R-I-T Project Improvement Project

Matthew BonaventuraJimmy Ichihana

Eric MacCormackCody RathColin Roy

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

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

Facility Layout

Final Assembly

ConsignmentVMITubing and

Instrumentation

Weld Booths

Cutting, Bending, Cleaning

*Current State

System Needs and Proposed SolutionCurrent State Issues:

• Weld booths in Final Packaging presents large safety issue with overhead cranes• Final Packaging needs increased capacity to catch up on 2 year backlog• Worker break room is an inefficient use of space and provides a ‘hide-out’ for workers

where management cannot see what they are doing• Flow of material is inefficient

Analysis:• Consulted with workers and management to determine system needs• Developed 5 possible layout options• Assessed each layout based on final packaging floor space, material handling distance,

flow between cells and ease of implementation• Chose the best layout based on these assessments

Solution:• The weld booths are moved out of Final Packaging and into a central location• An increase in floor space of 23% and an increase in capacity for products on the floor of

33%.• VMI is moved into the break room in order to more efficiently utilize the space• Travel distances and the overall flow of material are improved

Facility Layout

Facility Layout

Selected Concept

Weld Booths

System Needs and Proposed SolutionWeld Booths

Current State Issues: • Construct exhaust system to remove gasses generated from welding• Provide welders with proper equipment• Standardize weld booth to better use space by eliminating unnecessary

equipment/materials and allow welders the flexibility of using any weld booth• Install visual controls to ensure welder is always busy

Analysis:• Consulted with workers and management to determine system needs• Used continuous feedback to tweak original design to generate optimal layout

Solution:• Add pipe rollers to weld booths to increase productivity• Eliminate the need for welders to go outside and fill up argon tanks (currently 2x per

week), alleviating unnecessary lifting and walking• Dig trenches to remove tripping hazard from cords lying along the floor • Install visual control system to allow pipe-fitters to be aware of when/which welder

needs work and make pipe-fitters aware of when welder has completed work• Simple exhaust system to keep weld curtains closed at all times and decrease potential

for weld flashing

Proposed DesignWeld Booths

Lockers

Work Table

Vice Stick RodRollers

Quench Tank

Power Supply

Welder

Rod Oven

Oscillating Fan

Cell 1 Cell 2

Curtain Entrance

Staging Area

*Proposed Equipment (listed in red)

Argon

Hydro Table

System Needs and Proposed SolutionPrimary Needs:

• Incorporates Hydro HAZOP recommendations for production pipe• Safety mechanism to prevent hazards of catastrophic pipe failure• Allow worker to face direction of testing• Improve control layout to designate high and low pressure ranges

Analysis:• Reviewed needs and developed an initial layout for a new gauge board design• Developed three concepts that satisfy the safety concerns of the current state• Selected an appropriate design based on customer feedback and preference

Solution:• Implement a 360° safety cage to minimize injuries due to pressurized pipe failures

and prevents workers from straying into hazard area.• Relocate the controls so that the part being tested is in the line of site with the

gauges allowing the operator to observe both during testing• Eliminate the necessity for second worker by relocating control board

Hydro Table

Selected ConceptHydro Table

Moving Forward

Above is a sequence of moves that will be followed in order to assure a safe and efficient move

Questions ?