Systems Design Review

Rotor 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 Analysis

Weight (1-5) Roll Out-Racks

Pull Out Bleacher Style Fixed Steps

Flow Through Pallet Racks

Access-ability from Crane 5 10 8 8 7Footprint Reduction 4 8 8 5 2

In-Use Foot Print 4 7 3 5 2Move-ability 3 7 4 4 2

Safety 4 7 5 5 10Ease of Use 3 8 5 5 7

Ability to Organize 3 10 5 5 4Risk 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