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Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE)

Multidisciplinary Senior Design Rochester Institute of Technology Dresser-Rand Painted Post P10459 Detailed Design Review 2/26/10. Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE) Faculty Guide: John Kaemmerlen. Overview. Expectations Background

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Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE)

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  1. Multidisciplinary Senior DesignRochester Institute of TechnologyDresser-Rand Painted PostP10459Detailed Design Review2/26/10 Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE) Faculty Guide: John Kaemmerlen

  2. Overview • Expectations • Background • Systems Level Breakdown • Project Status Update • Target Specifications Update • Machine Configuration Status Update • Layout Concepts • Process Improvement Concepts • Material Handling Detailed Design • Material Storage Detailed Design • Risk Assessment Update • MSD II Project Plan

  3. Expectations • Discussion • Feedback on current status • Suggestions for improvement • Different thoughts/points to consider • Clear view of next steps • Action items for MSD II • Decisions to me made today. • Location: shop 6 or 17 • Heiligenstadt • Money for pallet prototype • Gilbert

  4. 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 • Stakeholders • RIT: John Kaemmerlen, Senior Design Program • D-R: Dennis Rice, Mike Decerbo, John Woedy,

  5. Systems Level Design Mechanical Engineering Alex Rachel Phil Machine Material Material Handling Material Handling Machine Configuration Machine Configuration Material Storage Material Storage New Layout with best safety, productivity and quality Cell Layout Problem Solving Visual Controls Method Man Metrics Industrial Engineering Pete Yi

  6. Project Status Overview • Time Frame • MSD I: Nov. 30, 2009 – Feb. 19, 2010 (Completed) • MSD II: Mar. 8, 2010 – May 14, 2010

  7. Target Specifications Updated *Based on 2009 Metrics (Jan – Sep)

  8. Travel Distance

  9. Machine Configuration • Currently parts are machined on vintage 50’s and 60’s machines. • Slow machining time • Frequent maintenance and repair • Parts are difficult to find and expensive • Manual machines can lead to more frequent defects in parts or “out of round” conditions. • Machining operation depends on tribal knowledge of operators • We are researching other alternatives such as the purchase of a used or new CNC horizontal or vertical lathe. • We will attempt to justify the cost with the savings in process time as well as reduced operating cost of the machines. R· I· T Mechanical Engineering Department

  10. Machine Configuration • Currently the average process time is about 35.47 hours per liner (shop order details) • We will attempt to reduce that number by about 50% to 17.64 hours. • In the last 2 years liner cell produced 555 liners. • At a burden rate of $105, One hour of reduced process time comes out to about $29,138 a year R· I· T Mechanical Engineering Department

  11. Machine Configuration • This results in a total savings per year of about $513,994 • A brand new Toshiba TUE 150 costs around $500,000 with tooling. • Looking at a payback period of about one year R· I· T Mechanical Engineering Department

  12. Machine Configuration • Justification • Video taped time studies on in house machines • Data from Morris Great Lakes • CICS hours charged on liners • Production data from 2008 and 2009 • Morris Great lakes has already been brought in on this project to provide assistance on the best machine choice and they are putting together a proposal for us. R· I· T Mechanical Engineering Department

  13. Cell Layout Design & Selection • Options include everything from: • Utilizing Shop 6 • Utilizing Shop 17 • Buying a new VTL • Scrapping old machines • Bringing in machines from other departments.

  14. As Is • Liner Cell in Shop 21, Shop 6, & Shop 17 • High travel distance & future wall necessitate the re-layout.

  15. Option #1 • Moving Shop 21 into Shop 17 • Cost of removal of the Heyligenstaedt & the Betts • Room available for possible new machine(s)

  16. Option #2 • Moving Shop 21 & the Gilbert porting machine into Shop 17 • Cost of removal of the Heyligenstaedt & the Betts • Porting brought to Shop 17

  17. Option #3 • Moving Shop 21 & a new VTL CNC machine into Shop 17 • Cost of removal of the Heyligenstaedt & the Betts • Majority of work performed on VTL with Shop 21 machines for backup • Need to propose a viable business case for the new machine

  18. Option #4 • Moving Shop 21 & Shop 6 into Shop 17 • Cost of removal of the Heyligenstaedt & the Betts • Cost of foundation preparation & move of Norton Grinder & American Lathe • Liner Cell moved out of Shop 21 & 6

  19. Option #5 • Moving Shop 21, the Gilbert porting machine & a new VTL CNC into Shop 17 • Cost of removal of the Heyligenstaedt & the Betts • Porting brought to Shop 17 • Majority of work performed on VTL with Shop 21 machines for backup • Need to propose a viable business case for the new machine

  20. Option #6 • Moving Shop 21 & the Gilbert porting machine into Shop 17, along with the removal of the Summit machine – Drawing A • Cost of removal of the Heyligenstaedt, the Betts, & the Summit • Porting brought to Shop 17

  21. Option #7 • Moving Shop 21 & the Gilbert porting machine into Shop 17, along with the removal of the Summit machine – Drawing B • Cost of removal of the Heyligenstaedt, the Betts, & the Summit • Porting brought to Shop 17

  22. Option #8 • Moving Shop 21, the Gilbert porting machine, & a new VTL CNC into Shop 17, along with the removal of the Summit machine • Cost of removal of the Heyligenstaedt, the Betts, & the Summit • Porting brought to Shop 17 • Majority of work performed on VTL with Shop 21 machines for backup • Need to propose a viable business case for the new machine

