Final Project Review

1. 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 Final Project Review Topics: Last Quarter Review: Heat treat B & OS This Quarter: Arena Model Status Scheduling System Vectra Table Concept

2. 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..)

3. 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

4. Roll-Out Racks Heat Treat • 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

5. 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

6. 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

7. Standard Racks • Specifications • 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

8. Layout in B&OS

9. Status? • Are there any plans to implement the shelves?

10. 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

11. 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

12. 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

13. 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

14. 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.

15. 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.

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

17. Vectra Table Concept Development • Initial design concepts

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

19. 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

20. Rotary Bearing • 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 Rotational Base True surface from Manufacturing

21. 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

22. 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

23. 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

24. Next Steps • Arena Model: • 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

25. 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