Dresser-Rand Gasket Cell Relocation

1. Dresser-Rand Gasket Cell Relocation Team Members: Cody Willmart, Aaron Marcotte, Jacky Li, Daniel Swol, Tyler Borden Mentor: John Kaemmerlen [Revision: Feb 2011]

2. Meeting Purpose Purpose– Interactive discussion of the project with stakeholders. Provide recommendation for the future state of the Gasket Cell. Goal– Gain feedback to determine the direction for the rest of the project. PLEASE – Comment or ask questions at any time

3. Agenda • Introductions • Project Summary • Customer Needs and Engineering Specs • Review Current System • Concept Feasibility • Upgraded Technology Options • Layout Options • Visual Management • Cost Analysis • Project Schedule and Next Steps

4. Project 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

5. Expected 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

6. Work Breakdown Structure

7. Customer Needs

8. Engineering Specifications

9. Current Layout Red = Machine Yellow = Table Blue = Storage Total Footprint: 6000 sq. ft.

10. Current State Value Stream Map • Please see attached 11x17 document in review packet

11. Three Main Options • Relocate current process into new area of the plant • Update die cutting equipment with a single press and move process into new area • Invest in completely new technology, eliminate the need for dies, patterns, and the hand cut area. Significant footprint reduction

12. Options 1 & 2 - Concept Feasibility? Current Area = 6,000 sq.ft. Improved Area = 5260 sq.ft. Footprint Reduction of 710 sq.ft. (12%)

13. 3) Higher Cost, Highest Risk, Maximum Benefit • 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.)

14. Waterjet 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. Safety: 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.

15. Laser 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 Safety: 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.

16. CNC Blade Cutting 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 Safety: 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.

17. Pugh Chart – Revised after further research

18. Machine Specs

19. Current Recommendation • Eastman CNC Blade Cutting Table

20. 5M’s

21. Future State VSM • Please see 11x17 handout

22. Layout Options Possible Relocation Area

23. Layout Options

24. Layout Options

25. Layout Options

26. Visual Management Ideas

27. Heijunka Box • Eliminates the need to search through a pile of orders to see what gaskets need to be produced for the day

28. Risk Assessment

29. Project Schedule

30. Next Steps – Machine Testing • Test Heavy Duty Head • ¼ inch holes, blade or punch? • Test pen on different materials • Waiting on final quote

31. Next Steps and Action Items • Capital Acquisition Requirements • Kaizen opportunity? • Analyze feasibility of new process • Implementation plan • Test waterjet?

32. Questions

33. www.dresser-rand.com info@dresser-rand.com