R-I-T Project Improvement Project Matthew Bonaventura Jimmy Ichihana Eric MacCormack Cody Rath Colin Roy

Crane Safety “Approximately 50 or more people die, and hundreds more are injured every year in the United States as a result of overhead crane accidents. Overhead crane accidents are considered one of the leading causes of death or serious injury in the construction/manufacturing industry.” “OSHA requires that employers take every precaution possible to prevent overhead crane injuries. When an employer’s negligence causes or contributes to injury or death in overhead crane accidents, they can be held liable for any damages that were caused. Parties who have been injured in overhead crane accidents caused or contributed to be another party’s negligence have the legal right to seek compensation for there losses.” Source: Overhead Crane Accidents

Project Approach After initial review of Dresser-Rand Piping and Packaging area it has been determined that the best approach is to break up the floor into several subsystems: Facility Layout Weld Booths Consignment and VMI Inventory Tubing and Instrumentation Pipe Prep – Cutting and Bending Hydro and Cleaning Final Packaging

Facility Layout Final Assembly Consignment VMI Tubing and Instrumentation Weld Booths Cutting, Bending, Cleaning *Current State

System Needs and Proposed Solution Current State Issues: Weld booths in Final Packaging presents large safety issue with overhead cranes Final Packaging needs increased capacity to catch up on 2 year backlog Worker break room is an inefficient use of space and provides a ‘hide-out’ for workers where management cannot see what they are doing Flow of material is inefficient Analysis: Consulted with workers and management to determine system needs Developed 5 possible layout options Assessed each layout based on final packaging floor space, material handling distance, flow between cells and ease of implementation Chose the best layout based on these assessments Solution: The weld booths are moved out of Final Packaging and into a central location An increase in floor space of 23% and an increase in capacity for products on the floor of 33%. VMI is moved into the break room in order to more efficiently utilize the space Travel distances and the overall flow of material are improved Facility Layout

Selected Concept

Weld Booths

System Needs and Proposed Solution Weld Booths Current State Issues: Construct exhaust system to remove gasses generated from welding Provide welders with proper equipment Standardize weld booth to better use space by eliminating unnecessary equipment/materials and allow welders the flexibility of using any weld booth Install visual controls to ensure welder is always busy Analysis: Consulted with workers and management to determine system needs Used continuous feedback to tweak original design to generate optimal layout Solution: Add pipe rollers to weld booths to increase productivity Eliminate the need for welders to go outside and fill up argon tanks (currently 2x per week), alleviating unnecessary lifting and walking Dig trenches to remove tripping hazard from cords lying along the floor Install visual control system to allow pipe-fitters to be aware of when/which welder needs work and make pipe-fitters aware of when welder has completed work Simple exhaust system to keep weld curtains closed at all times and decrease potential for weld flashing

Proposed Design Weld Booths Lockers Work Table ViceStick Rod Rollers Quench Tank Power Supply Welder Rod Oven Oscillating Fan Cell 1Cell 2 Curtain Entrance Staging Area *Proposed Equipment (listed in red) Argon

Hydro Table

System Needs and Proposed Solution Primary Needs: Incorporates Hydro HAZOP recommendations for production pipe Safety mechanism to prevent hazards of catastrophic pipe failure Allow worker to face direction of testing Improve control layout to designate high and low pressure ranges Analysis: Reviewed needs and developed an initial layout for a new gauge board design Developed three concepts that satisfy the safety concerns of the current state Selected an appropriate design based on customer feedback and preference Solution: Implement a 360° safety cage to minimize injuries due to pressurized pipe failures and prevents workers from straying into hazard area. Relocate the controls so that the part being tested is in the line of site with the gauges allowing the operator to observe both during testing Eliminate the necessity for second worker by relocating control board Hydro Table

Selected Concept Hydro Table

Moving Forward Above is a sequence of moves that will be followed in order to assure a safe and efficient move

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