Project Status Update P09457 – Process Improvement Project Eric MacCormack (IE) Colin Roy (IE)

Project Status Update Project Name – Process Improvement Project Project Number – P09457 Project Family – Sustainable Technology for the Global Market Track – Process Improvement Innovations Start Term – planned academic quarter for MSD1 End Term – planned academic quarter for MSD2 Faculty Guide – Professor John Kaemmerlen Faculty Consultant – Dr. Kuhl, choice for simulation Faculty Consultant – Dr. Carrano, choice for manufacturing processes Primary Customer – Dresser-Rand with the point of contact being Dennis Rice at the Olean facility

Mission Statement The mission of the Process Improvement Project is to implement lean principles into the piping and packaging line at Dresser-Rand Corporation’s Olean facility. Goal: reduce cycle time by 30%. Approach: improve the flow of products, warehousing of parts, visual controls, and reduce the waste within the line.

Current Layout Piping Assembly & Packaging Assembly Test Parts

Customer Needs Reduce Cycle Time – Improve Flow of Product Visual Controls System Standardize Work Processes Accurate Drawings Free Up Floor Space Maintain High Level of Safety

Staffing Requirements NameDisciplineRoles/Skills Professor John KaemmerlenFaculty Guide Will work closely with the team on an on-going basis to facilitate success. Colin RoyI.E.Project Manager, Point of contact for Dresser-Rand. Construct and submit deliverables. Lead in Simulation and Factory CAD software. Eric MacCormackI.E.Chief Engineer, Focus direction of work. Assist in any necessary tasks. Lead in lean. I.E. Student (TBD)I.E.Engineer, Strong background in the fields simulation, lean and ergonomics. I.E. Student (TBD)I.E.Engineer, Strong background in the fields simulation, lean and ergonomics. M.E. Student (TBD)M.E.Engineer, Skills for work with parts family assessment and part number consolidation. Custom tooling. Set-up reduction opportunities.

Work Breakdown Structure Improve Flow/Cycle Time Establish Baseline Identify Current Metrics Create Current State Value Stream Map Find Solutions Evaluate Alternative Line Design Accurate Drawings Lean Techniques Create KANBAN System Create Future State Value Stream Map Reduce Set-up Time Eliminate Bottlenecks 6S KAIZEN Evaluate New Equipment Visual Controls Analyze/Verify Solution Cost-Benefit Analysis Modeling or Simulation P – D – C – A

Work Breakdown Structure MemberWeek 1Week 2Week 3 Colin Tour the Facility. Bring all group members up to speed with Customer Needs Direct each team member/obtain data on current state Monitor and facilitate each team member in their active roles Eric Tour the Facility. Bring all group members up to speed with Customer Needs Acquire all current data D-R has on the current process. Reiterate current state value stream map IE Tour the Facility. Bring all group members up to speed with Customer Needs Begin Factory CAD analysis on current D-R CAD layout. Continue on Factory CAD analysis on current D-R CAD layout IE Tour the Facility. Bring all group members up to speed with Customer Needs Begin preliminary current state simulation model. Continue on current state simulation model. ME Tour the Facility. Bring all group members up to speed with Customer Needs Become familiar with the various parts that are used in the assembly process Evaluate ways part drawings can become more accurate to the products

Risks and Constraints Risks – Quality – Tradeoff of quality vs. speed – Worker resistance to change – Disruption to other processes – Increased cost to production Constraints – Factory distance (Olean plant 2 hour drive) – 22 week improvement period – Cameras not allowed in facility – D-R staff availability

Resources Required Personnel Professor Kaemmerlen Dr Kuhl Dennis Rice Dan Krenn Environment Senior Design Lab ISE/ME Computer Labs Olean Facility Equipment Arena Software Factory CAD Software

Deliverables Current State Value Stream Map Future State Value Stream Map Detailed Current State Layout Future State Layout Factory CAD Drawings and Analysis Simulation Models and Analysis Cost-Benefit Analysis Visual Control System

Team Values Punctual Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one teammate prior to the expected absence. An absent team-member should confirm that a teammate has received their message. Thorough Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow. Timely Each team member will fully complete their tasks at or before the due date for the deliverable. Professional and Ethical Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers. Committed Each team member will contribute an equal share to the success of the project Teamwork Each team member will be supportive of one another. All must realize we are working to achieve a common goal. If any conflicts are to arise during problem solving or execution they shall be resolved professionally and timely. If necessary, mediation will be provided by group leads.