Project Information Project Name Process Improvement Project Project Number P09457 Project Family Sustainable Technology for the Global Market Track Process Improvement Innovations Faculty Guide Professor John Kaemmerlen Primary Customer Dresser-Rand Piping and Packaging Area Team Members Eric MacCormack Colin Roy Jimmy Ichihana Cody Rath Duke Bonaventura

Agenda Topic of Review Introduction of Project Team, Agenda Project Approach, Needs, Specs Facility Layout Changes Facility Layout Risks Weld Booth Changes & Risks Hydro Table Changes & Risks Move Sequence Total Cost Conclusion

Project Approach For 25 years process improvement has been overlooked at Dresser-Rand’s facility. There are many opportunities at making improvements throughout the facility. Many problems could be individual capstone projects Proposing quick and inexpensive solutions to several problem areas is the focus of this project Even without any IE work, the past two years have been D-R’s best two financial years.

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

Overview of Plant 1 Not in Packet

Customer Needs Customer Need # Importance Description Comments/Status CN1 1 - 1 Increased worker safety by decreasing/preventing recordable injuries and near misses Holds the most weight in reason for change CN2 1 - 2 Increased plant capacity/flexibility More floor space allows for more skids on the floor CN3 1 - 3 Increased throughput of final product Improve processes CN4 2 - 1 Standard work stations so any employee can quickly identify and operate equipment Improve standards in work processes, work zones, booths CN5 2 - 2 Improve flow of parts and material between cells Find solutions to allow parts to flow through the factory CN6 3 - 1 Install visual controls Allow for faster retrieval or parts, resources, personnel priorities CN7 3 - 2 Eliminate unnecessary inventory Some parts in the consignment area have a thick layer of dust Cust. Need #: enables cross-referencing (traceability) with specifications Importance: 1=must have, 2=nice to have, 3=preference only First number determines importance level. Second number lists the priority the customer has placed on that specific need.

Specification (description) Specifications Engr. Spec. # Importance Source Specification (description) Unit of Measure Marginal Value Ideal Value Comments/ Status ES1 1 CN1 Recordable Injury Injuries / yr  0 Should be  ES2 Near Miss Injury Near Miss Injuries / yr ES3 CN2 Increased floor space for new opportunity sq ft 10% 30%   ES4 CN3 Finished products out the door Parts / yr 5% 15% ES5 2 CN4 Standard welding stations Specs Same Y Yes/No ES6 CN5 Total distance materials travel ft -15% -40% ES7 3 CN6 Consignment part availability Percent Available  90%  100% ES8 Trigger response to recognize what seeing Response Time  <5s  <1s ES9 CN7 Inventory turnover Time 30 Days   16 Days Minimize Importance: 1=must have, 2=nice to have, 3=preference only Marginal Value: Minimal improvement value Ideal Value: Best case scenario given constraints

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 http://www.onlinelawyersource.com/personal_injury/crane-accident/overhead.html

System Needs Facility Layout Primary Needs: Ensure worker safety through improved floor layout 6S (Sort, Set in order, Shine, Standardize, Sustain, Safety) Maximize floor space to allow for additional product to be placed on the final packaging floor Separate welding from the path of the crane Secondary Needs: Improved flow of material Install visual controls for better efficiency, flow of parts, etc in the shop Eliminate any unused or unnecessary equipment, inventory, processes Make continuous improvements as necessary

Piping and Packaging Area Current State Weld Booths Final Packaging Hydro & Cleaning Pipe Prep Consignment VMI Tubing and Instrumentation

Muther Chart Value Closeness A Absolutely Necessary E   Final Assembly (1) Weld Booths (2) Consignment (3) VMI (4) Cleaning (5) Cutting and Bending (6) Tubing and Instrumentation (7) Pipe Storage (8) I 2 O U 4 3 E 5 1 Value Closeness A Absolutely Necessary E Especially Important I Important O Ordinary closeness okay U Unimportant X Undesirable Code Reason 1 Frequency of use high 2 Frequency of use medium 3 Frequency of use low 4 Share common function 5 Only used between two cells

Proposed Layout 1 VMI VMI Final Packaging Final Packaging Hydro & Cleaning Hydro & Cleaning Pipe Prep Pipe Prep Weld Booths Weld Booths Tubing and Instrumentation Consignment Tubing and Instrumentation Consignment

Proposed Layout 2 VMI Final Packaging Hydro & Cleaning Pipe Prep Weld Booths Consignment Tubing and Instrumentation

Proposed Layout 3 VMI Final Packaging Weld Booths Pipe Prep Hydro & Cleaning Tubing and Instrumentation Consignment

