Project Status UpdateP09457 – Process Improvement

Project

Eric MacCormack (IE)Colin Roy (IE)

Project Status Update• Project Name

– Process Improvement Project• Project Number

– P09457 • Project Family

– Sustainable Technology for the Global Market• Track

– Process Improvement Innovations• Start Term

– 2008-2 planned academic quarter for MSD1• End Term

– 2008-3 planned academic quarter for MSD2• Faculty Guide

– Professor John Kaemmerlen• Faculty Consultant

– Dr. Kuhl, choice for simulation• Faculty Consultant

– Dr. Carrano, choice for manufacturing processes• Primary Customer

– Dresser-Rand with the point of contact being Dennis Rice at the Olean facility

Mission Statement• The mission of the Process Improvement Project is to implement lean

principles into the piping and packaging line at Dresser-Rand Corporation’s Olean facility.

• Goal: reduce cycle time by 30%.• Approach: improve the flow of products, warehousing of parts, visual

controls, and reduce the waste within the line.

Current Layout

Piping Assembly & Packaging

Assembly

Test

Parts

Customer Needs• Reduce Cycle Time

– Improve Flow of Product• Visual Controls System• Standardize Work Processes• Accurate Drawings

• Free Up Floor Space• Maintain High Level of Safety

Staffing RequirementsName Discipline Roles/Skills

Professor John Kaemmerlen Faculty Guide

Will work closely with the team on an on-going basis to facilitate success.

Colin Roy I.E. Project Manager, Point of contact for Dresser-Rand. Construct and submit deliverables. Lead in Simulation and Factory CAD software.

Eric MacCormack I.E. Chief Engineer, Focus direction of work. Assist in any necessary tasks. Lead in lean.

I.E. Student (TBD) I.E. Engineer, Strong background in the fields simulation, lean and ergonomics.

I.E. Student (TBD) I.E. Engineer, Strong background in the fields simulation, lean and ergonomics.

M.E. Student (TBD) M.E. Engineer, Skills for work with parts family assessment and part number consolidation. Custom tooling. Set-up reduction opportunities.

Work Breakdown Structure

P – D – C – A

Work Breakdown StructureMember Week 1 Week 2 Week 3

ColinTour the Facility. Bring all group members up to speed with Customer Needs

Direct each team member/obtain data on current state

Monitor and facilitate each team member in their active roles

EricTour the Facility. Bring all group members up to speed with Customer Needs

Acquire all current data D-R has on the current process.

Reiterate current state value stream map

IETour the Facility. Bring all group members up to speed with Customer Needs

Begin Factory CAD analysis on current D-R CAD layout.

Continue on Factory CAD analysis on current D-R CAD layout

IETour the Facility. Bring all group members up to speed with Customer Needs

Begin preliminary current state simulation model.

Continue on current state simulation model.

METour the Facility. Bring all group members up to speed with Customer Needs

Become familiar with the various parts that are used in the assembly process

Evaluate ways part drawings can become more accurate to the products

Risks and Constraints• Risks

– Quality – Tradeoff of quality vs. speed– Worker resistance to change– Disruption to other processes– Increased cost to production

• Constraints– Factory distance (Olean plant 2 hour drive)– 22 week improvement period– Cameras not allowed in facility– D-R staff availability

Resources Required

PersonnelProfessor KaemmerlenDr KuhlDennis RiceDan Krenn

EnvironmentSenior Design LabISE/ME Computer LabsOlean Facility

EquipmentArena SoftwareFactory CAD Software

Deliverables• Current State Value Stream Map• Future State Value Stream Map• Detailed Current State Layout• Future State Layout• Factory CAD Drawings and Analysis• Simulation Models and Analysis• Cost-Benefit Analysis• Visual Control System

Team Values

Punctual

Each team member will be prompt and arrive at the team meetings on time. If an unexpected conflict comes up, the absent team member will notify at least one teammate prior to the expected absence. An absent team-member should confirm that a teammate has received their message.

Thorough

Each team member will complete their tasks thoroughly and completely, so that the work does not have to be re-done by a peer on the team. If a member does not know how to complete a task, feels overwhelmed, or needs assistance then the member notifies peers, and seeks assistance either from a peer, the faculty guide, a faculty consultant, or another person

Accurate Each team member completes their work accurately and in a way that can be easily checked for accuracy by peers and the faculty guide. All work is fully documented and easy to follow.

Timely Each team member will fully complete their tasks at or before the due date for the deliverable.

Professional and Ethical

Each team member gives credit where credit is due. All work completed includes citations to appropriate literature, or sources of assistance. If a team member has gotten assistance from a publication or individual, then that assistance or guidance is fully documented in the reports prepared. Each team member is honest and trustworthy in their dealings with their peers.

Committed Each team member will contribute an equal share to the success of the project

Teamwork

Each team member will be supportive of one another. All must realize we are working to achieve a common goal. If any conflicts are to arise during problem solving or execution they shall be resolved professionally and timely. If necessary, mediation will be provided by group leads.