Final Presentation: Compressor Transport System & Layout P13458 RIT Senior Design Team May 10, 2013 10-10:30AM 09-2030 Dresser- Rand, Painted Post http://edge.rit.edu/edge/P13458/public/Home
Agenda Problem Statement Accomplishments For The Transport System Design History Final Design Summary Of Test Results Recommendations Accomplishments For The Layout Design History Final Design & Test Results Recommendations Reflection On The D-R/RIT Partnership Reflection On Our Code Of Ethics
Problem Statement Design a flexible material handling system that is easy to use and incorporates the safest design elements within cost and functionality constraints. This design 6-throw MOS Compressor fully supports the new process layout in Dresser- Rand’s strategic project to increase capacity for the MOS compressor projected sales. New Shop Floor
Transport System Design History Design Considerations Long Beam Caster System Short Frame Caster System (Yellow Frame) Air Bearing Technology Free Support System Fixed Support System Modified Support System
Design Considerations Movement nt Propul pulsi sion
Long Beam Caster System Assumed entire compressor assembly would be loaded, including cylinders Assumed massive CG changes while loaded Large structural members necessary
Short Frame Caster System Yellow Frame Design Versatile – to account for multiple product families Modular – to account for multiple product sizes Could not be used at test station Was prototyped Many design flaws surrounding caster system
Air Bearing Technology Unidirectional Nearly frictionless Reduces horizontal force required to 1lb per 1000lbs Air supply is common in industrial setting Requires flat, smooth floor surfaces
Free Support System Based on the short frame system Adapted for air pallet use Legs fixed to support beam Concerns regarding clearance between floor and legs during movement
Fixed Support System Vertical “legs” of the Free system are now fixtures placed at each station Eliminates floor clearance concerns while moving from station to station Simplifies manufacturing Easily integrated into testing and shipping
Removable Support System Conceptual design Method of manufacture and dimensions undetermined Removable fixture attaches to beam and acts like a jack stand Overcomes flaws that were revealed during the 3P event Stress analysis not completed results should be comparable to the free system results
Removable Support Qualities Pros No more fixtures Resolves ergonomic issues discovered during the 3P event Lowers move prep time – no longer need to configure fixtures from station to station Bolt on legs removable for test and shipping Cons Requires the floor to be leveled
Test Results P13458:� House� of� Quality� &� Test� Plan 3/15/13 5/7/13 Metric� Value Current� Status� � for� Caster� Number� of� Results� After� Target� � � Value Marginal� Value Dir System� Prelim� Design Tests� Required Testing Additional� Comments Eng� Metrics Summary� for� Phase� I� Prelim� Design Test� Plan Measure� time� for� prototype� Did� not� measure� time� movement� between� station� to� because� full� scale� station� using� a� stopwatch,� use� 5� per� station prototype� and� Air� Tugger� should� be� able� to� move� in� under� 20� minutes,� however� heaviest� compressor� model� as� it� will� pallets� were� not� Time� to� move 5min 20min - there� are� no� actual� speed� specifications� on� the� device have� the� lowest� acceleration ordered� yet 5� per� Full� scale� prototype� Won't� know� until� final� design,� will� depend� on� type� of� casters� used� Measure� time� for� setup� using� a� stop� compressor� never� built Time� to� setup� move 0min 10min - and� leveling� system� implemented watch model Measure� the� time� to� return� Full� scale� prototype� prototype� from� the� end� of� the� line� to� 5 never� built Time� to� return 10min 30min - Need� to� finalize� return� process the� cart� storage� location Weights� were� estimated� Current� Estimate:� (air� caster� version� was� estimated� at� 1,160� lbs,� 1 based� on� cadd� data� and� airfloats� catalog� is� down� so� I� can't� find� the� weights … � to� subtract� Weigh� protoype� using� a� hanging� material� weights Cart� Weight 1500lb 2500lb - out) scale Current� Status� � for� Caster� Number� of� Results� After� Target� � � Value Marginal� Value Dir System� Prelim� Design Tests� Required Testing Additional� Comments Eng� Metrics Summary� for� Phase� I� Prelim� Design Test� Plan Measure� the� strain� in� the� tugger� connection� interface� during� Actual� tugger� system� 5 300lb� force� necessary.� � Benchmark� research:� tuggers� can� handle� movement� of� the� heaviest� was� not� ordered� yet Force� to� move 100lb 500lb + over� 500lbs compressor� using� strain� gauges Mark� the� ideal� path� on� the� floor,� Covered� through� the� 3P� 5� cycles� after� moving� the� prototype� to� the� event.� � Moved� stations� through� next� station� measure� the� difference� farther� apart� for� more� stations� 1-5 clearance Stays� in� Line 3ft 5ft + Need� to� finalize� caster� layout with� a� tape� measure Not� tested� although� 1� per� Dresser� Rand� is� working� compressor� with� Airfloat� to� make� Test� capability� of� a� single� tugger� model sure� they� have� proper� system� to� move� each� compressor� air� capabilities Power� Sources� Required 1 2 - 1� Battery� operated� Tugger model Measure� the� distance� it� takes� for� 5� per� Air� bearings� stop� each� compressor� model� to� coast� to� a� compressor� immediately� when� air� stop� from� maximum� velocity� using� a� model supply� is� cut Stopping� distance 5ft 10ft - Unsure� of� safe� deceleration� value� and� therefore� stopping� distance tape� measure Data� can� be� derived� Combine� measured� cart� weight� with� 1 from� cadd� models� and� Dresser� Rand's� data� on� compressor� known� material� weights Weight� per� cart 15T 10T + HOSS� Will� be� included� in� cart� design.� � 15T� capabilities� are� met. weight
Recommendations Modify testing station to incorporate free-system design Possible lifting/attachment to test bed Determine lifting/loading method Need 3-axis positioning without a crane Modified Grey Portable Lifting system for vertical lifting Back truck under lifted compressor Air bearings under truck bed Driver positioning
Layout Design History 3P Event Result Factors Affected Status Took dimensions of required Returnability equipment and space for each Flexibility station in the assembly, test, and Tested U-shape design paint process in the current state Pass-by/Pass-through Space Utilization Added new cylinder assembly flow line Inventory Access Created factors of varying Inventory Access importance Operators and managers evaluated the layout and gave feedback on Ease of Movement by Operator parts and people flow and equipment requirements Movement Time Designed 4 different layouts – 2 straight-line, 2 U-shaped – in the Found hidden problems and Space Utilization new shop floor constraints i.e. spacing between stations, jib crane requires oil pump station next to column Maintenance Access Conducted a 3P event on a U- shaped layout using cardboard to Tested – good outlook check theoretical values against Needs further testing, but predict a good outlook actual feedback from operators Needs attention, was not addressed and line side managers
Final design Top Level Assembly Level Flow
Recommendations Re-evaluate test bay requirements for sizing and safety – retractable blast walls Add in and test inventory flow and information flow Understand exact requirements and locations for energy/power/air sources Full dimensioning of layout Computer simulation of process flow Continuous evaluation and improvement 5S taping and marking to indicate specific areas, i.e. operator walking zone inside cell, in-process kanban, visitor aisle way Identify and allocate future expansion area
Recommend
More recommend
