Systems Design Review

1. Systems Design Review Rotor Cell Productivity Improvement Dresser-Rand Olean, NY January 18, 2013

2. Project Overview • Improve throughput in Rotor Cell • 3 different deliverables/goals: • Heat Treat Layout and Storage • Balance and Over speed Storage • Lean Principles: Visual Status of WIP and Production • WIP prioritization • What do you want to know about a part on the floor?

3. Heat Treat Specifications • Constraints • Fit within space: 10’x17’ • Accessible from over-head crane • Accommodate large impellers (80% < 24 inch) (20%>24 inch) • Accommodate high volumes (20-30 impellers) • Load Rated 2,000 lbs per shelf • Goal • Reduce foot print • Utilize vertical space • Storage space for 20-30 impellers • Flexibility in layout for future expansion

4. Racking Alternative Analysis Keeping Ergonomics in mind, height would be limited to 4 ½ ft

5. Variations Approximately $3,000 -$5,000 per Rack depending on size and style.

6. Heat Treat Risk Assessment

7. Heat Treat Layout Alternatives

8. Layout One

9. Layout Two

10. Layout Three

11. Layout Four

12. Layout Five

13. Layout Six

14. Layout Seven

15. Balance and Over Speed

16. Balance and Over Speed Specifications • Constraints • Accommodate varying balance plate sizes • Fit within current space 12’ x 20’ • Maintain organization methodology (by size) • Make large plates accessible to over-head crane • Space for future plate storage (+10%) • Goals • Implement 5S in design • Reduce foot print • Improve Lay-out • Layout flexibility for future growth

17. Balance and Over Speed Risk Assessment

18. Potential Designs: Minimal Action • Add more shelves to current design. • Layout: • Reposition shelving so shelves are back-to-back • Or Reduce down aisle width • Pro: • Minimal cost • Con: • Visibility/Reaching Parts • Flexibility with layout is constrained by single sided access

19. Potential Designs: Shelving Tree • Layout: • Modular Shelving Units • Could be arranged in multiple configurations. • Pro: • Accessible from all sides • Easy to relocate • Fits in tight, non-traditional spaces • Reduce down aisle width • Con: • Stability Risk • 5S: Sustaining organization B&OS Pit

20. Potential Designs: Shelving Tree 2 • Layout: • Modular Shelving Units • Could be arranged in multiple ways. • Pro: • Accessible from all sides • Easy to relocate • Fits in tight, non-traditional spaces • Reduce down aisle width • Con: • Stability Risk • 5S: Sustaining organization

21. Potential Designs: Vegetable Rack • Layout: Modular Design • Larger Foot-print • Possibly more centrally located • Pros: • High Parts Density • CAD model shows≈108 plates per shelf (6 in. Diameter) • Vertically Stored • 5S: Missing parts are easily identified • Cons: • More parts = Greater Load Rating • Non-mobility Higher Cost (Although Fewer Racks would be needed)

22. Potential Designs: Vertical Library Stand • Layout: Modular Design • Tighter Footprint • Pros: • High Parts Density • Similar in total storage Density to Vegetable Rack • 5S: Missing parts are easily identified • Shelving bins: size ranges- ascending • Less Leverage on Shelves • Possible adjustable shelf height • Cons: • Accommodating Variable Part Sizes

23. Visual Lean

24. Visual Lean • Two Possible Goals: • Make the floor look neat and organized • Queuing lanes, Signage, 5S and/or • Implement self managed Inventory Flow • Reduce searching times • Reduce meetings • No communication necessary

25. Visual Lean • What does management want to know about a part on the floor? • Where is that part going next? • Where is the part in the process? • What machines can a part be run on? • Is the part late or on time? • When is the part due? • Establish priority rules based on the parts status • Operator’s Perspective • What part am I doing next? • What am I running today? tomorrow? • How long of a queue exists at a machine? • Establish specific queuing locations for a machine

26. Moving Forward • Detailed design review in 4 weeks Heat Treat • Integrate design into new layout • Procurement Procedures for Dresser-Rand B & OS • Design Requirements for Dresser-Rand • Full Implementation Plan Lean (MSDII) • Initiate Information gathering now • Possibly multiple Kaizen events next quarter