© Copyright 2010 Dresser-Rand Gasket Cell Relocation [Revision: Feb 2011] Team Members: Cody...
-
Upload
chad-roberts -
Category
Documents
-
view
218 -
download
2
Transcript of © Copyright 2010 Dresser-Rand Gasket Cell Relocation [Revision: Feb 2011] Team Members: Cody...
© C
opyr
ight
201
0
Dresser-Rand Gasket Cell RelocationDresser-Rand Gasket Cell Relocation
[Revision: Feb 2011]
Team Members: Cody Willmart, Aaron Marcotte, Jacky Li, Daniel Swol, Tyler Borden
Mentor: John Kaemmerlen
© C
opyr
ight
201
0
2
Meeting PurposeMeeting Purpose
PurposePurpose – Interactive discussion of the project
with stakeholders. Provide recommendation for the
future state of the Gasket Cell.
GoalGoal – Gain feedback to determine the direction
for the rest of the project.
PLEASE PLEASE – Comment or ask questions at any time– Comment or ask questions at any time
© C
opyr
ight
201
0
AgendaAgenda
1. Introductions
2. Project Summary
3. Customer Needs and Engineering Specs
4. Review Current System
5. Concept Feasibility
6. Upgraded Technology Options
7. Layout Options
8. Visual Management
9. Cost Analysis
10. Project Schedule and Next Steps
3
© C
opyr
ight
201
0
4
Project BackgroundProject Background
DR Painted Post relocating and consolidating
processes to reduce plant footprint
Gasket and Sheet Metal Cells are on the “Wrong side
of the wall”
Primary focus is the Gasket Cell Relocation and
Improvement
Timeline: 22 week project
Started: 12/3/2010 End: 5/13/2011
© C
opyr
ight
201
0
Expected Project BenefitsExpected Project Benefits
An updated, efficient, and safe gasket cell in an
operating area of Dresser-Rand’s Painted Post
facility
A model project for process innovation and the
implementation of lean principles for both
Dresser-Rand and RIT
5
© C
opyr
ight
201
0
6
Work Work Breakdown Breakdown StructureStructure
© C
opyr
ight
201
0
7
Customer NeedsCustomer Needs
Summary CN#Operational Excellence Customer Need Importance
1 Cost Footprint Reduction (Improved Layout) 92 Delivery Relocation to Point of Use 33 Cost Make Cell Adaptable to many locations in plant 14 Delivery Die & Pattern Organization and Standardization 95 Delivery Match Inventory of dies/patterns with their current use 36 Cost Inventory Management (Raw & Finished Goods) 37 Delivery Tool Storage & Organization 38 Whole Star Upgrade Technology 39 Whole Star Digital Technology Option 310 Delivery Movement toward lean - one piece flow 911 Quality Process Standardization 312 Delivery More Effi cient Cell 913 Delivery Fast Response Time 914 Safety Safety is the highest priority 9
Reduce the space required for the cell and determine a feasible location for the
cell in a new area of the plant
Develop a new inventory management system for raw materials, finished goods,
dies and patterns, and tools
Develop an effi cient process for producing gaskets with the new
equipment
Research and recommend modern technology options
© C
opyr
ight
201
0
8
Engineering SpecificationsEngineering SpecificationsES# Importance
Operational Excellence Specification (description)
Unit of Measure
Current Value Marginal Value
1 9 Cost Square footage of gasket cell sq. ft. 5900 > 50% Reduction2 3 Delivery Travel time to direct customers min. 10 > 50% Reduction3 3 Cost Cost to move equipment $4 1 Cost Requirement for OE manufacture to move equipment Binary5 3 Delivery Search time for dies and patterns min. <5 2 min6 3 Delivery Store only actively used dies and patterns Binary No Yes7 3 Delivery Search time for raw material min. 5-10 2 min8 9 Delivery Search time for finished goods/kitting min. 209 3 Delivery Search time for tools min. <5 2 min
10 3 Delivery Average batch size # 20% Increase11 9 Delivery Process cycle time min. 35-40 20% Decrease12 3 Cost Scrap sq. ft. 20% Decrease13 9 Delivery Setup time min. <5 20% Decrease14 1 Quality Standard Work Available Binary No Creation15 3 Delivery Work in Process (WIP) # orders 2 As Needed16 9 Cost Return on Investment (ROI) rate 11% Hurdle17 9 Cost Payback period years 1 Year18 9 Cost Operation and maintenance costs $ Minimized19 9 Delivery Throughput #20 3 Delivery Machine Time sec 20% Reduction21 9 Cost Cost of Labor $ 35/hr/person22 3 Cost Tool life days Maximized
© C
opyr
ight
201
0
9
Current LayoutCurrent Layout
Red = Machine Yellow = Table Blue = Storage
Total Footprint: 6000 sq. ft.Total Footprint: 6000 sq. ft.
