RDP Semester ReviewRotation #2

Sarah Brown, 6/11/15

Agenda

Introduction

Facts About the Rotation

Rotation Participation Details

Projects

Continues Improvement Initiatives

Lessons Learned

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Introduction

University Attended &Majors/Minors

Indiana University – Purdue University Indianapolis (IUPUI)Mechanical Engineering TechnologyTechnical Communications CertificateLean Six Sigma Green Belt

Organization Involvement

Society of Women EngineersEngineers Without Borders American Society of Mechanical Engineers Society of Manufacturing EngineersEngineering Technology Student CouncilInternational Society of AutomationEngineering Technology Leadership Development Program

Study Abroad Experience

No International Experience - Yet

Travel throughout the United States with organizations:- California, Michigan, Wisconsin, Florida, Ohio, Illinois, Louisiana, New York- Heard from many local engineers on their companies and what they are doing in varying industries

Fun Facts about Yourself

- I play the violin and the piano - I enjoy bourbon, beer, and wine tastings - I like to cook/bake, read, draw/paint - I love to travel & try to visit at least one new place per year - I can speak some Spanish & Italian and am working to become more fluent in both

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Facts About the Rotation

Rotation # 2

Core Field Operations

Executive Mentor Eddie Millington, Continuous Improvement Director, FECT - NAO

Site Manager Alex Portas, Industrial Engineering Manager , FAS - SHO

Location / Division Faurecia Automotive Seating – Sterling Heights, MI

Objectives of the Rotation

1. Introduction to Process/Industrial Engineering in a JIT Facility2. Participate in a Launch Program3. Participate in Plant MOD Reduction Plan through Hoshin Events4. Attend Successful Manager Training Modules5. Experience Working w/ Plant JIT Diagnostic Tool

Next Rotation Faurecia Automotive Seating – Simpsonville, KY

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Rotation Participation Details

Plant Projects and Activities Participation in Women@Faurecia Initiative University Visits

Central Michigan University Career Fair Purdue University Women in Business Conference Oakland University Diversity and Inclusion Conference

Ignition Workshop – Technology Implementation for Efficient Operations RDP Workshop Session Lead – Millennials & Mentors RDP Candidate Interviews Participation Training

Successful Manager Training Interviewing Talent for Faurecia FES NAO Coaching Modules – Employee Empowerment, 7 Delivery Basics, 7

Inventory Basics, New QRCI, HSE and 13 Mandatory Rules, 7 Quality Basics in Production, 7 Quality Basics in Program, and QRCI in Program

Projects

Cadillac Omega Line – Flow & WIP Racks for Offside Stations Scope

Act as liaison between Program Team & Supplier (Trilogiq) Gather data/information, communicate needs/limitations,

approve drawings, collect & approve quotes, facilitate rack build & delivery

Result Currently being built – 3 WIP Racks & 2 Flow Racks w/ Carts

Actions Determined overall rack dimensions

Space constraints & ergonomic standards Found optimal number of Kit Boxes & WIP Communicated updates & design changes as

Program Team needs changed Approved drawing & received quote approval Currently keeping communication between

Program Team & Trilogiq as racks are beingbuilt

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Projects

Cadillac Omega Line – Kit Boxes Scope

Acted as liaison between Program Team & Suppliers Gather data/information, create needed layouts,

communicate needs/limitations, determine correct parts, approve drawings, collect & approve quotes, facilitate rack build & delivery

Result 2 Inner Kit Box Layouts Prototypes for customer viewing Enough Kit Boxes for run at rate & full production

Actions Found information on part delivery Scheduled supplier visits to discuss needs Created several inner layout designs & updates Analyze supplier capability vs. Program Team

needs & limitations Receive quotes & approve layouts

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MOD Reduction Hoshins Plant (UF) MOD: 176 on 12/31/14 Plant (UF) MOD Target: 166 by 7/1/15

LH/RH 140 Reduction (MOD -2) – Complete

LH 130 Elimination (MOD -2) – Complete

Clip Installer Elimination (MOD -2) – Complete

LH/RH 95 Elimination (MOD -4) – Complete

RC 33 Elimination (MOD -2) – In Process

Projects

9 10 11 12 18160162164166168170172174176178 176

166

MOD Convergence 2015

WeekM

OD

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Projects

MOD Reduction Hoshins Scope

Day long events to find areas of improvement on the line

Reduce MOD by improving layout, process, etc.

