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2014 Alcoa Summer Internship Program Packaging Intern Cleveland, Ohio

By: Alexander Flanagan

Introduction

Name: Alexander Flanagan

Major: Packaging

School: Michigan State University Senior

Hometown: Lansing, Michigan

Alcoa Position: Packaging Intern

Supervisor: Steve Dominish

Mentor: Daniel Smink

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Hobbies:• Sports, Adrenaline, and trying new things

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Returnable Dunnage Packaging Improvement

Business Case: • Total spend for transportation from TWI and AWPM to ASL locations is $2,164,268 ($1,414,713 + $749,555). Current dunnage creates inefficiencies.

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:

• Current dunnage designed to fit 19”- 24.5” wheels.• 80% of shipments to ASL are 22.5” wheels.

672 wheels

= $4.61 /whl

$356,000 in

transportation

savings

528 wheels

= $6.02/whl

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T-Ring Trials

Extruded T-Ring Trial

Molded T-Ring Trial w/ Stretch warp

Molded T-Ring Trial banded w/ stretch wrap

Pros:• Eco Pack cover

Cons:• Clips came apart• Cloth created separation • wheels sliding on pallet

Pros:• Shipment from Mogadorto Chillicothe• Eco Pack cover • Stretch wrap

Cons:• T-Ring movement • Wheel movement on pallet • wheels sliding on pallet• Damaged T-Rings

Pros:• Shipment from Mogador to Chillicothe• Eco Pack cover• Stretch wrap • Banding

Cons:

Plastic Pallet • T-Ring movement • Wheel movement • Sliding on pallet • Damaged T-Rings

Wooden Pallet • No physical damage• Not reusable

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Forging Improvement

Business Case: TWI spends $0.39/forging to repack forgings produced in Cleveland for export to Japan and China (projected volume is 115,000 forgings from CLE to Asia in 2015). The double handling is unnecessary and ties up steel guarded pallets within the flow path until repacked at TWI.

Successful Trial with GA23906F in FSW:

Future Recommendations

Current Flow Path

Target Flow Path

$44,850 in

labor savings

• Will need containers in CLE and Oracle enabled

• Need new equipment in CLE

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

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AWTP Experience

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