© C
opyr
ight
201
0
Current State Value Stream MapCurrent State Value Stream Map
Please see attached 11x17 document in review packet
10
© C
opyr
ight
201
0
Three Main OptionsThree Main Options
1. Relocate current process into new area of the plant
2. Update die cutting equipment with a single press
and move process into new area
3. Invest in completely new technology, eliminate the
need for dies, patterns, and the hand cut area.
Significant footprint reduction
11
© C
opyr
ight
201
0
Options 1 & 2 - Concept Feasibility?Options 1 & 2 - Concept Feasibility?
12
Current Area = 6,000 sq.ft.Improved Area = 5260 sq.ft.
Footprint Reduction of 710 sq.ft. (12%)
© C
opyr
ight
201
0
Purchase a laser, blade, or waterjet cutting machine
Dies and patterns are no longer required with a digital
interface
Goal is to replace all die cutting and hand cutting with a
single machine
A significant footprint reduction can be achieved
Develop an entirely new process around the new
equipment
Incorporate lean principles into design (visual
management, 5S, standard work, flow, etc.)
13
3) Higher Cost, Highest Risk, Maximum Benefit3) Higher Cost, Highest Risk, Maximum Benefit
© C
opyr
ight
201
0
WaterjetWaterjetSafety:Spray shields and cutting head guards.
Emergency shut off valves.
Electronic perimeter shut off system.
Quality: Meets tolerance requirements.
Gasket materials can soak up moisture from
waterjet, which may cause slight
discoloration.
Delivery:Can complete jobs fast and efficient and
should be able to meet any delivery
deadline.
Cost:Most expensive machine at $165,000.
Most expensive annual operating cost.
Consumables: $2/machine hour
Utilities: $6/machine hour
Abrasives: $20/machine hour (operation can be run without abrasives)
People:Operation can be run with 2-3 people instead of 7.
Limitations:Excess water spray
Might be too powerful for gasket application.
© C
opyr
ight
201
0
LaserLaserSafety:Fully enclosed cutting area.
All doors and covers have redundant safety
interlocks that, when doors are opened, turn
off power to the laser and place a shutter over
the laser beam path.
Crash sensor and break away nozzle to
reduce the risk of damage due to set up
errors.
Quality: Meets tolerance requirements.
Gasket materials can get scorched by the
laser.
Delivery:Can complete jobs fast and efficient and
should be able to meet any delivery deadline.
Cost:Machine costs $100,000.
Operating costs $1/machine hour.
The cost of running a compressor (air assist)
Consumables $500 per year (mainly replacing
table every 6 months)
Installation of fume hood and stack
People:Operation can be run with 2-3 people instead of 7
Limitations:Needs fume extraction.
Government approval for fume stack required
© C
opyr
ight
201
0
CNC Blade CuttingCNC Blade CuttingSafety:Fully enclosed cutting head
Only exposed to blade tools when changing head for depth or tool type
Emergency stops on each end of table and gantry
Stop machine if runs into obstacle by yellow disks, can resume cutting from stop
Quality: Meets tolerance requirements.
