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Detailed Design Review

Detailed Design Review. Rochester Institute of Technology Multi-Disciplinary Senior Design Project: P13457. Team Members: Michael Then, Katherine Poehlman , Allison Doster , William Slaughter, William Swift. Dresser- Rand : Rotor Cell Improvement Project Topics: Heat treat B & OS

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Detailed Design Review

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  1. Detailed Design Review Rochester Institute of Technology Multi-Disciplinary Senior Design Project: P13457 Team Members: Michael Then, Katherine Poehlman, Allison Doster, William Slaughter, William Swift Dresser- Rand : Rotor Cell Improvement Project Topics: Heat treat B & OS Capacity Determination

  2. Re-Cap • Improve Throughput in the Rotor-Cell • Layouts: Heat Treat and B&OS • Shelving choices • Quotes and Lead Times • Layout Configurations • Capacity Determination (Moving Forward…MSDII)

  3. 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 • 15lbs of force to pull-out fully loaded rack

  4. 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

  5. Note: This includes one Rack and extra shelf for B&OS Total Cost: Roll Out Racks • Lead Time = 10-12 business days

  6. B&OS: Standard Racks • 6 racks should fit all parts • Modeled in Auto-Cad • 5 storage shelves/rack • 6th shelf 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. Rack Quote 1: 6 racks - 5 shelves • Top Shelf open • 60” height • Lower top shelf with 10 inch spaces between shelves. • Total: $3,255.62 • Lead Time = 4-8 business days

  10. Rack Quote 2: 6 racks - 6 shelves • 72” height (6 ft.) • Gives more vertical space options • Lower the 5th shelf • Leave 6th shelf at top to prevent dust settling on parts. • Total: $3861.21 • Additional $600 • Lead Time = 4-8 business days

  11. Moving Forward (MSDII):Capacity Determination Focus is on Impeller throughput • Impeller routings are complex • Rotor Assembly process adds to complexity • Moving Bottleneck • Bottleneck = Plant Capacity First bottleneck: Milling • What to send out? What to keep in house? • Parts mix determines Capacity / Bottlenecks • Monthly standard ≈ 70-80% parts outsourced for this process Goal: • Given your parts mix each month: • Maximize Machine Usage • Maximize Throughput • Keeping Impellers of same Rotor Assembly on same pace • Could you decrease rented vendor space - $$ • Most importantly: What parts mix stabilizes flow?

  12. Why start in Milling? • All parts go through this process • Most Variability in Process Times from part to part • Other processes are more similar • Parts mix is less relevant • Easier problem to analyze • Comes down to stabilizing flow • Process Times can be accurately measured • Decision to send out here initiates “waves” in flow • Creates “Moving” Bottlenecks Stabilizing flow through this step in the process will help flow throughout facility • Add more complexity (i.e. further steps in the process) as we progress

  13. Capabilities • 5-Axis • Large • Single-Piece Basic Model Inputs and Logic Mill 460 • 3 & 5-axis • 29” max for 2-piece • 23” max for 1-piece Mill 437 • 5-Axis • Single-Piece Mill 435 Create Assign Decide Generic Part Created • 5-Axis • Single-Piece • Routes Parts Based on Machine Capability and part Attributes • Gives Parts Attributes based on Parts Mix (Probability) • 2-piece • 1-piece • Semi • Diameter • 5-Axis • 3-Axis Mill 431 • 3-axis Mill 429 • TBD: Vendor Lead Time; Part Types; Affect of Attribute on Time • Batch Sizes for Shipping O/V

  14. Next Steps • Data Collection • John Russell – Highest Month Parts list • DISCO Reports- Milling Times • Programming List- 3-axis, 5-axis, if Vendor was used • Build Preliminary Model of Mills • Validate Model Logic • Initial Goal: • Optimize Planning through Milling • Analyze impact of returning parts quantity on processes downstream • If time allows, incorporate other areas of work cell

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