Intern Report Out Summer 2016

Alexandria Vivar Mechanical Engineering Intern

Alcoa Mill Products, Lancaster, PA
August 17, 2016

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About Me

China
Da lian,

School: The Pennsylvania State University

Major: Mechanical Engineering

Campus Involvement:
Engineers Without Borders
Research Assistant The Biomechanics and Imaging Lab
Penn State Advanced Vehicle Team Procurement

Fun Fact:
Interned in Dalian, China for 3 Months in Summer 2015

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Overview of Accomplishments

MILL FINISHING INTERLEAF SCRAP PAPER CART - DESIGN

COMPLETED
MILL FINISHING #11 SLITTER BIN SHAKER DOOR GUARDING -
INSTALLATION COMPLETED

POLY DRUM BRIDGE CRANE - DESIGN COMPLETED

CAST HOUSE MELTING FURNACES BILL OF MATERIAL - TO BE

COMPLETED AFTER INSTALLATION
CAST HOUSE #5 PIT EQUIPMENT REDESIGN - DESIGN IN
PROGRESS
MILL FINISHING #11 SLITTER BANDING CART DEFLECTOR -
INSTALLATION COMPLETED

PLATE MELTING FURNACE DRAWING UPDATES - COMPLETED

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 Mill Finishing Interleaf Scrap Paper Cart

Team Project with Emily Docherty

ESR to improve functionality of existing

cart
Redesign requirements:
Position with an overhead crane
Multidirectional forklift pockets
Anti-tipping mechanism

Existing Cart:
Bent Wheels
Difficult to Push
Drive is Broken

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 Mill Finishing Interleaf Scrap Paper Cart

Initial Design Final Design

Tasks:
Performed Static and Dynamic Analysis
Presented Initial Design to Production Crews
Drew the Final Design in AutoCAD for Fabrication
Obtained Price Quotes From Vendors
Performed Cost Analysis
RFA Paperwork Completed
Shovel Ready Project

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Mill Finishing - #11 Slitter Bin Shaker Door Guarding

Completed ESR to solve issues at the #11 slitter bin shaker

Existing Problems

#11 Slitter - Bin Shaker Door Track being Damaged by Forklifts

#11 Slitter Sleeve Rack Damaging Bin Shaker Enclosure

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Mill Finishing - #11 Slitter Bin Shaker Door Guarding

Brainstorm Solutions & Reviewed

with Maintenance:
Add removable bollards to protect the
outside of the enclosure from the
sleeve racks and add steel plates to
the existing bollards to protect the
track for the door

Tasks:
Created a Plan Layout in AutoCAD
Load Calculations
Worked with Contractors
Obtained Quotes
Supervised installation of changes
Project Successfully Completed

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Lab Department Poly Drum Transport

ESR to Address Ergonomic Issue Handling

Chemical Drums:
Create a way for workers in the chemical lab
to move 900 pound acid drums from wooden
pallets to the spill pads

Design Challenges:
Low ceilings restrict headroom and
equipment from the coating line occupies half
of the hallway

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 Lab Dept. Poly Drum Crane Frame

Option 1: Bridge Crane Option 2: Counterbalance

Tasks:
Vertical Lift
Developed Possible Solutions
Reviewed with Lab and
Maintenance
Obtained Quotes From Vendors
For Two Possible Options
Performed Momentum
Calculations for Push Force
Conducted a Cost Analysis
Decided in favor of the
hands-free bridge crane even
though it was the more
expensive option
Completed a Project Charter and
a PEHSR Bridge Crane = $ 7,356.00 Universal Drum Lifter = $ 295.00 +
Supporting Structure = $ 12,337.00 10CBH(Hydraulic) = $ 6,886.00 OR
Currently Seeking Funding Total = $ 19,693.00 10CBDC(Battery) = $ 8,445.00
Target to Complete by the end of
2016

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Cast House Furnaces 9 & 10

Incident: Cast House #10 Open Well Furnace Molten Metal Spill July 18th

Issue: Little documentation on materials used for a

furnace rebuild.
Solution: Create a standard bill of material for the cast
house melting furnaces using drawings from Adept and
material quantities from vendors.

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Mill Finishing - #11 Slitter Banding Cart

Worked with Nigel Braun

Reaction to Employee Injury:

Design a temporary deflector so that
production does not have to lock out
machine until the permanent
solution is installed

Tasks:
Designed deflector in AutoCAD
Ensured the design met Alcoa EHS
specifications concerning machine
guarding
Supported fabrication in the Machine
Shop
Supervised Installation

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Takeaways

Ask Questions

Safety AutoCAD

Project
Management

Communication Compromise

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Whats Next?

Tibet & Vietnam

Graduation

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Acknowledgements

Ed Daughenbaugh
Sharon Davis
Shane Anton
Paul Wolfinger
Frank DeCesare
Jeff Unton
Mario Gallello
Cyndi Moore
Ram Eranki
Jaime Pena
Pete Higgins
Evan Falk
Jim Hauer
Mike Adkins
Bill Buskirk
Fred Witmer

Ed Roldan
Roger Pritchett
Richard Plummer 14
Bruce Ahr
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