Multidisciplinary Senior Design Rochester Institute of Technology Dresser-Rand Painted Post P10459 Systems Level Design Review 1/22/10 Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE) Faculty Guide: John Kaemmerlen

Expectations Discussion Feedback on current status Suggestions for improvement Different thoughts/points to consider Clear view of next steps

Background Problem Liner cell is located in 3 different parts of the plant One part is in a location that will be closed off Objective Provide a detailed plan for movement/consolidation Maximize productivity, safety, quality, and profitability in new layout Time Frame MSD I: Nov. 30, 2009 – Feb. 19, 2010 MSD II: Mar. 8, 2010 – May 14, 2010 Stakeholders RIT: John Kaemmerlen, Senior Design Program D-R: Dennis Rice, Malcolm Cliff, Mike Decerbo, Chris Benesch, John Woedy, Shane Kinney

Customer Needs/Work Breakdown NeedMetricCurrent*MarginalTarget Machine Configuration (Alex) Overhead Cost$87,991-10%-20% Process Time30 days<=25 days<=15 days Man Power643 Defect Cost$40,623-10%-15% Cell Layout (Pete) Travel Distance1,280 ft-40%-50% Process Time30 days<=28 days<=25 days Process Improvement (Yi) # Injuries000 Process Time30 days<=28 days<=25 days Defect Cost$40,623-10%-20% Material Handling (Rachel) Defect Cost$40,623-20%-25% Material Storage (Phil) Space Utilization6584 sq ft-20%-30% Travel Distance1,280 ft-10%-20% *Based on 2009 Metrics (Jan – Sep)

Systems Level Design New Layout with best safety, productivity and quality MachineMaterial Method Metrics Machine Configuration Material Handling Material Storage Cell Layout Industrial Engineering Mechanical Engineering AlexRachelPhil YiPete Man Problem Solving Visual Controls Machine Configuration Material Handling Material Storage

R· I· T Mechanical Engineering Department Machine Configuration o Goal: Determine the optimal configuration of machines to reduce production time and cost. o Options o Keep the old machines, Liner cell needs to be moved anyway, savings will come by consolidating these machines and figuring out a good layout o Buy a new CNC VTL, we are looking at some machines that are capable of doing most of the steps in the process, reducing set up time.

R· I· T Mechanical Engineering Department Machine Configuration o Preferred Machine Specifications o Capable of running any liner from 14 in up to 42 in o Chuck size around 50 in o Maximum tooling height around 60 in o Live Tooling o Reducing changeover time in operations o Horizontal milling attachment o Can be used for porting o Must have x and y axis capabilities o Inspection probe o Inspect liner inside the machine so that the operator does not have to pull it out to do the inspection process.

R· I· T Mechanical Engineering Department Machine Configuration o Benefits of a new CNC VTL o Eliminate the grinding operation o Possibly eliminate the bore sheet and machine part to the print instead o Reduce operator errors o Ultimately the deciding criteria will come down to which option has the best return on investment over time compared to the current process. o With a new machine we think that we can cut production time, cost and man power. o The new configuration will also be versatile enough to handle higher work loads.

Cell Layout R· I· T Mechanical Engineering Department o Moving Shop 21’s Liner Cell to Shop 6 and 17 o Planned Improvements: o Greatly reduced travel time and distance (Present Base Route seen here) o A more centered layout o Improve Product flow

Cell Layout R· I· T Mechanical Engineering Department o The Probable Options o “As Is” process: o Use of the same machines presently being used o No new machines added o “Improved” process: o Replacement of the grinder with a vertical turning lathe (VTL) o The grinder will become unnecessary o “Re-Developed” process o Purchasing and using a multi-axis CNC machine as part of the main process flow. o Present tools will be kept to back up the CNC

Cell Layout R· I· T Mechanical Engineering Department o Possible looks at Re-layouts o Many factors to still consider: o Which unused machines can we scrap and replace? o Use or need of high and low bay space

Process Improvement R· I· T Mechanical Engineering Department Goal: Provide visibility to management and operators on metrics: – Safety – Productivity – Quality 6S for a clean and sustainable workplace Standard work for consistent process, easy training and identification of out of standard process. Provide environment for continuous improvement

Process Improvement R· I· T Mechanical Engineering Department Why? Operators – Simplified process – Able to detect and prevent defects – Understand status of part/line at all times – Safer workplace Managers – Have knowledge of part/line status at all times – Immediately detect out of standard conditions – Easy to train new operators, cross train current

Process Improvement R· I· T Mechanical Engineering Department How? Metrics – Productivity (On time delivery, output/day, part status, cycle time, down time, weekly schedule) – Safety (Safe work days, accidents) – Quality (Defects, number good parts) 6S – Labeled tool storage, machine locations, floor markers, cleaning schedule, audits Standard Work – Work charts, combination tables Continuous improvement – Problem solving board w/ lean training – Morning market

Material Handling R· I· T Mechanical Engineering Department o Current Material Handling Procedure: o Liners set vertically onto wooden pallets, moved by forklift o Causes parts to fall if forklift must stop short, resulting in defects o Current Defect Cost: $40,632 (Jan-Sep 2009) o Concerns: o Safety o Ease of Travel o Minimize Product Defects o Secure liners during travel o Support Adequate Load o Largest drum dimensions: o 42” OD x 55” tall o 2000 lb weight

Material Handling R· I· T Mechanical Engineering Department o Create fixture for pallets: Flat piece with indentation to allow liner to settle, secure with ratchet straps o Modify wooden pallets: Remove center pieces of pallet to allow liner to settle, secure with ratchet straps Pallet Fixture/Modification

Material Handling R· I· T Mechanical Engineering Department o Moving Shop 21’s Liner Cell to Shop 6 and/or 17 o Dimensions o 48" x 48" x 36" o Features: o 10,000 lb rated ratchet strap attaches at 3 different heights o Can be moved using forklift o Doubles as storage unit *Designed originally for gas cylinders Cost: $812

Material Storage R· I· T Mechanical Engineering Department o Functions of Drum Rack o Support load of drums o Each shelf can support 4,825 lb o Total capacity is 14,475 lb o Restrict drum movement o Individual Brackets o Safety o Built to OSHA standards Cost - $ ea.

Material Storage R· I· T Mechanical Engineering Department o Dual Purpose o Drum rack could be used for liners o Standard drum dimensions o 22.5” OD x 34.5” tall o Modifications needed: o Deeper shelf for liners o Support for large OD liners o Interchangeable brackets

Material Storage R· I· T Mechanical Engineering Department o Cart designed for liners o Largest drum dimensions o 42” OD x 55” tall o 2000 lb weight o Features: o Mobility for liners o Support for large OD liners o Doubles as storage unit o Liners stored vertically o Take up less space (4’ x 4’) o Will not interrupt walkway

Risk Assessment RiskImportance*Action to mitigate Design doesn’t meet needs6Weekly meetings with management, be open to criticism/suggestions Operators don’t accept new system 6Weekly meetings with operators, use their input if possible Injury of RIT or D-R team member 6Review safety procedures, do not distract others when working Design exceeds budget4Budget review meeting Maintenance of tools/process after completion 4Documentation of processes and tools, obtain buy in from all parties, build to last years Layout drawings don’t reflect reality 3Verify drawings with actual measurements, double check measurements Down time during movement3Detailed cutover plan with anticipated down times *Based on Severity (1-3) x Likelihood (1-3). 1= lowest, 9= highest

Project Plan