Project Information Project Name Process Improvement Project Project Number P09457 Project Family...

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



Proposed Layout 1

Weld Booths

Final Packaging

VMI

Consignment



Weld Booths

Final Packaging

VMI

Consignment



Proposed Layout 2

Weld Booths

Final Packaging

VMI

Consignment

Hydro & Cleaning

Pipe Prep


Proposed Layout 3

Weld Booths

Final Packaging

VMI

Consignment



Proposed Layout 4

Proposed Layout 5

Weld Booths

Final Packaging

VMI

Consignment



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


Weld Booths

Hydro & Cleaning

Weld Booths

Final Packaging

VMI

Hydro & Cleaning


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.


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.


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.


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

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


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 ?

Project Information Project Name Process Improvement Project Project Number P09457 Project Family...

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