systems design review
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Systems Design ReviewRotor Cell Productivity Improvement Dresser-Rand Olean, NY January 18, 2013
Project Overview• Improve throughput in Rotor Cell
• 3 different deliverables/goals:• Heat Treat Layout and Storage• Balance and Over speed Storage • Lean Principles: Visual Status of WIP and
Production • WIP prioritization • What do you want to know about a part on the floor?
Heat Treat Specifications• Constraints• Fit within space: 10’x17’• Accessible from over-head crane• Accommodate large impellers (80% < 24 inch) (20%>24
inch)• Accommodate high volumes (20-30 impellers)• Load Rated 2,000 lbs per shelf
• Goal• Reduce foot print • Utilize vertical space• Storage space for 20-30 impellers• Flexibility in layout for future expansion
Racking Alternative AnalysisWeight (1-
5) Roll Out-RacksPull Out Bleacher
Style Fixed StepsFlow Through Pallet
RacksAccess-ability from Crane 5 10 8 8 7
Footprint Reduction 4 8 8 5 2In-Use Foot Print 4 7 3 5 2
Move-ability 3 7 4 4 2Safety 4 7 5 5 10
Ease of Use 3 8 5 5 7Ability to Organize 3 10 5 5 4
Risk of Parts Damage 4 6 6 6 10
Score 237 170 166 170
Keeping Ergonomics in mind, height would be limited to 4 ½ ft
VariationsCisco Eagle EZ Glider Lista Global Industrial (Modern Equipment) Jarke EZ Glide
Model # Varies Order to Spec 258178 Not givenWeight per Shelf 2000lb/shelf 2200lb/shelf (1000kg) 2000lb/shelf 2000lb/shelfRoll Out Depth 100% 65% or 100% 100% Not givenMinimum Dimension (in.) 36 x 36 x 62 (3 shelves) 34 x 59 x 35 48 x 48 x 72 36 x 36 x 62.5 (3 shelves)Maximum Dimension (in.) 48 x 48 x 84 (4 shelves) 50 x 98 x 51 48 x 48 x 84.5 (4 shelves)Add-ons? Yes Based on original order Yes YesPrice $3,113.33 -$4,794.40 Not given $2,482.95 $3700-$5000Space between racks 2" adjustable 4" adjustable 2" adjustable 2" adjustableSafety/Ergonomics Shelf lock system Column guard/ LiLoFork list assessable Yes Yes Yes YesContact info 1-888-877-3861 1-877-465-4782 1-888-978-7759 1-888-316-2223Photos
Approximately $3,000 -$5,000 per Rack depending on size and style.
Heat Treat Risk AssessmentRisk Category Risk Description
Probability of Occurrence
Magnitude of Negative Impact
Risk Level Measure for Managing Risk Areas
Shelf Level Parts might be dropped when lifted onto shelves. 1 3 3Design for more space to be on the bottom shelves so that larger impellers can be placed closer to the floor to minimize lifting
Shelf Level Impellers may fall while unloading into racks 3 2 6Design for more space to be on the bottom shelves so that larger impellers can be placed closer to the floor to minimize lifting
Height The overall height of the shelves exceeds the comfortable working level of a worker.
2 2 4Obtain shelves that can be moved based on customer demands but do not exceed 4'-6' which is chest level for the average height of a person.
Broken ShelfShelves could break and cause impellers to fall on parts nearby or worker
1 3 3Shelves will have a rating of 2000 lbs. per each shelf and should not be exceeded based on the majority of impellers weighing around 200 lbs.
Falling PartsParts could fall off the side of the shelves if loaded improperly
1 3 3Side shield may need to be included on the final shelves that are installed.
BottleneckWhile shelves are being assembled, a back-up of impellers could become congested in the staging area
2 1 2Shelves will come pre-fabricated but must be assembled. Pick a week that is less busy than another. Use the other side of the offi ce for staging impellers.
Misfit Shelves do not fit into area allotted 1 3 3When procuring shelving units verify that the dimensions will fit within the allotted space.
Remove Jib CraneJib crane on the wall will need to be removed for shelves to fit properly.
1 2 2The new layout will be designed to fit around the Jib crane or plans will be made with DR to have crane removed
Poor assemblyRack might not be assembled correctly during implementation
1 3 3Racks should be assembled by vendor or other qualified personnel.
Long term financial scenario
Poor return on investment 1 3 3Senior design team will research and analyze the cost of shelving units.
Impeller falls Racks could be filled past capacity 1 3 3Make sure that the user understands the capacity of each shelve and have clear labels.
User Risks
User Integration User does not want to use new racking system2 2 4
Include the user when purchasing racks and implementation
User Integration User misuses new racking system 1 2 2
Senior design team will make sure that the user understand the intent of the new system
User Integration User wants to change the layout of the racking system1 2 2
Senior design team as well as RD management will include user in the design of the new layout
Financial Risks
Durability/ Quality Risks
Safety Risks
Implementation Risks
Risk Assessment
Heat Treat Layout Alternatives
Layout One
Layout Two
Layout Three
Layout Four
Layout Five
Layout Six
Layout Seven
Balance and Over Speed
Balance and Over Speed Specifications
• Constraints• Accommodate varying balance plate sizes• Fit within current space 12’ x 20’• Maintain organization methodology (by size)• Make large plates accessible to over-head crane• Space for future plate storage (+10%)
• Goals• Implement 5S in design• Reduce foot print• Improve Lay-out• Layout flexibility for future growth
Balance and Over Speed Risk AssessmentRisk Category Risk Description Probability of Occurrence
Magnitude of Negative Impact
Risk Level Measure for Managing Risk Areas
Shelf Level Parts might be dropped when lifted onto shelves. 1 3 3Design for more space to be on the bottom shelves so that larger plates can be placed closer to the floor to minimize lifting
Broken ShelfShelves could break and cause plates to fall on parts nearby or worker
1 3 3Shelves will have a rating of 500 lbs. per each shelf and should not be exceeded based on the majority of impellers weighing around " "lbs.
