1. P13458: Dresser-Rand Compressor Assembly Line Team Members: Lauren Kraft –Project Manager, Nick Feng – IE Cole Bowden – ME, Shawn Moseley – ME Jordon Boggs – ME, Alex Peterson – ME Preliminary Detailed Design Review Phase I: Assembly Stations 1-5

2. Agenda Key Objectives of this Review Problem Statement Preliminary Detailed Design of Caster System: Caster Design Cart Design Universal Frame Interface Frame and Caster Plate Stress Analysis Design Risks Identified Detailed Design Needs Ergonomic Justification Process Layout Update Economic Analysis Project Outlook & Timeline

3. Key Objectives of this Review Prototype DesignOverall Process layout Catch mistakes Improve design from operator feedback Specs (needs) are addressed Risks are addressed Decisions are made to further design Receive feedback on current layout Consider alternatives and application of lean principles What are we missing?

4. Problem Statement Design a flexible material handling system to incorporate 5,000 to 22,000 pounds 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.

5. Caster Design Designing to 5000lbs/plate Casters per plate: 4 Caster load: 1250lbs Caster considerations Swivel lock Low diameter Non-Metal Construction Cost Hamilton WH-4NYB 4 inch diameter nylon wheel 2000lb load capacity Model Total Weight Plates Weight per Plate HOSS 28,70042175 HOSS 415,40043850 HOSS 621,90063650 HOS 25,20041300 HOS 410,60042650 HOS 615,40043850 MOS 25,00041250 MOS 48,80042200 MOS 61,320043300

6. Swivel Lock Casters Locking casters allow for strict 2 directional motion Each caster must be turned and locked by hand 4 unidirectional caster sets will over-constrain the system Solves guidance issue Creates a directional control issue Creates an ergonomics issue

7. Preliminary Cart Design

8. Preliminary Cart Dimensions

9. Universal Frame Interface Single interface compatible with all 3 compressor families Tapered pin on top face for ease of frame positioning Dual pin configuration on bottom face for stability Ease of manufacture and assembly

10. MOS HOS HOSS Unloaded Beam Universal Frame Interface

11. Beam Model Output

12. Frame Stress Analysis – On Casters Peak stress of 6850psi, n<4 Agrees well with initial calculation of 6930 psi, n<4 Max deflection.01 inches

13. Frame Stress Analysis – On Jackstands

14. Caster Plate Stress Analysis

15. Design Risks Casters cannot support cylinder weights Tugger integration not yet determined Directional control issues with casters Ergonomics of swivel-lock rotation Tolerance stack-up Weld joint stress analysis Caster bolt pattern not standard Manufacturability deadlines Highest Risk Lowest Risk

16. Detailed Design Needs Dimensioned frame drawings with tolerance Design safety standards (if applicable) Finalized cylinder attach decisions Finalized caster decisions Casters or air bearings decision

17. Ergonomics Male horizontal reach = 731 mm (95%) Female horizontal reach = 676 mm (95%) 10% of female = 641 mm Height of compressor (711.2 mm) + carts (457.2 mm) = 1168.4 mm Male vertical reach = 1732.5 mm (mean) 1844.04 mm (95%) Female V.R = 1602.7 mm (mean) 1711.96 mm (95%) 1518.9 mm (10%)

18. Ergonomics Horizontal Reach Envelope

19. Conceptual Assembly Process Sub-assembly Main Assembly Phase II Phase I Source: Dresser-Rand

20. Process Layout

21. Economic Analysis AFE presented to team and reviewed Estimates apply only to MOS compressor product launch and does not take into consideration the financial effects of the mixed model format of the line Inflow and Outflow data used to calculate several figures to justify the pursuit of this project

22. Project Outlook Phase 1 (currently here) Assembly stations 1-5 of main line Proven prototype with detailed design for full scale system Phase 2 Test, Paint, Shipping of main line without the use of a crane Possible detailed design for full scale system Integration Ensure Phase I and Phase II functionally support the process flow and the physical flow in the assembly line

23. Project Timeline ① Completed: Systems Design Review for Assembly Stations 1-5 (Phase I) Preliminary Detailed Design of Caster System ② Current Work: Process Layout of Assembly Line Concept Development of Phase II – test, paint, shipping ③ Future Work: Finish detailed design of Phase I Review Phase II concepts