Proposed Layout 4 VMI Final Packaging Weld Booths Hydro & Cleaning Pipe Prep Tubing and Instrumentation Consignment

Proposed Layout 5 VMI Final Packaging Hydro & Cleaning Pipe Prep Weld Booths Tubing and Instrumentation Consignment

Pugh Assessment Concept Criteria Weight 1 2 3 4 5 Safety 0.25 Cost Implementation 0.15 Final Packaging Floor Space 0.20 Material Handling Distance 0.10 Flow Between Cells Worker Resistance to Change 0.05 Ease of Implementation Weighted Score 2.65 2.5 1.7 2.45 1 – Much Worse than Datum 2 – Worse than Datum 3 – Same as Datum 4 – Better than Datum 5 – Much Better than Datum

Piping and Packaging Area VMI Weld Booths Final Packaging Final Packaging Hydro & Cleaning Hydro & Cleaning Pipe Prep Pipe Prep Consignment VMI Weld Booths Tubing and Instrumentation Tubing and Instrumentation

Flow Between Cells Flow Final Packaging Pipe Racks Consignment Cutting & Bending Welding VMI Hydro & Cleaning

Piping and Packaging Area Proposed Layout with Crane Sweeps

Proposed Design Changes Facility Layout Proposed Design Changes Current Weld Booth Location Large safety liability with current weld booths. There are several cranes that operate heavy equipment directly over the welders. Moving off of Final Packaging creates an increase in floor space of 23% and an increase in capacity for products on the floor of 33%. Proposed Weld Booth Location A central location with small negative impact to the current process. Ease of implementation – available floor space Welding supplies within the break room will be moved into the current VMI location.

Proposed Design Changes Facility Layout Proposed Design Changes Proposed VMI Location The VMI parts are used only at Final Packaging making it beneficial to have them as close as possible. The break room provides a sufficient amount of space and is adjacent to Final Packaging. Break Room In order to compensate for the break room eliminated near final packaging, the break area was relocated closer to the weld booths.

Proposed Design Changes Facility Layout Proposed Design Changes New Aisle Moving the weld booths places a disconnect on the Pipe fitters and welders, increasing travel distance. A new aisle decreases the travel distance between pipe fitter and welder. New Space for Conduit A larger area is needed for conduit cell.

Proposed Design Changes Facility Layout Proposed Design Changes Additional Pipe Rack An increase in skid capacity will result in the need for additional parts on the floor to ensure we never run out. An additional pipe rack will help mitigate some of this risk. New Storage for Flanges Flanges storage was combined and condensed to create more floor space for the new aisle.

Status and/or Contingency Plans Facility Layout Risks and Contingencies Risk Item Severity Probability Owner Status and/or Contingency Plans Worker resistance to change High Team/ Dave Management has expressed commitment to address risk. Team will develop ways to minimize resistance. Possible use of Performance Mgmt Techniques Parts unavailable for Final Packaging as a result of increasing the capacity. Team Additional pipe storage rack requested. Additional space in old break room can be converted to storage. Increased frequency of shipments from suppliers. Pipefitters unaware of when they need to drop off and pick up parts from welders (due to moving weld booths) Medium The team is suggesting lights that signal when a welder is working, needs work, and when material needs to be picked up. Changes in individual cells creates change in overall layout Low Will focus on optimizing the processes and issues within each subsystem while maintaining their effect on overall layout. Cost of move is too great for management Colin Proposed solutions will need to incorporate changes with smaller financial penalties. Timeline for implementation of move not feasible Eric Order of precedence established for move. Durations of move need to be estimated.

Additional Costs (Pending Quotes) Total Cost Buy Items Item Qty Price Total Welding Curtains   Option 1 10 $1,700 $17,000 Option 2 $365 $3,654 Option 3 $160 $1,600 Curtains For Hydro Table Have in stock Hydro Cage $3,400  Build Hydro Controls  $6,000 Wood Cart 24" x 48" 1 $185 Wood Cart 30" x 60" $210 Metal Cart 24" x 48" $309 Metal Cart 30" x 60" $359 Rollers 12 $101 $1,210 New Welders  2 $12,000 Ladders (4', 3', 2') Captured under other safety initiative Tungston Grinder $2,500 Fan for Welder 6 $244 $1,464 $31,291 Additional Costs (Pending Quotes) Item Cost Place 2 electrical boxes for welders   Run Argon to all new weld booths Construct Temporary Walls Dig Trenches for welding wires Work lights for Welders Knockout break room door Total $0 *Total calculated with option 2

