project information
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Project Information. Project Name Process Improvement Project Project Number P09457 Project Family Sustainable Technology for the Global Market Track Process Improvement Innovations Faculty Guide Professor John Kaemmerlen Primary Customer Dresser-Rand Piping and Packaging Area - PowerPoint PPT PresentationTRANSCRIPT
Project Information Project Name
Process Improvement Project Project Number
P09457 Project Family
Sustainable Technology for the Global Market Track
Process Improvement Innovations Faculty Guide
Professor John Kaemmerlen Primary Customer
Dresser-Rand Piping and Packaging Area Team Members
Eric MacCormack Colin Roy Jimmy Ichihana Cody Rath Duke Bonaventura
Agenda
Topic of Review
Introduction of Project Team, Agenda
Project Approach, Needs, Specs
Facility Layout Changes
Facility Layout Risks
Weld Booth Changes & Risks
Hydro Table Changes & Risks
Move Sequence
Total Cost
Conclusion
Project Approach
For 25 years process improvement has been overlooked at Dresser-Rand’s facility. There are many opportunities at making improvements throughout the facility. – Many problems could be individual capstone
projects– Proposing quick and inexpensive solutions to
several problem areas is the focus of this project
Project Approach
After initial review of Dresser-Rand Piping and Packaging area it has been determined that the best approach is to break up the floor into several subsystems:– Facility Layout– Weld Booths– Consignment and VMI Inventory– Tubing and Instrumentation– Pipe Prep – Cutting and Bending – Hydro and Cleaning– Final Packaging
Overview of Plant 1
Not in Packet
Customer NeedsCustomer
Need #Importanc
eDescription Comments/Status
CN1 1 - 1
Increased worker safety by decreasing/preventing recordable injuries and near misses Holds the most weight in reason for change
CN2 1 - 2 Increased plant capacity/flexibility More floor space allows for more skids on the floor
CN3 1 - 3Increased throughput of final product Improve processes
CN4 2 - 1
Standard work stations so any employee can quickly identify and operate equipment Improve standards in work processes, work zones, booths
CN5 2 - 2Improve flow of parts and material between cells Find solutions to allow parts to flow through the factory
CN6 3 - 1 Install visual controlsAllow for faster retrieval or parts, resources, personnel priorities
CN7 3 - 2 Eliminate unnecessary inventory Some parts in the consignment area have a thick layer of dust
Cust. Need #: enables cross-referencing (traceability) with specifications
Importance: 1=must have, 2=nice to have, 3=preference only
SpecificationsEngr.
Spec. #Importa
nceSource Specification (description) Unit of Measure
Marginal Value
Ideal Value
Comments/ Status
ES1 1 CN1 Recordable Injury Injuries / yr 0 0 Should be
ES2 1 CN1 Near Miss InjuryNear Miss Injuries /
yr 0 0 Should be
ES3 1 CN2Increased floor space for new opportunity sq ft 10% 30%
ES4 1 CN3 Finished products out the door Parts / yr 5% 15%
ES5 2 CN4 Standard welding stations Specs Same Y Y Yes/No
ES6 2 CN5 Total distance materials travel ft -15% -40%
ES7 3 CN6 Consignment part availability Percent Available 90% 100%
ES8 3 CN6Trigger response to recognize what seeing Response Time <5s <1s
ES9 3 CN7 Inventory turnover Time 30 Days 16 Days Minimize
Importance: 1=must have, 2=nice to have, 3=preference only
Marginal Value: Minimal improvement value
Ideal Value: Best case scenario given constraints
Crane Safety“Approximately 50 or more people die, and hundreds more are injured every year in the United States as a result of overhead crane accidents. Overhead crane accidents are considered one of the leading causes of death or serious injury in the construction/manufacturing industry.”
“OSHA requires that employers take every precaution possible to prevent overhead crane injuries. When an employer’s negligence causes or contributes to injury or death in overhead crane accidents, they can be held liable for any damages that were caused. Parties who have been injured in overhead crane accidents caused or contributed to be another party’s negligence have the legal right to seek compensation for there losses.”
