1. Eric Albanese Helen Jervey Barret Zeinfeld Josh Monsees Faculty Guide: Professor Kaemmerlen

2. What is Process Engineering? Implementation of significantly better production method or process Develop better processes, quicker and more efficiently Each project takes a system of the stakeholder and works to improve Why do this? To save money and reduce costs Done with lean engineering and process improvement Each senior design project involves a customer wanting to increase profit, reduce cost, or make their facility safer

3. Past Process Innovation Projects

4. Parlec Automated Oiling System 1 IE, 1 CE, 2 ME’s Dresser Rand Compressor Stand 2 IE’s, 3 ME’s Dresser Rand Layout Redesign 4 IE’s, 1 ME Wegmans Automated Cookie Line Improvement 2 IE’s, 2 ME’s, 2 EE’s Wegmans Fresh Bread and Roll Scaling Area 3 IE’s, 2 ME’s Wegmans Commercial Roll Line Shrink Reduction 3 IE’s, 2 ME’s Cooper Vision Capacity Analysis 4 IE’s Gleason Gear Quenching 1 IE, 3 ME’s, 2 EE’s

5. Wegmans Automated Mini-Cookie Separation System Primary Stakeholders Scott Young, Chris Isaacson Problem Profit loss due to over-packing containers Potential annual savings of $208,000 Requirements Separate cookies into batches by weight Maintain or increase throughput Keep hand-packed look

6. Wegmans Automated Mini-Cookie Separation System Initial Prototype Powered conveyor Sifter bar Chute Weighing System Push bar Final Design Funnel system replaced sifter bar Client approved Budgetary concerns

7. Dresser-Rand Problems Overhead crane traveled over 8 weld booths with workers working below, moving thousand pound skids. Severe potential safety risk Process improvement activities overlooked for over 25 years leading to a hazardous and inefficient (expensive) environment Goals of the group: Redesigned floor layout in order to increase safety, productivity, flow and reduce waste Reduce potential injuries or near misses ($) Increase available floor space for additional capacity and make space available for the 8 welding booths ($) Improve material and part flow for warehouse to reduce cycle time and decrease waste($) Reduce unused inventory ($) Customers Dennis Rice, Process Innovation Director at Dresser-Rand Team Eric McCormick (IE), Colin Roy (IE), Matt Bonaventura (IE), Jimmy Ichihana (IE), Cody Rath (ME)

8. Dresser-Rand Accomplishments Redesigned weld booth to eliminate safety hazard of the overhead crane Added new curtains exhaust fan for ventilation Add pressure valve for safety in hydro testing Changed control layout for more accurate operation Improved floor space capacity by 33% Reduced walking time by adding center lane Moved supplies closer weld booths Reduced setup and process time by putting rollers on weld booth Changed design of hydro table to require only 1 worker with faster output Inventory reduction to save space Designed new consignment checkout procedure for faster parts ordering Challenges Shop floor buy in; some of experienced group didn’t understand why money was going into the facility and not their pockets. Traveling distance; less face-to-face time Different ideas about how to accomplish goals