SENIOR DESIGN PROJECT P08455 Value Engineering Dresser Rand Compressor Case SENIOR DESIGN PROJECT P08455 Stephen Papa (IE- Project Manager), Chris Bulawa (ME), John Foley (ME), Eric Hodecker (ME) and John Roylance-(IE)

Value Engineering in a Manufacturing Facility Objective: Design and build a safe compressor final internal assembly stand for the Olean Manufacturing Facility.

Identify Customer Needs Step 1: Gather Raw Data From Customers Interviews Dresser Rand Site Visits Step 2: Interpret Raw Data in Terms of Customer Needs Customer Statement -> Interpreted Needs

Step 3: Project Requirements Key Needs: Adjust to different sized compressors. [Length (35”-86”) and Diameter 21”-43”)] Be able to support up to 30,000lbs for a week. Support different sized Heads Work bench to support assembly tools Organize the Needs into a Hierarchy: Need 1: The holding technique and hardware needs to be safe. Need 2: The holding technique and hardware needs to avoid damage. Need 3: The holding technique and hardware needs to support compressor case functions. Need 4: The holding technique and hardware needs to be adjustable. Need 5: The holding technique and hardware needs to be quick. Need 6: The lifting technique and hardware needs to be cost effective. Need 7: The holding technique needs to be standardized. Organize the Needs into a Hierarchy:

Step 4. Establish the Relative Importance of the Needs

Step 3: House of Quality:

Competitive Benchmarking Head Pipe Clamps to Support Head Top Half is Removed During Final Assembly Bundle Cradles Complete Bundle on Contract Tooling

Concept Subsystems Sub Systems Main Compressor Stand Head Support Work Bench Feet Length Adjustability

Concept Subsystems (Compressor Stand) Main Compressor Stand Solid “V” Design Adjustable “V” Design Adjustable Support design

Solid “V” Design Advantages: Simplicity Low cost No moving parts Fits all compressor diameters Disadvantages: Height not adjustable Length not adjustable Lacks ergonomics

Adjustable “V” Design Advantages: Adjustable V and length using track system Disadvantages: Height ergonomics

Adjustable Support Design Advantages: Adjustable V and length using track system Supports optimum height work level Disadvantages: More Complex Cost

Compressor Stand Selection (Pughs)

Concept Subsystems (Head Support) Jack Stand Drawer End Table V Pin V

Jack Stand Drawer Advantages: Integrated into compressor stand Industry used jack stand Disadvantages: Maintenance of track Drawer support

End Table V Advantages: Simplicity Rigidity Disadvantages: Not height adjustable Separate table

Pin V Advantages: Simplicity Holds all heads Disadvantages: Separate table

Head Support (Pughs)

Concept Subsystems (Work Bench) Bracket Bench Swivel Bench Fold Away Table

Swivel Table Advantages: Adjustable height Able to be moved to different locations Disadvantages: Wear on joints Cumbersome

Bracket Table Advantages: Movable Adjustable in height Rigid Disadvantages: Time to move Ergonomics

Fold Away Table Advantages: Adjustable in height Fold away to get out of way Rigid Disadvantages: Ergonomics

Work Bench (Pughs)

Concept Subsystems (Length Adjustability) Track Screw Pin Hole

Screw Advantages: Ergonomics Changeover Speed Adjustability Disadvantages: Cost Manufacturability

Pin Hole Advantages: Ergonomics Rigidity Stability Disadvantages: Safety Ergonomic Changeover

Track Advantages: Ergonomics Rigidity Stability Disadvantages: Changeover speed Ease of use

Concept Subsystems (Length Adjustability)   Concepts A Track B Screw C Pin Hole Selection Criteria Weight Rating Weighted Score Cost 3 4 12 2 6 Manufacturability 24 18 Ergonomic (work) 5 25 20 Ergonomic (changeover) 10 30 Adjustability (length) 40 50 Maintenance Safety Encumbrance 15 Ease of use (changeover) Compressor Accessibility Changeover Speed Durability 9 45 36 Stability 7 28 35 Total 359 313 348 Rank 1 Continue ? yes no develop

Concept Subsystems (Feet) Spring Loaded Casters Screwed Feet (Stationary)

Spring Loaded Polyurethane Wheel Advantages: Allows easier changeover Stability Disadvantages: Unable to change workstation level Maintenance

Braked Casters Advantages: Strong Able to lock in place for a secure workstation Disadvantages: Unable to change workstation level Maintenance

Threaded Feet Advantages: Strong Easy to level workstation Disadvantages: Cumbersome when adjusting table

Concept Subsystems (Feet)   Concepts A Spring loaded B Casters C Screwed in Feet Selection Criteria Weight Rating Weighted Score Cost 3 2 6 9 Manufacturability 5 15 Ergonomic (work) 10 4 40 50 Ergonomic (changeover) 30 Maintenance 24 Safety Leveling ability Encumbrance 12 Ease of use (changeover) Changeover Speed 18 Durability 8 32 Stability Total 371 362 368 Rank 1 Continue ? yes no

Final Design