Multidisciplinary Senior Design Rochester Institute of Technology Dresser-Rand Painted Post P10459 MSD II Update Presentation 4/9/10 Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE) Faculty Guide: John Kaemmerlen

Overview Expectations Project Status Machine Configuration – Change of Scope Cell Layout – 3P – Layout Proposal Process Improvement Material Handling Project Plan

Expectations Discussion Feedback on current status Suggestions for improvement Different thoughts/points to consider Clear view of next steps Decisions to be made today Discontinue CNC VTL? Continue with automatic Fit Up? OK on proposed layout? Timeline for layout Maintenance, Move, Start Up

Project Status Overview Time Frame MSD II: Mar. 8, 2010 – May 14, 2010 Customer Needs Concept Generation Concept Improvement Concept Selection Detailed DesignTestBuild Machine Configuration Cell Layout Process Improvement Material Handling Material Storage

R· I· T Mechanical Engineering Department Machine Configuration o Currently we are waiting for Morris Great Lakes to present 2 machines to us for consideration. o We are still waiting for time studies to be conducted on the shop 1 VTL for comparison to current machining times.

R· I· T Mechanical Engineering Department Fit Up Booth

R· I· T Mechanical Engineering Department Fit Up Booth

R· I· T Mechanical Engineering Department Fit Up Booth

3P (Production Preparation Process) Goal – Compress liner cell into 1 location (Manage by sight) – Improve flow of products – Reduce process time – Support lean principle of visual controls Dates: 3/26-4/2 Attendees: 1st & 2 nd shift liner cell, John Woedy, RIT Main outcomes – Retain all machines in liner cell – Utilize 3 sections of shop 6 – Bring in Cincinnati Gilbert (dedicated porting)

3P Event

3P 5 Phases- Where we are

Original layout

Proposed Layout

Proposed Layout w/flow

New Layout Justification Liner Type Current Travel Distance Proposed Travel Distance DiffWalking time saved Cost saved/ liner 2009 Prod Run Cost saved/ liner type Lrg Prod1890 ft881 ft1009 ft (53%) 3.8 Min$6.6545$ Sml Prod1952 ft868 ft1022 ft (54%) 3.9 Min$ $ Lrg Serv2464 ft1881 ft583 ft (24%) 2.2 Min$3.8534$ Sml Serv1745 ft1046 ft906 ft (46%) 3.4 Min$5.9550$ Total Cost savings: $

Process Improvement R· I· T Mechanical Engineering Department To move towards a more lean manufacturing cell starting with use of visual controls Short term activities (1-2 weeks from now) – Process Control Board – Waste Tracking Sheet – Flow Analysis/Action Resolution (courtesy Don Mills) – Machine D/T board – Training with operators and supervisors on lean manufacturing Planned long term activities (3-4 weeks from now) – Training with supervisors on lean management – Performance Improvement Plan and Performance Analysis activities with supervisors and continuous improvement team

Process Control Board – Quick visual status update of line flow – Helps determine priority and issues Machine D/T Board – Central location for machine failure info – Status of D/T made clear Waste Tracking Sheet – Identify true process flow of liners – Identify waiting time between processes Flow Analysis Action/Resolution – Team effort to solve problems – Facilitates continuous improvement Visual Controls

Resolution Identification (Visual Controls) Problem Visual Control System Design Long Term problems Immediate Problems Hidden Problems Machine D/T Board Process Control Board Waste Tracking Sheet Flow Analysis Action/ Resolution board

Material Handling R· I· T Mechanical Engineering Department

Test Plan R· I· T Mechanical Engineering Department Pallet Specs: – 42” x 42” pallet with 1.5” x 3.5” pine top deck boards Test will be pass/fail since a fracture will render the pallet unusable Verify that the prototype can withstand loading of two liners (if possible) Failure Criteria – Pallet slat fracture under load – V-block fracture under load – Strap or strap connection point fails under load

Test Plan R· I· T Mechanical Engineering Department Phases of Testing – Check pallet before test, be sure it is fit for service No initial fractures V-blocks installed correctly – Load liners onto pallet – Strap liners down to secure them in place – Check pallet components for fracture – Check clearance for tow-motor forks V-block pins are not protruding into fork path

Updated MSD II Project Plan