1. Rochester Institute of Technology
Final Project Review
Dresser- Rand : Rotor Cell Improvement Project
Rochester Institute of Technology
Multi-Disciplinary Senior Design
Project: P13457
Team Members: Michael Then, Katherine Poehlman, Allison Doster, William Slaughter, William Swift
Topics:
Last Quarter Review:
Heat treat
B & OS
This Quarter:
Arena Model Status
Scheduling System
Vectra Table Concept

2. Potential Project Concepts
The goal of this project was to help the Dresser-Rand Rotor Cell increase productivity. Multiple improvement project were suggested to the RIT team, including:
Develop a production model for scheduling and capacity
Design storage racks
Develop tools to visualize part flow
Optimize use of flow lanes
Methods for space utilization
Production status visual (ahead, behind, on-time..)

3. Project Synopsis Layouts: Heat Treat and B&OS
Shelving choices
Quotes and Lead Times
Layout Configurations
DR’s status?
Capacity Determination through Arena
Data Issues…
Scheduling Screens for Production Area
Bill of Materials
Vectra Table
CAD model of Concept
Risk assessment
Design Considerations

4. Roll-Out Racks Heat Treat B & OS 3 racks for the Heat Treat area
3 adjustable shelves per rack
B & OS
1 rack for Finger Mandrels
Recommend additional shelf to increase capacity
Rack Specs
2,000lbs /shelf
48”x 48” shelf space
15 lbs of force to pull-out fully loaded rack

5. Layout in Heat Treat Layout Option: 3 Large Racks- Straight Line
Most viable given constraints
Can’t move office
Can’t block door
24-40 impellers

6. B&OS: Standard Racks 6 racks should fit all parts
Modeled all sizes in Auto-CAD
5 storage shelves/rack
6th shelf as cover for dust?
Very low, if any, maintenance
Consistent with current shelving
Layout of plates will remain the similar

7. Standard Racks Specifications Versatility 3000lbs per shelf
Heavy gauge steel
72-L x 24-W x 60-H
72 x 24 x 72 (Second Option)
Versatility
Shelves can be adjusted in 1 inch increments
Not bolted to the floor so they can be rearranged
Accessible on both sides

8. Layout in B&OS

9. Status?
Are there any plans to implement the shelves?

10. Arena Model Status Goal: Determine the Capacity of the Plant
How: Complex routings require use of Arena Simulation
Plan:
Use historical process times for parts that vary in:
Size
Complexity
Heat Treatment
Etc…
Calculate Statistical variables to input to Arena
RIT: Data Analysis
DR: Arena Model Architecture (Sean Frier)
Issues:
Data not complete enough to make conclusions

11. Arena Model Status Status:
Sean Frier has initiated a survey for process time approximations ( High, Medium, Low – Triangular Distribution)
Manually look up individual work orders too time consuming
Sean has outlined the model, just needs data

12. Scheduling System Objective
Reduce communication redundancies in scheduling
Allow supervisors to spend time more efficiently
Communicate daily scheduling in a more timely manner
Present daily schedule so that it is visible to everyone walking the floor

13. Scheduling System Requirements
Manage Remotely
Microsoft Compatible
Real time schedule to each cell- continuously updating
Each cell will have its own display
Specific spreadsheet schedules display to cell specific monitors
All displays can be managed from the same source
System needs to be able to expand and add more displays and schedules as they are added to each cell

14. Scheduling Solution
Use Hiperwall software to input a daily schedule to display on screens on the manufacturing floor.
Work with DataBranch to continue to expand the new scheduling system.

15. Vectra Table
Task
Design a system for the current table so it is capable to do run-out measurements while the fins are being installed. This will eliminate wasted time as a result of needing to relocate the rotor horizontally for run-out measurements on the fins.

16. Vectra Table Other Criteria: Eliminate use of the collar
Tolerance ± .0001
Supports up to 2000 lbs
Makes use of current table
Eliminate horizontal transfer

17. Vectra Table Concept Development
Initial design concepts

18. V-Block Mounts Mounted under the table One fixed One linear motion
Four 5 inch diameter feed blocks

19. V-Block Mounts: Rail System
Similar to current system on the table for the vertical rods
Still need a rail system for the v-blocks to move
Electric rail system
Mount v-blocks right on the block of the rail system
Manual movement rail system that locks in place
Could be used on the “permanent” side to adapt to any sized shaft diameter

20. Rotational Base Rotary Bearing Face Plate Needs Testing for sizing
Smaller diameter may allow easier turning
Needs to handle large loads
Face Plate
Face plate has a dome center
Align center of Rotor with center of rotation
Maintain vertical position
Avoid “Walking-Effect”
Size Uncertain although shaft has a pivot hole on bottom
True surface from Manufacturing

21. Rotational Base: Center
Centered **
Critical to design
Align Center of dome with center of rotor
Center of V-Blocks
Would need to outline process for initial alignment
Re-alignment Procedure
Fine tune placement of V-blocks or build adjustments so base can be moved in small increments

22. Rotational Base: Center
Centered **
Critical to design
Align Center of dome with center of rotor
Center of V-Blocks
Would need to outline process for initial alignment
Re-alignment Procedure
Fine tune placement of V-blocks or build adjustments so base can be moved in small increments

23. Next Steps: Vectra Table
Things to Consider:
Linear Drive would need locking mechanism
Electric linear drive might lock in place
Needs to support weight
Base plate nose size could be smaller
Wearing out the plate
V-block configuration 2 x 2 (top-bottom) keeps shaft vertical
Could use 3 v-blocks in triangular pattern
Centers like drill chuck with electric linear drives
Procedure for alignment

24. Next Steps Arena Model: Scheduling Vectra Table Assess process times
Evaluate and build into the Arena model
Finish the model so that it can be used and integrated in the facility
Scheduling
Work with vendor to create steps of how the system will be implemented along
Gain more technical knowledge of the system to dig deep into the pro’s and con’s of each implementation in a cell
Vectra Table
This was only one design concept so more could be developed and improved upon
Accumulate more precise implementation along with mathematical calculations
Pass Vectra Table Work to new Senior Design Team

25. RIT Team Reflection
Overall, the project allowed the team to explore diverse opportunities for improvement
Layouts
Evaluating capacity
Visual systems integration
Process improvement through tool re-design
Possible Drawbacks:
Vectra table was great project- disappointed it was so late
Would have been good as a full project on its own- design and implementation
Enjoyed the diversity, but lack of one clearly defined project
Hard to fully develop every concept within the time
Would have been nice to have a build/ prototype associated with the project