Final Project Review
Dresser- Rand : Rotor Cell Improvement Project
Multi-Disciplinary Senior Design
Project: P13457
Topics:
• Last Quarter Review:
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Heat treat
B & OS
This Quarter:
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Arena Model Status
Scheduling System
Vectra Table Concept
Potential Project Concepts
The goal of this project was to help the Dresser-Rand Rotor Cell
increase productivity. Multiple improvement project were suggested to the
RIT team, including:
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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 Treat
Layout Option: 3 Large Racks- Straight Line
 Most viable given constraints
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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 Plant
How: Complex routings require use of Arena Simulation
Plan:
 Use historical process times for parts that vary in:
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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
Task
 Design 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 Mounts
Mounted under the table
 One fixed
 One linear motion
 Four 5 inch diameter feed blocks
V-Block Mounts: Rail System
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Similar to current system on the
table for the vertical rods
Still need a rail system for the vblocks to move
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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 Vblocks 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 Vblocks 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
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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