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2015 Alcoa Summer Internship Program Global Logistics Intern Cleveland, Ohio

By: Alexander Flanagan

Introduction

Name: Alexander Flanagan

Major: Packaging

School: Michigan State University Senior Graduating in December

Hometown: Lansing, Michigan

Alcoa Position: Packaging Engineer

• (Steve Dominish) Global Logistics

Supervisor: Danielle Hurt

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Hobbies:• Sports, Adrenaline, and giving Back

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Last Year’s Returnable Dunnage Packaging Improvement

Target Condition: • New pallet pack with T-rings will cost less than current dunnage. • Will increase the capacity in a truck from 528 wheels to 672 wheels• Potential for $356,388 in saving s for AWPM and CLE+ (DI# 106502 for CLE+, DI needed for AWPM).

Current 22.5’ Truck Load: Target 22.5” Truck Load:

672 wheels

= $4.61 /whl

$356,000 in

transportation

savings

528 wheels

= $6.02/whl

Results After One Year $1,079,209 in TRN savings35%

Improvement

528 wheels

= $6.02/whl800 wheels

= $3.97 /whl

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CVW Ingot Pad

Sink holes formingPreventing Tow MotorDrivers from using The bays.

Bay rails misaligned

No organization on how or where to unload, and what to consume for production.

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CVW Ingot Pad Problems

Why is this an issue: Production has run into the issue of ingot bars not being able

to scan. Either the sticker endure weather damage and are no longer able to scan, or bars are being consumed for production before they have officially been received in the system. This leads to bars being labeled as DOES NOT EXIST, and placed into a QA Hold area.

FIFO Plan: The new ingot pad plan will allow for production to load and

pull bars for production in a first in first out matter.

July 4th Lot Fix: During the July 4th outage, the ingot pad was able to be fixed of

all sink holes and damaged bays to implement the FIFO plan.

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Ingot Lot Re-Organization

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NAFTA (North American Free Trade Agreement)

What is NAFTA : North American free trade agreements are implemented to help

companies avoid duties and fees while importing and exporting NAFTA qualifying goods.

NAFTA qualifying goods include products that originate from the United States, Canada, and Mexico.

Product that is sent back to warranty that did not originate in North America is charged a duty fee of 2.5% of $250 which is a per wheel price.

Duty Fee No Duty Fee

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My Role at Alcoa

Auditing of Canadian Imports to Warranty Cross reference customer part numbers in Oracle

Check to make sure customer part numbers are matched with an Alcoa part number.

Check is this part is NAFTA certified If not certified print a Costed BOM (Bill of Materials) Create an FTA organization worksheet to be further audited and

approved by members of the logistics team Double check the part numbers on a master list to identify the country of

origin.

Completed Chrysler and General Motors LLC Sales order of Acknowledgements for daily shipments Reorganization of trip planning and traffic notes for Daimler and

New Flyer shipments TPM Participation

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The Numbers Don’t Lie

This chart identifies the duties and fees avoided on imported NAFTA qualifying goods.

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Process Improvement

Business Case: TWI spends $0.39/forging to repack forgings produced in Cleveland for export to Japan and China. The double handling is unnecessary and ties up steel guarded pallets within the flow path until repacked at TWI.

Future Trial with GA23917F in CVW:

Current Flow Path

Target Flow Path

Target Condition: • Eliminates labor cost of $0.39/forging.• Eliminates wheel handling / potential injury.• Eliminates use of steel guarded pallets.

GA23917 2015 Production Forecast

30,816 Total GA23917: • Steal guarded pallets fit 24 forgings per pallet.• Heat treated pallets same dimensions • Potentially free up 1,284 steal guarded pallets for production.

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Experience and Feedback

The Alcoa Experience: This is my second year with Alcoa. Work environment and atmosphere Ability to challenge one self Opportunity

Internship Feedback: Comparison to last summer Lead team interaction On boarding process Career path counseling

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AWTP Experience

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