Source:Overhead Crane Accidentshttp://www.onlinelawyersource.com/personal_injury/crane-accident/overhead.html
System Needs
Primary Needs: 1. Ensure worker safety through improved floor layout2. 6S (Sort, Set in order, Shine, Standardize, Sustain, Safety)3. Maximize floor space to allow for additional product to be placed on the final
packaging floor4. Separate welding from the path of the crane
Secondary Needs:1. Improved flow of material2. Install visual controls for better efficiency, flow of parts, etc in the shop3. Eliminate any unused or unnecessary equipment, inventory, processes4. Make continuous improvements as necessary
Facility Layout
Piping and Packaging Area Current State
Final Packaging
ConsignmentVMI
Tubing andInstrumentation
Weld Booths
Hydro & Cleaning Pipe Prep
Muther Chart
Final Assembly (1)
Weld Booths (2)
Consignment (3) VMI (4) Cleaning (5)
Cutting and Bending (6)
Tubing and Instrumentation
(7)Pipe Storage
(8)
Final Assembly (1)
Weld Booths (2)I 2
Consignment (3)O U 4 3
VMI (4)E U U 5 3 3
Cleaning (5)I U U U 2 3 3 3
Cutting and Bending (6)I O E U U 1 4 1 3 3
Tubing and Instrumentation (7)
O U U U U U 2 3 3 3 3 3
Pipe Storage (8)U U O U U E E 3 3 4 3 3 1 1
Code Reason
1 Frequency of use high
2 Frequency of use medium
3 Frequency of use low
4 Share common function
5 Only used between two cells
Value Closeness
A Absolutely Necessary
E Especially Important
I Important
O Ordinary closeness okay
U Unimportant
X Undesirable
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning Pipe Prep
Tubing andInstrumentation
Proposed Layout 1
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning Pipe Prep
Tubing andInstrumentation
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning Pipe Prep
Tubing andInstrumentation
Proposed Layout 2
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning
Pipe Prep
Tubing andInstrumentation
Proposed Layout 3
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning Pipe Prep
Tubing andInstrumentation
Proposed Layout 4
Proposed Layout 5
Weld Booths
Final Packaging
VMI
Consignment
Hydro & Cleaning Pipe Prep
Tubing andInstrumentation
Pugh AssessmentConcept
Criteria Weight 1 2 3 4 5
Safety 0.25 3 3 2 1 1
Cost Implementation 0.15 3 3 1 1 3
Final Packaging Floor Space 0.20 2 3 3 1 3
Material Handling Distance 0.10 2 3 4 4 4
Flow Between Cells 0.10 2 3 5 4 3
Worker Resistance to Change 0.05 4 3 4 3 3
Ease of Implementation 0.15 3 3 1 1 2
Weighted Score 2.65 3 2.5 1.7 2.45
1 – Much Worse than Datum2 – Worse than Datum3 – Same as Datum4 – Better than Datum5 – Much Better than Datum
Piping and Packaging Area
Final Packaging
ConsignmentVMI
Tubing andInstrumentation
Weld Booths
Hydro & Cleaning
Weld Booths
Final Packaging
VMI
Hydro & Cleaning
Tubing andInstrumentation
Pipe Prep Pipe Prep
Flow Between Cells
Flow1. Final Packaging2. Pipe Racks3. Consignment4. Cutting & Bending5. Final Packaging6. Welding7. Final Packaging8. VMI9. Final Packaging10. Hydro & Cleaning11. Final Packaging
Piping and Packaging Area Proposed Layout with Crane Sweeps
Current Weld Booth Location– Large safety liability with current weld booths. There are several
cranes that operate heavy equipment directly over the welders.– Moving off of Final Packaging creates an increase in floor space of
23% and an increase in capacity for products on the floor of 33%.
Proposed Weld Booth Location– A central location with small negative impact to the current process.
• Ease of implementation – available floor space– Welding supplies within the break room will be moved into the
current VMI location.
