Rochester Institute of Technology Final Project Review Dresser- Rand : Rotor Cell Improvement Project Rochester Institute of Technology Multi-Disciplinary Senior Design Project: P13457 Team Members: Michael Then, Katherine Poehlman, Allison Doster, William Slaughter, William Swift Topics: Last Quarter Review: Heat treat B & OS This Quarter: Arena Model Status Scheduling System Vectra Table Concept

Potential Project Concepts The goal of this project was to help the Dresser-Rand Rotor Cell increase productivity. Multiple improvement project were suggested to the RIT team, including: Develop a production model for scheduling and capacity Design storage racks Develop tools to visualize part flow Optimize use of flow lanes Methods for space utilization Production status visual (ahead, behind, on-time..)

Project Synopsis Layouts: Heat Treat and B&OS Shelving choices Quotes and Lead Times Layout Configurations DR’s status? Capacity Determination through Arena Data Issues… Scheduling Screens for Production Area Bill of Materials Vectra Table CAD model of Concept Risk assessment Design Considerations

Roll-Out Racks Heat Treat B & OS 3 racks for the Heat Treat area 3 adjustable shelves per rack B & OS 1 rack for Finger Mandrels Recommend additional shelf to increase capacity Rack Specs 2,000lbs /shelf 48”x 48” shelf space 15 lbs of force to pull-out fully loaded rack

Layout in Heat Treat Layout Option: 3 Large Racks- Straight Line Most viable given constraints Can’t move office Can’t block door 24-40 impellers

B&OS: Standard Racks 6 racks should fit all parts Modeled all sizes in Auto-CAD 5 storage shelves/rack 6th shelf as cover for dust? Very low, if any, maintenance Consistent with current shelving Layout of plates will remain the similar

Standard Racks Specifications Versatility 3000lbs per shelf Heavy gauge steel 72-L x 24-W x 60-H 72 x 24 x 72 (Second Option) Versatility Shelves can be adjusted in 1 inch increments Not bolted to the floor so they can be rearranged Accessible on both sides

Layout in B&OS

Status? Are there any plans to implement the shelves?

Arena Model Status Goal: Determine the Capacity of the Plant How: Complex routings require use of Arena Simulation Plan: Use historical process times for parts that vary in: Size Complexity Heat Treatment Etc… Calculate Statistical variables to input to Arena RIT: Data Analysis DR: Arena Model Architecture (Sean Frier) Issues: Data not complete enough to make conclusions

Arena Model Status Status: Sean Frier has initiated a survey for process time approximations ( High, Medium, Low – Triangular Distribution) Manually look up individual work orders too time consuming Sean has outlined the model, just needs data

Scheduling System Objective Reduce communication redundancies in scheduling Allow supervisors to spend time more efficiently Communicate daily scheduling in a more timely manner Present daily schedule so that it is visible to everyone walking the floor

Scheduling System Requirements Manage Remotely Microsoft Compatible Real time schedule to each cell- continuously updating Each cell will have its own display Specific spreadsheet schedules display to cell specific monitors All displays can be managed from the same source System needs to be able to expand and add more displays and schedules as they are added to each cell

Scheduling Solution Use Hiperwall software to input a daily schedule to display on screens on the manufacturing floor. Work with DataBranch to continue to expand the new scheduling system.

Vectra Table Task Design a system for the current table so it is capable to do run-out measurements while the fins are being installed. This will eliminate wasted time as a result of needing to relocate the rotor horizontally for run-out measurements on the fins.

Vectra Table Other Criteria: Eliminate use of the collar Tolerance ± .0001 Supports up to 2000 lbs Makes use of current table Eliminate horizontal transfer

Vectra Table Concept Development Initial design concepts

V-Block Mounts Mounted under the table One fixed One linear motion Four 5 inch diameter feed blocks

V-Block Mounts: Rail System Similar to current system on the table for the vertical rods Still need a rail system for the v-blocks to move Electric rail system Mount v-blocks right on the block of the rail system Manual movement rail system that locks in place Could be used on the “permanent” side to adapt to any sized shaft diameter

Rotational Base Rotary Bearing Face Plate Needs Testing for sizing Smaller diameter may allow easier turning Needs to handle large loads Face Plate Face plate has a dome center Align center of Rotor with center of rotation Maintain vertical position Avoid “Walking-Effect” Size Uncertain although shaft has a pivot hole on bottom True surface from Manufacturing

Rotational Base: Center Centered ** Critical to design Align Center of dome with center of rotor Center of V-Blocks Would need to outline process for initial alignment Re-alignment Procedure Fine tune placement of V-blocks or build adjustments so base can be moved in small increments

Rotational Base: Center Centered ** Critical to design Align Center of dome with center of rotor Center of V-Blocks Would need to outline process for initial alignment Re-alignment Procedure Fine tune placement of V-blocks or build adjustments so base can be moved in small increments

Next Steps: Vectra Table Things to Consider: Linear Drive would need locking mechanism Electric linear drive might lock in place Needs to support weight Base plate nose size could be smaller Wearing out the plate V-block configuration 2 x 2 (top-bottom) keeps shaft vertical Could use 3 v-blocks in triangular pattern Centers like drill chuck with electric linear drives Procedure for alignment

Next Steps Arena Model: Scheduling Vectra Table Assess process times Evaluate and build into the Arena model Finish the model so that it can be used and integrated in the facility Scheduling Work with vendor to create steps of how the system will be implemented along Gain more technical knowledge of the system to dig deep into the pro’s and con’s of each implementation in a cell Vectra Table This was only one design concept so more could be developed and improved upon Accumulate more precise implementation along with mathematical calculations Pass Vectra Table Work to new Senior Design Team

RIT Team Reflection Overall, the project allowed the team to explore diverse opportunities for improvement Layouts Evaluating capacity Visual systems integration Process improvement through tool re-design Possible Drawbacks: Vectra table was great project- disappointed it was so late Would have been good as a full project on its own- design and implementation Enjoyed the diversity, but lack of one clearly defined project Hard to fully develop every concept within the time Would have been nice to have a build/ prototype associated with the project