Height The overall height of the shelves exceeds the comfortable working level of a worker.
2 2 4Obtain shelves that can be moved based on customer demands but do not exceed 4'-6' which is chest level for the average height of a person.
Capacity Shelves are unable to accommodate all plates 1 3 3 SD team will design racks to fit the specs of current plates.
Plate organization New design is unable to maintain organization methodology. 1 2 2SD team will design the new system to maintain or improve the organization of plates.
Transport carts Access to transport carts are unable to be implemented. 1 3 3SD team will design racking system to accommodate the transport cart usage.
System Growth Racks may not be able to accomidate a 10% growth 1 2 2SD team will design new system to accomidate growth, by preforming the proper calcualtions and analyses.
Overhead crane Large plates are unable to be assessable by overhead crane. 1 3 3 SD team will design racks to fit the specs of the overhead crane.
Misfit Shelves do not fit into area allotted 1 3 3During design and constrution attention will be made to the correct demetions of the allotted space
Plate Storage Plates will need to be stored in another location during implementation of new system.
3 1 3Arrangements will be made in advance to have plates stored in a spearate location during implementation of the new system.
Poor assembly Rack might not be assembled correctly during 1 3 3 Racks will be assembled by qualified personnel.
Long term financial scenario Poor return on investment 2 3 6Senior design team will research and analyze the cost of shelving units.
Shelves fall Racks could be filled past capacity 1 3 3Make sure that the user understands the capacity of each shelve and have clear labels.
User RisksUser Integration User does not want to use new racking system 1 2 2 Include the user when purchasing racks and implementation
User IntegrationUser misuses new racking system (Parts not put back into Proper location)
2 3 6Senior design team will make sure that the user understand the intent of the new system
User Integration User wants to change the layout of the racking system1 2 2
Senior design team as well as RD management will include user in the design of the new layout
Risk AssessmentSafety Risks
Implementation Risks
Financial Risks
Durability/ Quality Risks
Design Risks
Potential Designs: Minimal Action
• Add more shelves to current design.
• Layout: • Reposition shelving so
shelves are back-to-back• Or Reduce down aisle width
• Pro: • Minimal cost
• Con:• Visibility/Reaching Parts• Flexibility with layout is
constrained by single sided access
Potential Designs: Shelving Tree• Layout:• Modular Shelving Units• Could be arranged in
multiple configurations. • Pro:• Accessible from all sides• Easy to relocate• Fits in tight, non-traditional
spaces• Reduce down aisle width
• Con:• Stability Risk• 5S: Sustaining organization B&OS
Pit
Potential Designs: Shelving Tree 2
• Layout:• Modular Shelving Units• Could be arranged in
multiple ways. • Pro:• Accessible from all sides• Easy to relocate• Fits in tight, non-traditional
spaces• Reduce down aisle width
• Con:• Stability Risk• 5S: Sustaining organization
Potential Designs: Vegetable Rack• Layout: Modular Design• Larger Foot-print• Possibly more centrally
located• Pros:• High Parts Density• CAD model shows≈108
plates per shelf (6 in. Diameter)
• Vertically Stored• 5S: Missing parts are easily
identified• Cons: • More parts = Greater Load
Rating• Non-mobility
Higher Cost (Although Fewer Racks would be needed)
Potential Designs: Vertical Library Stand• Layout: Modular Design
• Tighter Footprint• Pros:• High Parts Density• Similar in total storage
Density to Vegetable Rack• 5S: Missing parts are easily
identified• Shelving bins: size ranges-
ascending• Less Leverage on Shelves• Possible adjustable shelf
height• Cons: • Accommodating Variable Part
Sizes
Visual Lean
Visual Lean• Two Possible Goals:• Make the floor look neat and organized• Queuing lanes, Signage, 5S
and/or
• Implement self managed Inventory Flow• Reduce searching times• Reduce meetings• No communication necessary
• What does management want to know about a part on the floor?• Where is that part going next?• Where is the part in the process?• What machines can a part be run on?• Is the part late or on time?• When is the part due?• Establish priority rules based on the parts status
• Operator’s Perspective• What part am I doing next? • What am I running today? tomorrow?
• How long of a queue exists at a machine?• Establish specific queuing locations for a machine
Visual Lean
Moving Forward• Detailed design review in 4 weeks
Heat Treat• Integrate design into new layout• Procurement Procedures for Dresser-Rand
B & OS• Design Requirements for Dresser-Rand• Full Implementation Plan
Lean (MSDII)• Initiate Information gathering now• Possibly multiple Kaizen events next quarter
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