Increasing manufacturing quality and delivery times for high-speed reciprocating compressors

Our journey to “Supplier of Choice” begins with the High-speed Reciprocating Compressor Center of Excellence located in Oshkosh, Wisconsin. This line has been undergoing an overhaul of business and manufacturing processes to continuously attain the highest quality product; achieving growth rates of 160-200% year over year for the past two years – all while continuously ensuring customer satisfaction.

To support the overhaul, the Operations team has implemented Lean and Six Sigma principles into all aspects of the OTR (Order Through Remittance) process. We recognize delivery is critical. To shorten our cycles and improve on-time delivery, we have worked with our customers to implement Lean principles such as Heijunka – the process of level-loading our production facility and supply chain.

Initiating the process, a build forecast was mutually developed with our key customers regarding their targeted projects, market conditions and desired fleet levels, along with our own analysis of competitors, market conditions, NPI positioning and growth strategy. This information is used to develop a level-loaded build portfolio and slot plan permitting customers to coordinate package equipment. This strategy has contributed significantly to our on-time delivery performance as well as our ability to address short-cycle unit requests or emergency orders.

Following the level-loaded forecast, the next challenge is in developing a supply chain capable of executing on our customer needs. Working with existing and new suppliers, long-term material and capacity agreements have been negotiated to guarantee delivery for our customers. A Sourcing Quality organization, consisting of engineers focused on specific components and their respective manufacturing processes (such as cast cylinders, forged crankshafts, connecting rods), is in place to incorporate GE’s supplier qualification process. This process ensures vendors are making components adhering to the rigorous GE standards and quality requirements. The qualification process includes approved manufacturing process plans, quality holds points, first piece and pilot lot components, risk assessments and capacity analysis.

Additionally, all critical drawings are transformed into 3-D models to support design and advanced manufacturing:

• Finite element analysis used to improve robustness in our running gear and Piston Rods
• Casting solidification used to enhance casting yield and integrity in our API 618 Cylinders
• Computer aided manufacturing, streamlining our machining repeatability from supplier to supplier

After receiving component material from our suppliers, focused attention is placed on each customer’s project as it proceeds down one of our newly implemented single-piece-flow manufacturing lines. Each line is a mixed-model pulse line, similar in concept to those designed for our gas turbines as covered in our April Newsletter.

The first line handles our M and H product family, and the second handles A, D, E and F. The pulse line has simplified assembly and allows lean production with the development of standard work, standard tooling, material presentation and vendor managed inventory. Other investments to our facility include an in-line washing and painting booth, a new testing centre for our M and H product line, advanced tooling for torqueing and tensioning components and a 30-ton overhead crane. All of these elements help to establish seamless manufacturing operations and minimized assembly time reducing total production time through the factory from days to hours.

These are just a few of the steps on our journey to becoming the premier supplier of choice. There are additional items on our roadmap that will create greater value and opportunity to our customers.

For more information regarding the high-speed reciprocating compressor line or ongoing plans for improvement, please contact:

Jeff.Coleman@ge.com
Cell Leader – High-speed Reciprocating Compressors

Craig.Weidemeier@ge.com
Lean Leader – NA Operations