Final Project Review

Topics:• Last Quarter Review:

• Heat treat• B & OS

• This Quarter:• Arena Model Status• Scheduling System• Vectra Table Concept

Rochester Institute of Technology

Multi-Disciplinary Senior DesignProject: P13457

Team Members: Michael Then, Katherine Poehlman, Allison Doster, William Slaughter, William

Swift

Dresser- Rand : Rotor Cell Improvement Project

Potential Project ConceptsThe 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..)

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

Roll-Out Racks

Heat Treat• 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

Layout in Heat TreatLayout Option: 3 Large Racks- Straight Line

Most viable given constraints Can’t move office Can’t block door 24-40 impellers

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

Standard Racks• Specifications

• 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

Layout in B&OS

Status?

Are there any plans to implement the shelves?

Arena Model Status

Goal: Determine the Capacity of the PlantHow: Complex routings require use of Arena SimulationPlan: 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

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

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

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

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.

Vectra Table

TaskDesign 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.

Vectra Table

Other Criteria:

Eliminate use of the collar Tolerance ± .0001 Supports up to 2000 lbs Makes use of current table Eliminate horizontal transfer

Vectra Table Concept Development Initial design concepts

V-Block MountsMounted under the table

One fixed One linear motionFour 5 inch diameter feed blocks

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

Rotational Base Rotary Bearing

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

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

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

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

Next Steps Arena Model:

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

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