Innovative Production Strategies for Turbo compressors Enhancement
Explore how Danfoss Turbocor is revolutionizing commercial compressors production through advanced assembly lines, operational efficiency improvements, and addressing challenges and opportunities in the industry. Presented by Andrea Isaza and Andrew Hartsfield.
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Presentation Transcript
Production Alvaro Silva Andrea Isaza Andrew Hartsfield
Introduction Danfoss Turbocor creates commercial compressors Challenge from sales team 6,200-6,500 to 10,000 $57 million Presented by: Andrew Hartsfield 3
Scope Pre-Mechanical and Mechanical Assembly Lines Assumptions: Warehouse Delivery Time Rework Budget Presented by: Andrew Hartsfield 4
Threats Opportunities Decrease in operator and machine costs to manufacture item Increase in operator satisfaction Lower compressor price/ more profit per unit Production costs will remain the same and could go up Loss of profit Loss of revenue due to downtime without the potential profit Short Term Entrance of another competitor Loss of opportunity profit Losing customers because of inability to produce Increase in profit Increase in demand from lower prices Increase in sales and brand recognition Long Term Presented by: Andrew Hartsfield 5
SIPOC Diagram Supplier Input Process Output Customer College of Engineering Knowledge, training DMAIC Process to improve assembly line, measure tahkt times to reveal bottlenecks, improve bottleneck station product cycle time Assembly line that will produce 10,000 units per year and that will operate 20% more efficiently FAMU-FSU College of COE and IME Department Danfoss Turbocor, operators in line after mechanical line. Danfoss Turbocor Assembly Line, Resources, Knowledge, Personnel Presented by: Andrew Hartsfield 6
Pre-mechanical Assembly Housing Prep Warehouse Oven Insertion Stator Housing Measurements Common Components Assembly Stator Connecting and Testing Housing Cooling Presented by: Andrea Isaza 7
Mechanical Assembly Impeller and Diffuser Insertion and Securing Housing Measurements Radial Bearing Insertion Mechanical Hardware Levitation and Calibration Feed-Though Installation Shaft Insertion Presented by: Andrea Isaza 8
House Of Quality Presented by: Andrea Isaza 10
Business Analysis Budget is not explicit Cost of stopping production given by the following expression: Presented by: Alvaro Silva 15
Environmental Impact Current manufacturing impact on environment What is the impact on nearby communities? Are there any toxic by-products? Compressor s impact on the environment Magnetic bearing benefits Management of power draw Presented by: Alvaro Silva 16
Ethical Considerations Again, environmental considerations How are communities affected? How large is the compressors footprint? Are there any toxic by-products generated by manufacturing the compressor? Safety considerations Is the company putting the well-being of its workers as its top priority? Equality Does the company ensures equal opportunity when hiring new employees? Presented by: Alvaro Silva 17
Social and Political Consideration Resistance to change Irrelevant to new interactions made Considerations for ease transitioning to new procedures Presented by: Alvaro Silva 18
Sustainability Efficient operations Costs kept low Maximized profit per product Healthy workspace Employee satisfaction Employee well-being Environmental awareness Reassess periodically Company s needs change Presented by: Alvaro Silva 19
SWOT Analysis Strengths Small manufacturing plant changes. Easy to implement Team's motivation Weaknesses Resistance to change Team's lack of experience Internal Factors SWOT Matrix Danfoss Production Opportunities Access to COE faculty members COE technological resources (Software) Threats External Factors Budget cuts by external factors Negative Positive Presented by: Alvaro Silva 20
Risk Matrix Risk Severity Risk Catastrophic (A) Negligible (E) Probability Critical (B) Moderate (C) Minor (D) 5- 5A 5B 5C 5D 5E Frequent 4- Likely 4A 4B 4C 4D 4E 3- 3A 3B 3C 3D 3E Occasional 2- Seldom 2A 2B 2C 2D 2E 1- 1A 1B 1C 1D 1E Improbable Presented by: Alvaro Silva 21
Assessment Risk Index Assessment Risk Index Criteria Accountability Unacceptable under existing circumstances requires immediate action Manageable under risk control Acceptable after review. Requires tracking and recorded action plans Acceptable with continued data collection and trending for continuous improvement. 5A,5B,5C,4A,3B,3A All team members 5D,5E,4C,3B,3C,2A,2B All team members 4D,4E,3D,2C,1A,1B Individuals 3E,2D,2E,1C,1D,1E Individuals Presented by: Alvaro Silva 22
Conclusion Findings Next step: Measure Phase Presented by: Andrew Hartsfield 23
Questions Presented by: Andrew Hartsfield 24