Proposed Design Changes
Facility Layout
Proposed VMI Location– The VMI parts are used only at Final Packaging making it beneficial
to have them as close as possible.• The break room provides a sufficient amount of space and is
adjacent to Final Packaging.
Break Room– In order to compensate for the break room eliminated near final
packaging, the break area was relocated closer to the weld booths.
Proposed Design Changes
Facility Layout
New Aisle– Moving the weld booths places a disconnect on the Pipe fitters and
welders, increasing travel distance. A new aisle decreases the travel distance between pipe fitter and welder.
New Space for Conduit– A larger area is needed for conduit cell.
Proposed Design Changes
Facility Layout
Additional Pipe Rack– An increase in skid capacity will result in the need for additional
parts on the floor to ensure we never run out. An additional pipe rack will help mitigate some of this risk.
New Storage for Flanges – Flanges storage was combined and condensed to create more floor
space for the new aisle.
Proposed Design Changes
Facility Layout
Facility Layout
Risks and Contingencies
Risk Item Severity Probability Owner Status and/or Contingency Plans
Worker resistance to change High High Team/ Dave
Management has expressed commitment to address risk. Team will develop ways to minimize resistance. Possible use of Performance Mgmt Techniques
Parts unavailable for Final Packaging as a result of increasing the capacity.
High High Team Additional pipe storage rack requested. Additional space in old break room can be converted to storage. Increased frequency of shipments from suppliers.
Pipefitters unaware of when they need to drop off and pick up parts from welders (due to moving weld booths)
Medium Medium Team The team is suggesting lights that signal when a welder is working, needs work, and when material needs to be picked up.
Changes in individual cells creates change in overall layout
Medium Low Team Will focus on optimizing the processes and issues within each subsystem while maintaining their effect on overall layout.
Cost of move is too great for management
Medium Low Colin Proposed solutions will need to incorporate changes with smaller financial penalties.
Timeline for implementation of move not feasible
Low Low Eric Order of precedence established for move. Durations of move need to be estimated.
Total CostBuy Items
Item Qty Price TotalWelding Curtains
Option 1 10 $1,700 $17,000Option 2 10 $365 $3,654Option 3 10 $160 $1,600
Curtains For Hydro Table Have in stock Hydro Cage $3,400 Build Hydro Controls $6,000Wood Cart 24" x 48" 1 $185 $185Wood Cart 30" x 60" 1 $210 $210Metal Cart 24" x 48" 1 $309 $309Metal Cart 30" x 60" 1 $359 $359Rollers 12 $101 $1,210New Welders 2 $6,000 $12,000
Ladders (4', 3', 2')Captured under other
safety initiative
Tungston Grinder 1 $2,500 $2,500Fan for Welder 6 $244 $1,464 Total $31,291
Additional Costs (Pending Quotes)
Item Cost
Place 2 electrical boxes for welders
Run Argon to all new weld booths
Construct Temporary Walls
Dig Trenches for welding wires
Work lights for Welders
Knockout break room door
Total $0
*Total calculated with option 2
Platform Trucks
Platform Trucks
Rollers
Total CostQuoted Price $100.85 Quantity 12Total Cost $1,210.20
Weld Booths
Not in Packet
System Needs
Primary Needs: 1.Improve Safety2.Standardize weld booth
a) Better use of space by eliminating unnecessary equipment/materialsb) Allow welders the flexibility of using any weld booth
3.Install visual controls to ensure welder is always busy4.Construct exhaust system to remove gasses generated from welding
Secondary Needs:1.Make continuous improvements as necessary2.Eliminate the need for tools to be borrowed
Weld Booths
Standard Weld Booth
Work Table
Vice Stick RodRollers
Quench Tank
Power Supply
Welder
Lockers
Oscillating Fan
Cell 1 Cell 2
Curtain Entrance
Staging Area
*Proposed Equipment (listed in red)
Argon
Staging Area
Proposed Weld Equipment
Rollers
Oscillating Fan
Argon
Rollers
Visual Control Lights
Proposed Design Change
Elimination of Argon Cylinders– Argon tanks are being removed from each individual weld booth with
the inclusion of one large argon tank located outside. Argon will be piped to each weld station.
