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Impact Report

Impact Report. Project: Alpha CI Event / Standard Work Implementation. Problem Description: Insufficient per shift trailer production, resulting in excessive man-hours per unit.

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Impact Report

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  1. Impact Report Project: Alpha CI Event / Standard Work Implementation. Problem Description:Insufficient per shift trailer production, resulting in excessive man-hours per unit. Solution:Conducted CI events with Manufacturing, CI, and NGP groups; to establish appropriate manning requirements and develop station specific standard work. Benefits:Increased units / shift & reduced man-hours / unit. Annualized savings: $515,484. Sustainability:Associates added to production line and standard work developed per recommendations of CI event teams.

  2. Impact Report Project: Process Yield Improvement. Problem Description:Paint booths are dark and car lifts inside booths create blind spots when painting. After Before Solution: Install new lighting and new stands. Benefits: New lighting and stands will improve process yield and what the painter can see in the booth. Minimum of 60 seconds C.T. improvement. Sustainability: Replaced old lifts with stands.

  3. Impact Report Project: Duraplate -16 / 24 Die w/ automation. Problem Description:Process not capable and very labor intense. Before After Solution: Purchase new die w/ automated handling system. Benefits: $490,000 annual savings in labor, scrap, inventory, and lost-starts. Sustainability: GPC.

  4. Impact Report Project: Duraplate Panel Line #2 Rate Increase Problem Description:Duraplate panel line rate of 21.0 fpm - too slow. After Before Panel Line #2 running at 21 fpm for a cost per unit of $9.87/unit Panel Line #2 running at 28 fpm for a cost per unit of $7.47/unit Solution: Conducted DOE to increase production rate by 33.3% Benefits: $1,014,999 annualized savings. Sustainability: Daily process audits/verification sheets - GPC.

  5. Impact Report Project: Coil feed attachment strip cell Driving Issue:Current production process is: - labor intensive - prone to overproduction - prone scrap due to handling. Solution: Build a special production cell to: - reduce labor - produce to order, in one cell - improve handling to reduce part damage Before -punch -shear -offset -store After –make to order Benefits: $1,414,404 annual savings / reduced W.I.P. / reduced lead time Sustainability: Integrated new process, programmable for new parts or changes.

  6. Impact Report Project: Line 5 Curbside Decalling Station Lighting Problem Description:The lighting in this station is very poor and has an adverse effect on the quality of work that the associates can perform. Before After Solution:Instructed maintenance to add in some additional florescent lights to improve the operators conditions. Benefits:Better quality of workmanship on the decals. Sustainability:Lights will remain there to aid the associates.

  7. Impact Report Project: Set Press Lighting Problem Description:The lighting for the set press was extremely poor and didn’t allow for good product inspection for poor rivet quality. This allowed for rework down the line. Before After Solution:Facilities Maintenance installed some new florescent lights for better visibility. Benefits:Decreased possibility for poor rivet sets. Sustainability:Lights are mounted to the press and will always be a part of the line.

  8. Impact Report Project: Trash elimination from decalling walkways (WPO) Problem Description:The decallers don’t have anyplace to put their trash bags other than in the walkways. This creates a safety hazard. Before After Solution:Had new bag holders made to easily hang the trash over the railing. Benefits:Safety increase by opening up walkways. Sustainability:Associates have approved holders and three additional have been ordered.

  9. Impact Report Project:Line 3 Line Modifications Problem Description:The line configuration was not set up to optimize labor for the high option Chrysler Autohaul trailer run leading to very low process yield and throughput. Solution:Installed lift tables at Jig that created another usable option station in the sidetables area. Installed drilling platform allowing for the welding and pre-drilling of the lower floor scuff. Benefits:Substantial increase in process yield for PC run, Approximately 70 man hour per trailer reduction in labor for PC run. Line better set up for high interior option trailers. Eliminated safety concern with push sidewalls below knees. Sustainability:Equipment permanent to area

  10. Impact Report Project: Line 3 Panel Shear Problem Description:Because of the shear length, when Line 3 runs drop deck style trailers, the large panels are cut to size using a circular saw. Solution:Swapped shears with the old container line Benefits:New shear has longer blade that allows drop deck panels to be cut with the shear eliminating the need for the circular saw and improving the overall quality of the drop deck panels Sustainability:Old shear removed from area

  11. Impact Report Project: Line 4 Apron Wrapper Drill Fixture Problem Description:Associates were having a difficult time lining up the holes in the apron wrapper with the apron leading to standing bolt heads and rework of apron wrappers Solution:Modified fixture (old fixture was found to have drill guides out of position) and changed location method Benefits:No longer having any alignment issues and have eliminated standing or angled bolt heads in this assembly Sustainability:Old fixture was removed from area

  12. Impact Report Project: Ceiling shoe horn Problem Description:Due to hour-glassing of sides at the jig, the sides have to be pried out so that the ceiling can slip into place. The crow bar used would go into the assembly too far and crack/damage the ceiling liner. Old Tool New Tool Solution:Replaced crow bar with new tool. New tool only allows 3” of penetration such that the ceiling liner is no longer in danger of being damaged Benefits:Previous run cracked/damaged 90 trailers. Each liner patch kit takes about 2 man hours to replace. Estimate that this will save approximately 400 roof patches annually (labor avoidance + cost of patch kit) Sustainability:Crow bars in area removed, weekly audit for tool usage

  13. Impact Report Project: Line 2 slide rail fixture modification. Problem Description:Fixture not capable of producing a 300” slide rail for a tri-axle bogie. After Before Solution:Extend the fixture to enable production. Benefits:Greater product mix on line 2. Sustainability:Product/Process design change.

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