final project review
DESCRIPTION
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: - PowerPoint PPT PresentationTRANSCRIPT
Final Project Review
Topics:• Last Quarter Review:
• Heat treat• B & OS
• This Quarter:• Arena Model Status• Scheduling System• Vectra Table Concept
Rochester Institute of Technology
Multi-Disciplinary Senior DesignProject: P13457
Team Members: Michael Then, Katherine Poehlman, Allison Doster, William Slaughter, William
Swift
Dresser- Rand : Rotor Cell Improvement Project
Potential Project ConceptsThe 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..)
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
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
Layout in Heat TreatLayout Option: 3 Large Racks- Straight Line
Most viable given constraints Can’t move office Can’t block door 24-40 impellers
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
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
Layout in B&OS
Status?
Are there any plans to implement the shelves?
Arena Model Status
Goal: Determine the Capacity of the PlantHow: Complex routings require use of Arena SimulationPlan: 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
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
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
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
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.
Vectra Table
TaskDesign 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.
Vectra Table
Other Criteria:
Eliminate use of the collar Tolerance ± .0001 Supports up to 2000 lbs Makes use of current table Eliminate horizontal transfer
Vectra Table Concept Development Initial design concepts
V-Block MountsMounted under the table
One fixed One linear motionFour 5 inch diameter feed blocks
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
Rotational Base 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
True surface from Manufacturing
Rotational Base: Center
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
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
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
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
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