  23. Option #9 • Moving Shop 21, Shop 6, & the Gilbert porting machine into Shop 17, along with the removal of the Summit machine • Cost of removal of the Heyligenstaedt & the Betts • Porting brought to Shop 17 • Cost of foundation preparation & move of Norton Grinder & American Lathe • Liner Cell moved out of Shop 21 & 6

  24. Option #10 • Moving Shop 21 into Shop 6 • All moving can be done in house • Already open & available floor space • Liner Cell moved entirely into Shop 6 • Room available for possible new machine(s)

  25. Option #11 • Moving Shop 21 into Shop 6 • All moving can be done in house • Already open & available floor space • Liner Cell moved entirely into Shop 6 • Room available for possible new machine(s)

  26. Decision Matrix The breakdown of all the possible layouts (several are no longer possible as shown by feasibility) comes to show that one of the simplest solutions is proven to be the ideal one. Option #11 is ideal due to all the necessary machines being capable of in house movement, a nice semi-linear flow, the layout space only being used presently for WIP, & the open space left available in Shop 17 for possible additional machines.

  27. Process Improvement • Concept Selection and Improvement • Process control board • Machine downtime board • Cell safety and information placard • Standardized work charts • Waste tracking sheet R· I· T Mechanical Engineering Department

  28. Value Stream Map R· I· T Mechanical Engineering Department

  29. Process Control Board R· I· T Mechanical Engineering Department

  30. Machine D/T Board R· I· T Mechanical Engineering Department

  31. Cell Safety Information R· I· T Mechanical Engineering Department

  32. Standard Work Charts 7 9 1 4 3 2 6 8 5 R· I· T Mechanical Engineering Department

  33. Waste Tracking Sheet R· I· T Mechanical Engineering Department

  34. Material Handling • Current Material Handling Procedure: • Liners set vertically onto wooden pallets, moved by forklift • Causes parts to fall if forklift must stop short, resulting in defects • Current Defect Cost: Approximately $6,000 (Over 2 years) • Many more unreported incidents • Major safety concerns R· I· T Mechanical Engineering Department

  35. Concept Selection Concept Selected: #6, Standard w/ VBlock Fixture R· I· T Mechanical Engineering Department

  36. Final Concept Large V Block Holes for adjustable V Block spacing Small V Blocks Standard wooden pallet Method for strapping the liner to the pallet Standard wooden pallet with adjustable V Block fixtures for different sizing/length of liners R· I· T Mechanical Engineering Department

  37. Material Selection R· I· T Mechanical Engineering Department

  38. Material Handling BOM R· I· T Mechanical Engineering Department

  39. Feasibility Analysis Through a series of FEA analyses in COMSOL, it was determined that an oak pallet could withstand the weight of a 2000lb liner with a factor of safety of at least 4. R· I· T Mechanical Engineering Department

  40. Test Plan • Prototype pallet (1-3 units) • Purchase base pallet to specifications • Mfg V Blocks in RIT machine shop • Band Saw, Lathe, Hand Tools • Done in weeks 1-3 of MSD II • Mechanical engineer will manufacture • Run prototype at Dresser Rand • Use on shelf, floor, forklift • Place on liners (smallest to largest) • Check for any failures in the pallet, V blocks or straps R· I· T Mechanical Engineering Department

  41. Material Handling Risk Analysis R· I· T Mechanical Engineering Department

  42. Material Storage Current State R· I· T Mechanical Engineering Department

  43. Concept Generation • Pallet rack for liners • Liners stored on rack • Take up less floor space • Increase safety • Functions of Drum Rack • Support load of drums (14,475 lb) • Restrict drum movement (Brackets) • Built to OSHA standards for safety R· I· T Mechanical Engineering Department

  44. Material Storage • First Design Change • Include a wire mesh decking in order to support a wooden pallet if needed • Rack will be able to support any pallet • Second Design Change • Large liners stored vertically • Large liners will deform under their own weight http://www.rackingandshelving.com/acatalog/pallet_rack_wiredeck_2.jpg R· I· T Mechanical Engineering Department

  45. Material Storage • Third Design Change • Rack dimensions changed • Went from 48” x 144” to 42” x 86” based on availability of racks at DR http://www.rackingandshelving.com/acatalog/pallet_rack_wiredeck_2.jpg R· I· T Mechanical Engineering Department

  46. Concept Selection Matrix http://www.rackingandshelving.com/acatalog/pallet_rack_wiredeck_2.jpg R· I· T Mechanical Engineering Department

  47. Feasibility Analysis • Operational feasibility for installation of a rack system is high since it is cheap and easy to use. • The only issue with a shelf would be loading and unloading safely within the area of the shelf. • There needs to be enough clearance above the rack to be able to load the top shelf, and a clear path to and from the storage area. • There will need to be front to back supports to reduce the likelihood of an inaccurately placed load falling between the beams. R· I· T Mechanical Engineering Department

  48. Test Plan • Placing liners onto pallets and then place the loaded pallet on the rack. • The desired outcome is a rack system that can carry the load and maintain an excellent level of safety for the workers in Liner cell. • Testing the spacing between shelves. The shelves need to be adequately spaced to provide easy placement and removal of loaded pallets. • Use various forklifts to load and unload the rack to ensure compatibility with rack location. R· I· T Mechanical Engineering Department

  49. Bill of Materials R· I· T Mechanical Engineering Department

  50. Risk Assessment R· I· T Mechanical Engineering Department

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