1. 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

2. 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

3. 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.

4. 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

5. Overview of Plant 1
Not in Packet

6. 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.

7. 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

8. 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

9. 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

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

11. 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

12. 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

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

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

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

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

17. 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

18. 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

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

20. Piping and Packaging Area Proposed Layout with Crane Sweeps

21. 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.

22. 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.

23. 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.

24. 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.

25. 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.

26. 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

27. Platform Trucks

28. Platform Trucks

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

30. Weld Booths
Not in Packet

31. 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

32. *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)

33. Proposed Weld Equipment
Visual Control Lights
Rollers
Rollers
Argon
Oscillating Fan

34. 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

35. 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

36. 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.

37. 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

38. 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

39. 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
$ x 10 = $3,654

40. 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

41. Hydro Table
Not in Packet

42. 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)

43. Hydro Table Design

44. Gauge Board Design

45. Hydro Table Cage Design

46. 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

47. 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

48. 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.

49. Sequence of Moves

50. Questions ?