P13458: Dresser-Rand Compressor Cell Assembly Line
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Project Summary Project Information

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For an updated project description, click on the following link for the Project Readiness Package.

Current Process

Dresser-Rand, a manufacturer of heavy duty 5 to 30 ton air compressors, currently builds each compressor at a stationary workstation. Large overhead cranes move completed assemblies and sub-assemblies. Each compressor starts with a multi-ton iron frame casting and many sub-assemblies, such as compressor cylinders, are built off line and then installed onto the frame. Once compressors are built, they are cleaned and primed. Finished compressors are sent to a testing cell and reworked in-place, if necessary. After test, the compressors are prepped for shipping.

Currently, the assembly line is non-linear and scattered. All parts are moved by 35 ton overhead hoists, which require all workers to stop work and move out of the way when compressors are moved. Parts are shuffled between lines using a large wheeled cart, which can be towed by a forklift. Painting and testing are in a separate bay than assembly.

Our Project Goals

The overall goal of the project is to facilitate the implementation of a linear assembly line in a different shop, where the compressor can be loaded onto a cart or other means of ground transportation (avoiding the use of overhead hoists/cranes), which can move between assembly stations while the workers remain stationary.

Our projects are split into 2 main areas based on the new assembly process flow and the requirements of Dresser-Rand. These 2 areas are:

1. Transportation of Compressor: Design a material handling system to carry the compressor through the final assembly line, to test, to paint, then staging for shipping.

2. Process Layout: A layout of the new assembly line will incorporate different levels of design within CAD to ensure all requirements have a space within the new shop and ensure our material handling systems work within the process flow of materials, people, and information.

See the bottom of this page for a table of contents with detailed content.

New Shop Floor

New Shop Floor

Model Prototype Caster System

Model Prototype Caster System

Completed Compressor

Completed Compressor

Conceptual Process Layout from Dresser-Rand

Conceptual Process Layout from Dresser-Rand

Project Name
Compressor Cell Material Handling System
Project Number
P13458
Project Family
Separable/Gas Field Application
Start Term
2012-2
End Term
2012-3
Faculty Guide
John Kaemmerlen
Primary Customer
Henry Bastian, Quality Manager
Sponsor (financial support)
Dresser-Rand

Team Members

Team Photo (HOS Compressor Frame)

Team Photo (HOS Compressor Frame)

Member Role Contact
Alex Peterson Mechanical Engineer & Photography aip3745@rit.edu
Shawn Moseley Mechanical Engineer spm8299@rit.edu
Cole Bowden Mechanical Engineer cjb4166@rit.edu
Lauren Kraft Project Manager & Industrial Engineer lek7929@rit.edu
Jordon Boggs Mechanical Engineer jtb6066@rit.edu
Nick Feng Industrial Engineer ynf8536@rit.edu

Table of Contents

Planning & Data Transport System Process Layout Final Deliverables

Planning & Execution

Photo Gallery

Data from Dresser-Rand

Project Review

Systems Design

Detailed Design

Layout Design

Final Design & Recommendations

Final Presentation

Technical Paper

Poster

Acknowledgements

The team would like to express gratitude to all those who have invested their time and effort in this project. Sharing experiences and working through the problem has helped the team grow professionally and helped Dresser-Rand expand their business.

A special thank you goes to John Kaemmerlen for providing excellent guidance through the design process.

Also, the team would like to thank the Dresser-Rand team for sharing this opportunity with RIT Senior Design, including Henry Bastian, Brent Hoban, Joe Willig, Brian Spencer, John Woedy, Justin Anderson, and MacArthur Walton.