1. P13458 RIT Senior Design Team May 10, 2013 10-10:30AM 09-2030 Dresser- Rand, Painted Post http://edge.rit.edu/edge/P13458/public/Home Final Presentation: Compressor Transport System & Layout

2. Agenda Problem Statement Accomplishments For The Transport System Design History Final Design Summary Of Test Results Recommendations Accomplishments For The Layout Design History Final Design & Test Results Recommendations Reflection On The D-R/RIT Partnership Reflection On Our Code Of Ethics

3. Problem Statement Design a flexible material handling system that is easy to use and incorporates the safest design elements within cost and functionality constraints. This design fully supports the new process layout in Dresser-Rand’s strategic project to increase capacity for the MOS compressor projected sales. New Shop Floor 6-throw MOS Compressor

4. Transport System Design History Design Considerations Long Beam Caster System Short Frame Caster System (Yellow Frame) Air Bearing Technology Free Support System Fixed Support System Modified Support System

5. Design Considerations MovementPropulsion

6. Long Beam Caster System Assumed entire compressor assembly would be loaded, including cylinders Assumed massive CG changes while loaded Large structural members necessary

7. Short Frame Caster System Yellow Frame Design Versatile – to account for multiple product families Modular – to account for multiple product sizes Could not be used at test station Was prototyped Many design flaws surrounding caster system

8. Air Bearing Technology Unidirectional Nearly frictionless Reduces horizontal force required to 1lb per 1000lbs Air supply is common in industrial setting Requires flat, smooth floor surfaces

9. Free Support System Based on the short frame system Adapted for air pallet use Legs fixed to support beam Concerns regarding clearance between floor and legs during movement

10. Fixed Support System Vertical “legs” of the Free system are now fixtures placed at each station Eliminates floor clearance concerns while moving from station to station Simplifies manufacturing Easily integrated into testing and shipping

11. Removable Support System Conceptual design Method of manufacture and dimensions undetermined Removable fixture attaches to beam and acts like a jack stand Overcomes flaws that were revealed during the 3P event Stress analysis not completed results should be comparable to the free system results

12. Removable Support Qualities Pros No more fixtures Resolves ergonomic issues discovered during the 3P event Lowers move prep time – no longer need to configure fixtures from station to station Bolt on legs removable for test and shipping Cons Requires the floor to be leveled

13. Test Results

14. Recommendations Modify testing station to incorporate free-system design Possible lifting/attachment to test bed Determine lifting/loading method Need 3-axis positioning without a crane Modified Grey Portable Lifting system for vertical lifting Back truck under lifted compressor Air bearings under truck bed Driver positioning

15. Layout Design History Took dimensions of required equipment and space for each station in the assembly, test, and paint process in the current state Created factors of varying importance Designed 4 different layouts – 2 straight-line, 2 U-shaped – in the new shop floor Conducted a 3P event on a U- shaped layout using cardboard to check theoretical values against actual feedback from operators and line side managers 3P Event ResultFactors AffectedStatus Tested U-shape design Returnability Flexibility Pass-by/Pass-through Added new cylinder assembly flow line Space Utilization Inventory Access Operators and managers evaluated the layout and gave feedback on parts and people flow and equipment requirements Inventory Access Ease of Movement by Operator Movement Time Found hidden problems and constraints i.e. spacing between stations, jib crane requires oil pump station next to column Space Utilization Maintenance Access Tested – good outlook Needs further testing, but predict a good outlook Needs attention, was not addressed

16. Final design Top Level Assembly Level Flow

17. Recommendations Re-evaluate test bay requirements for sizing and safety – retractable blast walls Add in and test inventory flow and information flow Understand exact requirements and locations for energy/power/air sources Full dimensioning of layout Computer simulation of process flow Continuous evaluation and improvement 5S taping and marking to indicate specific areas, i.e. operator walking zone inside cell, in-process kanban, visitor aisle way Identify and allocate future expansion area

18. Reflection on the DR/RIT Partnership Overall, very successful learning experience Design process Iterative in nature – lots of ‘back to the drawing board’ moments Conceptualization and the funnel of idea development Understanding fluctuating customer needs Efficiency of communication Recommend a “consulting” contract be completed at the start To better establish the needs of Dresser Rand So the team can better prioritize efforts Recommend creating a communications protocol to prevent delay in work as the team awaits feedback

19. Reflection On Our Code Of Ethics 3 out of 11 components were not followed satisfactorily