D-R Compressor Cell

P13458 RIT Senior Design TeamMay 10, 201310-10:30AM09-2030

Dresser- Rand, Painted Post

http://edge.rit.edu/edge/P13458/public/HomeFinal Presentation: Compressor Transport System & Layout1Look at MSD Rubric:

Separate strengths/weaknesses of final design and recommendations for both layout and transport system

Need short but concise description of design history

Need reflection on team dynamic (norms and values assessment)

Put in summary of test plan results (red, green, yellow)

AgendaProblem Statement Accomplishments For The Transport SystemDesign HistoryFinal Design Summary Of Test ResultsRecommendationsAccomplishments For The LayoutDesign HistoryFinal Design & Test ResultsRecommendationsReflection On The D-R/RIT PartnershipReflection On Our Code Of Ethics2Problem StatementDesign a flexible material handling system 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-Rands strategic project to increase capacity for the MOS compressor projected sales.

New Shop Floor6-throw MOS Compressor 3Transport System Design HistoryDesign Considerations Long Beam Caster SystemShort Frame Caster System (Yellow Frame)Air Bearing TechnologyFree Support SystemFixed Support SystemModified Support SystemDesign Considerations How we got to cartsLong Beam CG Requirements dictated us use a 9 foot beam remember?Short Frame DR review led us to shorten the frame, and not worry about cylindersAir Bearing Tech OverviewFree Support Coles system with the yellow frame and air palletsFixed Support Shawns system with the in ground supports (removable?)Modified Support Current Design4Design ConsiderationsMovementPropulsion

Movement ability to stay on the set course

Propulsion power to move system5Long Beam Caster SystemAssumed entire compressor assembly would be loaded, including cylindersAssumed massive CG changes while loadedLarge structural members necessary

6Short Frame Caster SystemYellow Frame DesignVersatile to account for multiple product familiesModular to account for multiple product sizesCould not be used at test stationWas prototypedMany design flaws surrounding caster system

Air Bearing Technology

UnidirectionalNearly frictionlessReduces horizontal force required to 1lb per 1000lbsAir supply is common in industrial settingRequires flat, smooth floor surfacesFree Support SystemBased on the short frame systemAdapted for air pallet useLegs fixed to support beamConcerns regarding clearance between floor and legs during movement

COLE ADD IN YOUR RESEARCH A QUICK PICTURE AND DESCRIPTION OF SYSTEM9Fixed Support SystemVertical legs of the Free system are now fixtures placed at each stationEliminates floor clearance concerns while moving from station to stationSimplifies manufacturing Easily integrated into testing and shipping

SHAWN ADD IN YOUR RESEARCH A QUICK PICTURE AND DESCRIPTION OF SYSTEM10Removable Support SystemConceptual design Method of manufacture and dimensions undeterminedRemovable fixture attaches to beam and acts like a jack standOvercomes flaws that were revealed during the 3P eventStress analysis not completed results should be comparable to the free system results

11Removable Support QualitiesProsNo more fixturesResolves ergonomic issues discovered during the 3P eventLowers move prep time no longer need to configure fixtures from station to stationBolt on legs removable for test and shippingConsRequires the floor to be leveled

12Test Results

13RecommendationsModify testing station to incorporate free-system designPossible lifting/attachment to test bedDetermine lifting/loading methodNeed 3-axis positioning without a craneModified Grey Portable Lifting system for vertical liftingBack truck under lifted compressorAir bearings under truck bedDriver positioning

14Layout Design HistoryTook dimensions of required equipment and space for each station in the assembly, test, and paint process in the current state

Created factors of varying importance

Designed 4 different layouts 2 straight-line, 2 U-shaped in the new shop floor

Conducted a 3P event on a U-shaped layout using cardboard to check theoretical values against actual feedback from operators and line side managers3P Event ResultFactors AffectedStatusTested U-shape designReturnabilityFlexibilityPass-by/Pass-throughAdded new cylinder assembly flow lineSpace UtilizationInventory AccessOperators and managers evaluated the layout and gave feedback on parts and people flow and equipment requirementsInventory AccessEase of Movement by OperatorMovement TimeFound hidden problems and constraints i.e. spacing between stations, jib crane requires oil pump station next to columnSpace UtilizationMaintenance AccessTested good outlookNeeds further testing, but predict a good outlookNeeds attention, was not addressed15Final design

Top LevelAssembly LevelFlow16RecommendationsRe-evaluate test bay requirements for sizing and safety retractable blast wallsAdd in and test inventory flow and information flowUnderstand exact requirements and locations for energy/power/air sourcesFull dimensioning of layoutComputer simulation of process flowContinuous evaluation and improvement5S taping and marking to indicate specific areas, i.e. operator walking zone inside cell, in-process kanban, visitor aisle wayIdentify and allocate future expansion area

17Reflection on the DR/RIT PartnershipOverall, very successful learning experienceDesign process Iterative in nature lots of back to the drawing board momentsConceptualization and the funnel of idea developmentUnderstanding fluctuating customer needsEfficiency of communicationRecommend a consulting contract be completed at the startTo better establish the needs of Dresser RandSo the team can better prioritize effortsRecommend creating a communications protocol to prevent delay in work as the team awaits feedback

Contract - More formal and requires more detail than the Project Readiness Proposal presented at the start of the project- specs, deliverables, expectations

18Reflection On Our Code Of EthicsCode of Ethics ComponentsAssessmentRecommendationsExpectations for Team Behavior: Honesty, Respect, Accountability, Professional and Thorough CommunicationGood communication during meetings, but email communication was not responded to in a timely manner. Also, accountability could have been better during MSD II.Better individual time management, check email twice daily and respondExpectations for Integrity of Assigned Tasks: Tasks should be completed on-time and with the quality expected as seen in the MyCourses documentation and as discussed during assignment of the tasksCompletion of tasks was not always done on time, therefore resulting in wasted team meeting time catching up on work.Better individual time management, more thorough and clear description of tasksNot Meeting Expectations: Any complaints or inability of meeting expectations should be shared with the team in order to provide more resources and/or time, or reassign task to another memberMany tasks completed last minute and the individuals did not inform the team of their status or ask for help as often as they should have.Mid-week check-ins, project manager emphasizes team effort - offer help to others when your workload is light3 out of 11 components were not followed satisfactorily19