Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE)

1. Multidisciplinary Senior DesignRochester Institute of TechnologyDresser-Rand Painted PostP10459Final Project Review5/14/10 Team: Phil Eaton (ME) Alex Frenkel (ME) Rachel Koch (ME) Pete Lowry (ISE) Yi Xie (ISE) Faculty Guide: John Kaemmerlen

2. Outline • Overview • Results • Machine Configuration Summary • Cell Layout Summary • Material Handling Summary • Material Storage Summary • Process Improvement Summary • Project Evaluation • Future Steps/Recommendations

3. Project Description • Problem • Liner cell is located in 3 different parts of the plant • One part is in a location that will be closed off • Objective • Provide a detailed plan for movement/consolidation • Maximize productivity, safety, quality, and profitability in new layout • Stakeholders • RIT: John Kaemmerlen, Senior Design Program • D-R: Dennis Rice, Mike Decerbo, John Woedy • RIT MSD • December 2009-May 2010

4. Customer Needs/Engineering Specifications * Estimated

5. Travel Distance Specifications

6. Concept Summary: Machine Configuration/Fit Up Booth • Need: Increase productivity and safety through analysis of alternative machines • Originally we wanted to pursue investigating the purchase of new CNC equipment, this did not happen. • The final machine configuration brought all assets from shop 21 into the new cell. As well as an additional asset from outside of liner cell • The Cincinnati Gilbert will bring the porting operation into the cell greatly reducing the travel distance currently in place to port liners outside of the cell.

7. Fit-Up Booth • Additionally we suggest the purchase construction and installation of new equipment for a fit up booth. • Not only does this add value in saved time, but added safety also is achieved.

8. Fit-Up Booth

9. Fit-up Booth

10. Concept Summary: Cell Layout • All Concepts involved moving the Shop 21 Liner Cell into a new area (Either Shop 17 or 6) • Concepts considered moving the #6425 Norton Grinder, #6605 American Lathe &/or #6911 Gilbert in addition to the Shop 21 machines • Concepts considered purchasing a new Vertical Turning Lathe • Final Concepts were determined to involve using extended Shop 6 layout including the #6911 Gilbert, leaving #6425 Norton Grinder & #6605 American Lathe as is, adding Racks & a Fit-up booth, & not adding a new VTL.

11. Concept Summary: Cell Layout

12. Design Summary: Cell Layout • The Final Layout reduces travel distance by 600-1000 feet per liner type (an average of 45% less), saves 23% in foot print, and allows management by sight

13. Concept Summary: Material Handling Large V Block (Oak) Holes for adjustable V Block spacing Small V Blocks (Oak) Standard wooden pallet (Oak) Method for strapping the liner to the pallet Standard wooden pallet with adjustable V Block fixtures for different sizing/length of liners

14. System Testing Results: Material Handling • Initial inspection • There are no initial fractures in the pallet or v-blocks.  • Testing • We put a liner on a pallet and held it down using a tie-down strap. • We had a forklift operator move the pallet at working speed (approx. 3-4 mph):

15. Design Summary: Material Handling/Storage • Vertical storage rack reduces WIP storage footprint by 66% • Will improve cleanliness of work area and lower risk of damage since liners are organized at a central location

16. Process Improvement Problem Long Term problems Immediate Problems Hidden Problems Identification (Visual Controls) Machine D/T Board Process Control Board Waste Tracking Sheet Resolution Flow Analysis Action/ Resolution board Outputs Higher Quality Greater Productivity Best Safety

17. Process Control Board

18. Machine Downtime Board

19. Waste Tracking Sheet

20. Visual Control Management

21. Objective Project Evaluation: Success and Failure • Successes • Support from operators, CI team, and management • Targets met for layout and material storage • Successful pallet prototype • Buy-in for visual controls • Shortcomings • Multiple iterations • Change of scope • Lack of implementation

22. Opportunities/Suggestions for Future Work • Machine Configuration • Automated equipment • Involve all stakeholders in decision making process • Cell Layout • Go through 3P for all layout changes • Involve all stakeholders in decision making process • Process Improvement • Operators: Active problem solving and reporting • Supervisors: Consistent problem solving follow up • Management: Support for change initiatives • Limit problems to manageable amount

23. Opportunities/Suggestions for Future Work • Material Handling: • Investigate strapping options which have more than one connection point to pallet • Painting pallets to prevent loss • Material Storage • Updating processes and machines to reduce WIP storage • Less need for storage if a liner is completed with little interruption in the manufacturing process

24. Acknowledgements • Thank You • Operators: Wayne, Gary, Roland, Dave • Supervisors/Planner: John, Lori, Shane • Management: Don, Mike, Chris • CI team: John, Justin • Maintenance: Pat, Ron • Lastly, what can we leave you?