• Eliminates the need to manually handle cylinders (150 lbs). As a result strains and sprains, number 1 injury at Olean, will be reduced.
• Prevents the possibility of a gas leak from tipping, dragging, sliding, rolling or laying of the cylinders.
• Eliminates the need to refill portable tanks (currently approximately twice a week) as well as decrease clutter in weld booths.
Dig trenches for cords– By having a standard weld booth, trenches can be dug to eliminate any
tripping hazard from electrical and argon cords
Proposed Design Changes
Install visual control system– With the addition of colored lights, pipe-fitters will be aware of
when/which welder needs work– Pipe-fitters will also be aware of when the welders have completed
work to be picked up
Simple exhaust system– By adding an oscillating fan along each column, hazardous fumes are
drawn from the welding booths allowing workers to leave curtains closed
Proposed Design Change
Rollers For Every Weld Booth– Without rollers, workers need to rig together some sort of mechanism
to hold bigger pieces of pipe. A purchased roller will be safer then something created by the welder.
– As a result of adding a roller to each weld booth, setup time and process time are both decreased.
New Weld Curtains– Argon gas is heavier then air and will therefore settle in the weld
booths. Lifting the weld curtains a foot off the ground will provide better ventilation.
Improvements
Better weld booth ventilation Decreased potential for arch flashing Elimination of tripping hazard Proper pipe rolling equipment Minimized lifting requirements Eliminate ergonomic safety concerns in transporting argon tanks Eliminate safety concern in gas leaks from argon tanks
Weld Booths
Productivity Flexibility of work environment Eliminate travel time to replace argon tanks Increased communication → decreased downtime Proper pipe rolling equipment → decreased process and setup time
Safety
Cost: Weld CurtainsOption 1
Purchase all new weld curtains along with new frames to hold together.
Quoted at $1,700 per weld booth before shipping
Weld Booths
Costs: Weld CurtainsOption 2
Purchase single panel runs
Panel Size Qty PriceTotal Cost
6' x 13' 2 $85.80 $171.60 6' x 14' 2 $92.40 $184.80
Total cost per booth $356.40
Total Cost$365.40 x 10 = $3,654
Weld Booths
Cost: Weld CurtainsOption 3
Weld Booth NeedsDimensions 12' x 13'Linear feet needed per booth 54'Total booths 10Total linear feet needed 540'
Weld Curtain RollsDimensions 5' x 75'
Price $200
Total CostNumber of Rolls Needed 8Total Cost $1,600 Cost Per Booth $160
Weld Booths
Hydro Table Not in Packet
System Needs
Primary Needs: 1.Incorporates Hydro HAZOP recommendations for production pipe2.Safety mechanism to prevent hazards of catastrophic pipe failure3.Allow worker to face direction of testing4.Improve control layout to designate high and low pressure ranges
Secondary Needs:1.Better coding of pressurized hose for improved human factors (or visual control)2.Improved storage of pipe fittings for better storage and improved human factors (or visual control)
Hydro Table
Hydro Table Design
Gauge Board Design
Hydro Table Cage Design
Hydro Table Cage•Double Hinged Doors allow for more accessibility on the getting in and out of the caged area.
• Lift out panels provide easy access for larger pipes if needed
•Sliding doors are ideal for the sides where space is limited.
Design Improvements
Safety Cage– 360 degree safety cage minimizes injuries due to pressurized pipe
failures.– Cage prevents workers from straying into hazard area.
Worker Facing Operation Direction– With the new design the operator faces the direction of test allowing
him to always see the table and parts he is working on.– Eliminates necessity for second worker
Design Improvements
Better Coding– The new design of the gauge board separates high pressure gauges
from low pressure gauges to eliminate any confusion.– The introduction of a new coding system on the hydro table will
reduce human factor errors.
New Flange Storage– By eliminating old flanges, organizing them properly and locating
them in one location, cycle time decreases in the hydro table cell.
Sequence of Moves
Questions ?