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Separables Project Close-out

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The Senior Design Team at RIT presents the close-out report for designing a flexible material handling system for Dresser-Rand. This system aims to enhance capacity for the MOS compressor project while addressing ergonomic issues discovered during implementation. Key topics include project goals, accomplishments, recommendations for layout modifications, and reflections on the Dresser-Rand/RIT partnership. The project emphasizes cost-effective solutions, safety, and functionality, aiming for continuous improvement in the material handling process.

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Separables Project Close-out

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  1. Separables Project Close-out P13458 RIT Senior Design Team May 3, 2013 9AM-11AM Dresser- Rand, Painted Post http://edge.rit.edu/edge/P13458/public/Home

  2. Agenda • Problem Statement and Goals • Accomplishments & Recommendations: Transport System • Accomplishments & Recommendations: Shop 6 Layout • Reflections on the D-R/RIT Partnership

  3. Problem Statement Design a flexible material handling system that is easy to useand incorporates the safest design elementswithin cost and functionality constraints. This design fully supports the new process layout in Dresser-Rand’s strategic project to increase capacity for the MOS compressor projected sales.

  4. Air Pallet Design:3P Ergonomic Issues • During the 3P event it became apparent that the Fixed System would create a maze of obstacles when moving from station to station • Decisions were made to eliminate the fixtures at each station and modify the Free System for testing and shipping • Layout will also be spaced out to provide more maneuvering room from station to station

  5. Modified Free System • Conceptual design • Method of manufacture and dimensions undetermined • Removable fixture attaches to beam and acts like a jackstand • Overcomes flaws that were revealed during the 3P event • Stress analysis not completed • results should be comparable to the free system results

  6. Modified Free System Qualities • Pros • No more fixtures • Resolves ergonomic issues discovered during the 3P event • Lowers move prep time – no longer need to configure fixtures from station to station • Bolt on legs removable for test and shipping • Cons • Requires the floor to be leveled

  7. Recommendations – Movement • Modify testing station to incorporate free-system design • Possible lifting/attachment to test bed • Determine lifting/loading method • Need 3-axis positioning without a crane • Modified Grey Portable Lifting system for vertical lifting • Back truck under lifted compressor • Air bearings under truck bed • Driver positioning

  8. Shop 6 Layout - Post 3P Event Top Level Assembly Level

  9. 3P Event Results *Factors not considered yet: Future Expansion

  10. Recommendations • Re-evaluate test bay requirements for sizing and safety – retractable blast walls • Add in and test inventory flow and information flow • Understand exact requirements and locations for energy/power/air sources • Full dimensioning of layout • Computer simulation of process flow • Continuous evaluation and improvement • 5S taping and marking to indicate specific areas, i.e. operator walking zone inside cell, in-process kanban, visitor aisle way • Identify and allocate future expansion area

  11. Reflections on the D-R/RIT Partnership • Overall, very successful learning experience • Design process • Understanding fluctuating customer needs • Efficiency of communication • Recommend a “consulting” contract be completed at the start • Recommend creating a communications protocol to prevent delay in work as the team waits for feedback

  12. Thank you! • Henry Bastian • Brent Hoban • Brian Spencer • Joe Willig • John Woedy • + all those who contributed to this project

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