Pen tool can mark parts
Delivery:Can complete jobs fast and efficient and should be able to meet any delivery deadline.
Cost:Machine costs $86,000.
Annual operating cost: $3,000-$4,000.
People:Operation can be run with 2-3 people instead of 7.
Limitations:Tools required for different depths with depth limiters to extend table life
Replace table recommended each year and blades as they wear
© C
opyr
ight
201
0
17
Pugh Chart – Revised after further Pugh Chart – Revised after further researchresearch
Concepts A B C D E Current Hydraulic Press Blade Laser WaterjetSelection Criteria Footprint Reduction
Datum (Mix of Hand Cut and Die Cut)
0 + + +Efficient Cell 0 + + +Fast Response Time 0 + + +Movement toward lean principles + + + +Safety + + + +Maintenance and Operation Cost + + + -Labor 0 + + +Capital Investment - - - --Acceptable material size 0 + + +Quality of Product 0 + - -
Range of material type 0 + - -Sum + 's 3 10 8 7Sum 0's 7 0 0 0
Sum -'s 1 1 3 4
Net Score 2 9 5 3Rank 4 1 2 3
© C
opyr
ight
201
0
18
Machine SpecsMachine SpecsCut speed Head Speed Tolerance Cutting size
in/min in/sec
Blade Cutting 2000 60 0.015" 6’ x 12’
Laser Cutting 1000 16 0.002" 6'x6'
Water Jet Cutting (1) 400 8 0.003" 5.5x6.5
Water Jet Cutting (2) 1500 25 0.004" 6.5'x13'
Setup Time Machine Time Tolerance Cutting size
Required 1min 1min 0.015" 5'x5'
Blade Cutting 1min 1min 0.015" 6’ x 12'
Laser Cutting 1min 2min 0.002" 6'x6'
Water Jet Cutting 3min 2min 0.003" 5.5x6.5
© C
opyr
ight
201
0
Current RecommendationCurrent Recommendation
Eastman CNC Blade Cutting Table
19
© C
opyr
ight
201
0
20
5M’s5M’s
© C
opyr
ight
201
0
Future State VSMFuture State VSM
Please see 11x17 handout
21
© C
opyr
ight
201
0
Layout OptionsLayout Options
22
Possible Relocation Area
© C
opyr
ight
201
0
Layout OptionsLayout Options
23
© C
opyr
ight
201
0
Layout OptionsLayout Options
24
© C
opyr
ight
201
0
Layout OptionsLayout Options
25
© C
opyr
ight
201
0
Visual Management IdeasVisual Management Ideas
26
252321191715131197531
0.0640
0.0635
0.0630
0.0625
0.0620
Sample
Sam
ple
Mean
__X=0.062952
UCL=0.063893
LCL=0.062011
252321191715131197531
0.0024
0.0018
0.0012
0.0006
0.0000
Sample
Sam
ple
Range
_R=0.00092
UCL=0.002368
LCL=0
1
1
Xbar-R Chart of Thickness 5-4
© C
opyr
ight
201
0
Heijunka BoxHeijunka Box
Eliminates the need
to search through a
pile of orders to see
what gaskets need
to be produced for
the day
27
© C
opyr
ight
201
0
Risk AssessmentRisk Assessment
28
© C
opyr
ight
201
0
Project ScheduleProject Schedule
29
© C
opyr
ight
201
0
Next Steps – Machine TestingNext Steps – Machine Testing
Test Heavy Duty Head
¼ inch holes, blade or punch?
Test pen on different materials
Waiting on final quote
30
© C
opyr
ight
201
0
Next Steps and Action ItemsNext Steps and Action Items
31
Capital Acquisition Requirements
Kaizen opportunity?
Analyze feasibility of new process
Implementation plan
Test waterjet?
© C
opyr
ight
201
0
32
QuestionsQuestions