside of which is a mobile plate lowerator  98 . A plate is taken from the lowerator  98  and placed on the tray  50 .  
         [0034]    The operator then moves to the ergonomic entrée section  100 . Like other sections, this includes a framework  101  defining a lower compartment  102  in which is housed conventional refrigeration equipment again indicated schematically at  103 . The refrigeration equipment  103  serves to circulate air to keep chilled a plurality of entrée dishes  104  containing various entrée items. These dishes can have a variety of sizes and shapes, as detailed below. Above the entrée dishes  104 , there is a shelf  105  for specialty items.  
         [0035]    The compartment  102  is accessible from the front through doors  106 . Rear access doors can also be provided. Like the soup section  80 , the entrée section  100  includes a cover that can be lowered to protect the entrees, during operator breaks, etc.  
         [0036]    Thus, in use, an operator would select desired entrée items, as checked off on a menu ticket, and place these on the previously selected plate. If any specialty items are required, e.g. items that go with particular entrees, these would be selected from the shelf  105  and also placed on the tray.  
         [0037]    Finally, at the end of the counter  22  there is the beverage dispenser  120 , for dispensing hot beverages. A wheeled cart  122  is provided for cups and a cart  122  with a supply of clean cups is provided at the front of the dispenser  120 . Accordingly, when a menu ticket requests an appropriate beverage, the operator selects a cup, fills the cup from the beverage dispenser  120  and places the cup on the tray  50 .  
         [0038]    Beside the beverage dispenser  120  there is a mobile cart  130  for protective covers. This cart  130  includes plate covers indicated at  132  on a lowerator. A bin or slot  134  is provided for beverage covers. Accordingly, the operator selects required beverage covers and plate covers and places these on the items on the tray  50 , with separate soup covers being provided for the soup bowls.  
         [0039]    Adjacent the mobile cart  130 , there is an ergonomic swivel lift  140 . This enables carts for completed trays to be loaded in an efficient and ergonomic manner, for non-pass through types of carts. Thus, the cart would be placed on the swivel lift  140  and raised to a height somewhere between waist and shoulder height of the operator. This enables the operator to take each completed tray and slide it into a slot in the cart. Such carts typically have a first series of slots accessible from one end of the cart and a second series of slots accessible from the other end of the cart. Thus, once one end of the cart has been filled, the lift  140  enables it to be rotated through 180°, for the second or other end of the cart to be loaded with trays. However, some carts may permit loading from one end, so that this rotation operation is not required, and standard non-swivel left can then be used.  
         [0040]    Once the operator has loaded a full tray onto the cart, the operator merely turns around to start loading a new tray, due to the swivel lift  140  being located directly across the path of travel  21  from the start end  24  of the counter  22 .  
         [0041]    It will be noted that the arrangement of the various carts for supplying wares and the like is carefully configured, to enable ready replacement of these carts without interrupting the operator. Thus, the carts  52   a ,  52   b  for the trays and dividers, the wheeled soup bowl lowerator  81 , the mobile plate lowerator  98  and the mobile cart  130  for the covers are all located so that they can be replaced or exchanged, without crossing the path of travel  21 . Thus, in use, this enables each of these movable wheeled carts and the like to be replaced, while an operator continues to perform the usual tasks in the usual order. This is achieved by providing these various components either on the side of the counter  22  opposite from the path of travel, or at the ends of the counter, i.e. the first and last station. It will also be noted that many of the sections  40 ,  60 ,  80  and  100  can be replenished with food or condiment items, largely without interrupting the operator.  
         [0042]    The tray adjacent the ergonomic entrée section  100  is indicated at  50   a  in FIG. 1. This tray  50   a  shows typical layouts of the elements on the tray. Thus, the divider  54  is located in the middle of the tray, separating a hot side of the tray from a cold side of the tray. Foods that are to be served hot or warm are placed on the hot side of the tray, as indicated for the entrée plate  72  and the soup bowl  74 . On the cold side of the tray, cold beverages, desserts (to be served cold), baked goods, cutlery and the like are placed. In use, in the carts intended for use with these types of trays, the divider  54  serves to separate the two sides of the tray, in the manner permitting passage of different air flows over the two sides of the tray. Thus, heated air can be passed over the hot side of the tray, to heat the food thereon immediately before serving. At the same time, cold air can be passed over the cold side of the tray, to maintain foodstuffs on that side of the tray cold. It will thus be understood that all the food placed on the tray at the system or station  20  is initially placed on in a cold condition, to ensure that the food remains in an optimum condition and to minimize bacterial growth and the like. The food to be served hot is then only rethermalised prior to serving in a separate delivery system.  
         [0043]    The standard condiment bins  46  are of two sizes. Specifically, the bins  46   a  as shown in FIG. 2 are generally 4 and ½ inches wide by 4 and ½ inches deep and have a length of 11 inches. An alternative condiment bin  46   b  is also 4 and ¼ inches deep, but has a width and length that are both 11 inches.  
         [0044]    Typically, the soup containers  86  and entrée containers  104 , both shown in FIG. 1, are either 6, 9 or 14 cm deep.  
         [0045]    Other variations and modifications of the invention are possible. For example, while the present invention has been described above as implemented in an institutional setting, such as a hospital or a nursing home, it will be appreciated by those skilled in the art that the invention may be usefully applied in other contexts in which a single operator loads a plurality of trays. Such modifications or variations are believed to be within the sphere and scope of the invention as defined by the claims appended hereto.  
         [0046]    It is also possible that the system of the present invention would be used by more than one operator. The operator essentially travels in a circular manner around the path  21 , so two, or possibly more, operators could simultaneously travel around the path  21 , with their operations being staggered. For this purpose, it would likely be necessary to reconfigure the apparatus to increase the width between the two sides of the path  21 .