Platform Trucks

Platform Trucks

Rollers Total Cost Quoted Price $100.85 Quantity 12 $1,210.20

Weld Booths Not in Packet

System Needs Weld Booths Primary Needs: Improve Safety Standardize weld booth Better use of space by eliminating unnecessary equipment/materials Allow welders the flexibility of using any weld booth Install visual controls to ensure welder is always busy Construct exhaust system to remove gasses generated from welding Secondary Needs: Make continuous improvements as necessary Eliminate the need for tools to be borrowed

*Proposed Equipment (listed in red) Standard Weld Booth Staging Area Staging Area Curtain Entrance Work Table Rollers Vice Stick Rod Cell 1 Cell 2 Quench Tank Power Supply Argon Lockers Welder Oscillating Fan *Proposed Equipment (listed in red)

Proposed Weld Equipment Visual Control Lights Rollers Rollers Argon Oscillating Fan

Proposed Design Change Elimination of Argon Cylinders Argon tanks are being removed from each individual weld booth with the inclusion of one large argon tank located outside. Argon will be piped to each weld station. Eliminates the need to manually handle cylinders (150 lbs). As a result strains and sprains, number 1 injury at Olean, will be reduced. Prevents the possibility of a gas leak from tipping, dragging, sliding, rolling or laying of the cylinders. Eliminates the need to refill portable tanks (currently approximately twice a week) as well as decrease clutter in weld booths. Dig trenches for cords By having a standard weld booth, trenches can be dug to eliminate any tripping hazard from electrical and argon cords

Proposed Design Changes Install visual control system With the addition of colored lights, pipe-fitters will be aware of when/which welder needs work Pipe-fitters will also be aware of when the welders have completed work to be picked up Simple exhaust system By adding an oscillating fan along each column, hazardous fumes are drawn from the welding booths allowing workers to leave curtains closed

Proposed Design Change Rollers For Every Weld Booth Without rollers, workers need to rig together some sort of mechanism to hold bigger pieces of pipe. A purchased roller will be safer then something created by the welder. As a result of adding a roller to each weld booth, setup time and process time are both decreased. New Weld Curtains Argon gas is heavier then air and will therefore settle in the weld booths. Lifting the weld curtains a foot off the ground will provide better ventilation.

Improvements Safety Productivity Weld Booths Better weld booth ventilation Decreased potential for arch flashing Elimination of tripping hazard Proper pipe rolling equipment Minimized lifting requirements Eliminate ergonomic safety concerns in transporting argon tanks Eliminate safety concern in gas leaks from argon tanks Safety improvements are a must, and the productivity improvements support the need of the welders to have increased capacity. Productivity Flexibility of work environment Eliminate travel time to replace argon tanks Increased communication → decreased downtime Proper pipe rolling equipment → decreased process and setup time

Cost: Weld Curtains Weld Booths Option 1 Purchase all new weld curtains along with new frames to hold together. Quoted at $1,700 per weld booth before shipping

Costs: Weld Curtains Weld Booths Option 2 Purchase single panel runs Panel Size Qty Price Total Cost 6' x 13' 2 $85.80 $171.60 6' x 14' $92.40 $184.80 Total cost per booth $356.40 Total Cost $365.40 x 10 = $3,654

Cost: Weld Curtains Weld Booths Option 3 Weld Booth Needs Dimensions 12' x 13' Linear feet needed per booth 54' Total booths 10 Total linear feet needed 540' Weld Curtain Rolls Dimensions 5' x 75' Price $200 Total Cost Number of Rolls Needed 8 $1,600 Cost Per Booth $160

Hydro Table Not in Packet

System Needs Hydro Table 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 Secondary Needs: Better coding of pressurized hose for improved human factors (or visual control) Improved storage of pipe fittings for better storage and improved human factors (or visual control)

Hydro Table Design

Gauge Board Design

Hydro Table Cage Design

Hydro Table Cage Double Hinged Doors allow for more accessibility on the getting in and out of the caged area. Sliding doors are ideal for the sides where space is limited. Lift out panels provide easy access for larger pipes if needed

Design Improvements Safety Cage Worker Facing Operation Direction 360 degree safety cage minimizes injuries due to pressurized pipe failures. Cage prevents workers from straying into hazard area. Worker Facing Operation Direction With the new design the operator faces the direction of test allowing him to always see the table and parts he is working on. Eliminates necessity for second worker

Design Improvements Better Coding New Flange Storage The new design of the gauge board separates high pressure gauges from low pressure gauges to eliminate any confusion. The introduction of a new coding system on the hydro table will reduce human factor errors. New Flange Storage By eliminating old flanges, organizing them properly and locating them in one location, cycle time decreases in the hydro table cell.

Sequence of Moves

Questions ?