1. SENIOR DESIGN PROJECT P08455
Value Engineering in a Manufacturing Facility Compressor Stand for Final Assembly
SENIOR DESIGN PROJECT P08455

2. The Team John Foley (ME), Eric Hodecker (ME), Chris Bulawa (ME),
and John Roylance (IE) and Stephen Papa (IE- Project Manager)

3. Current Process Head Pipe Clamps to Support Head Top Half is Removed
During Final Assembly
Bundle
Cradles
Complete Bundle on Contract Tooling 3

4. Value Engineering in a Manufacturing Facility
Objective:
Design and build a safe compressor final internal assembly stand for the Olean Manufacturing Facility.
Iteration 1 - Key Needs:
Adjust to different sized compressors. [Length (35”-86”) and Diameter 21”- 43”)]
Be able to support up to 30,000lbs for a week.
Support different sized Heads
Work bench to support assembly tools [12” x 18” and support 100lbs.]

5. Final Design - Iteration 1
Removable and adjustable tool table
Adjustable plates for different diameter compressors
Track allows for adjustment to different length compressors

6. Pin adjusted height with 180o lateral motion
Tool Table - Iteration 1
Pin adjusted height with 180o lateral motion
Non-slip tool tray
Detachable base

7. Compressor Stand for Final Assembly – Key Needs Iteration 2:
The original budget was cut down to $5,000 between Senior Design I, and Senior Design II. After crucial evaluation of the current project, the team decided to eliminate some of the secondary needs without compromising the primary needs in an effort to meet the new budget.
Key Needs Iteration 2:
Adjust to different sized compressors. [Length (35”-86”) and Diameter 21”- 43”)]
Be able to support up to 30,000lbs for a week

8. Final Design - Iteration 2

9. Test Plan
Testing begins when fabrication of the stand is completed (5/9)
Testing will consist of:
Load tests (to be preformed by Dresser-Rand)
Ergonomic tests
Approval by Dresser-Rand management and operators
Testing will be performed at the Dresser-Rand Olean facility
Senior Design Team and Dresser-Rand Stakeholders will be present for testing.

10. System Test Results - Ergonomic Tests
3DSSPP Stress Analysis software was used to test biomechanical stresses placed on a stand operator.
Fig. 1” shows the body position used to test the biomechanical stress on the operator.
“Fig. 2” shows the percent of males able to handle the stress at each joint. These percentiles fall within the acceptable limit of 90 percent of males.
Work Instructions were presented and accepted by Dresser-Rand
Figure. 1
Figure. 2

11. System Test Results - Approval by Dresser-Rand management and operators:
Overall the design was robust and well thought out
The group was eager for feedback from our assemblers.
With only minor adjustments, the bundle stand can be used for production assembly
The group was able to explain the different functions/ applications of each component clearly and effectively
Developed comprehensive work instructions for alignment, use, and handling of the bundle stand

12. MSD II Project Schedule Milestones
Ergonomic Evaluation and Training
Test
Field Demo
Functional / Performance Review
Poster Submitted
Final User Documentation and Final
Presentation
Senior Design 2 Starts
Working on Test Plan
Develop Work Instructions
Work with PE to Certify the Design
Work with the Manufacturer
Order Parts
Manufacturing
Transportation

13. Conclusion Approval by Dresser-Rand management and operators
The stand prototypes were delivered to the Dresser- Rand Olean facility on May 9th, 2008.
It was determined that the stand we produced would provide an excellent basis for the future stands to be used in Dresser-Rand manufacturing facilities worldwide.
Project was under Budget

14. Acknowledgements – THANK YOU!
Dresser- Rand
Mark Wilson
Michael Bunce
RIT
Dr. Taylor
Dr. Debartolo
Dr. Kaemmerlen
John Bonzo
Justin Stabb (Certified Professional Welder)
RIT Machine Shop