Result Current UF MOD @ 166 – Target

Achieved Actions

Visit line - current cycle times & process recorded

Analysis of data & brainstorming Action Plan & PDCA Update Trial Prep & Data Collection Implementation Success/Failure

based on Data & Feedback

Projects

JIT Diagnostic Tool Purpose

Diagnose Direct Labor Potential Centralizes Program Information Improvement Opportunities Provides Program Target Helps generate & maintain PIP

Consists of Excel Sheet w/ Varying Tool Tabs

Labor Summary & Line Balance, Takt Time Calculation, Work Content Charts, Work Content by Weighted Volume (Bubble) Charts, Work Content Variant Charts, Labor Potential Calculations, Complexity Analyses, Diversity Tree

Binder All Tools from Excel Sheet, JIT Tool PDCA, Shift Volume Pulled by Customer, PDP Adherence,

Daily Variation of Mix, Customer Preliminary Module, Product Allocation, JIT Window, Current & Target MIFD/MIFA, Operating Times, Volumes of Finished Goods, Availability Analysis of Current Process, Supplier MPMs, Quality Level of Line, Inventory Segmentation, Target Layout, Target Line Balancing, Commitment on Quality, Labor, Delivery, etc., PIP, Training Logs & Meeting Sign-Ins, Questionnaire for Faurecia JIT Sequence Plants

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JIT Diagnostic Tool Scope

Build/Update UF JIT Tool Documentation/Binder (LH/RH/Row 2) Begin building JIT Tool for Omega Line

Result Complete & up-to-date JIT Diagnostic Tool for UF Line Progress on Omega JIT Tool Organized JS JIT Tool Binder

Actions Collected Cycle Times from each

line and input into Tool Updated Tool to be consistent

(layout, text, colors, etc.) and link data

Worked w/ other departments to gather necessary documentation & data

Printed, organized, labelled, and assembled binders & documentation

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Projects

Projects

JIT Diagnostic Tool Documents – Labor Summary & Line Balance

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JIT Diagnostic Tool Documents – Generated Information

Projects

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Projects

Miscellaneous Projects PC&L Cycle Times

PC&L had outdated/missing cycle times necessary to create SWIs

Created Excel file w/ data for each area of PC&L (except HiLo’s)

Designed a Flow Rack to Hold Seatbelt Buckles HSE Warehouse Fire &

Emergency Routes Miscellaneous Cycle Time

Collection ECR (Engineering Change

Request) Data Improvement Initiative Data

PC&L Area Safety Hoshin

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Omega Shadowing (Personal Improvement) Watched Omega Master Builders assemble seats

JIT Diagnostic Tool Changes JIT Diagnostic Tool Documentation Library Data linking in JIT Diagnostic Tool Excel files Updated layouts of documentation for Tool

consistency/ease of navigation Hoshins

Gather relevant information prior to Hoshin meeting Videos, Cycle Times, Pictures, etc.

Bring Improvement Idea Sheets to Hoshin Events Various changes to the line (as a team)

Rotational Development Program Objective Updates Training creation targeted for Millennials & Mentors

communication

Continuous Improvement Initiatives

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Daily Improvement Ideas JIT Diagnostic Tool

Function, Design, Capabilities Faurecia/Customer Interaction during New Program

“Slow Builds” – customer visit to analyze seat build Faurecia/Customer Interaction during Existing Program

Customer can add work content to line React quickly to protect customer & line

Involvement of Floor Representative in every Hoshin Importance of cross-functional team during

Hoshins & general team collaboration Continuous Improvement as a Leader RDP is New – Trainees need to reach out & take

charge of their own development Gain experience in other areas (PC&L, Quality,

Finance, etc.) FES is not a bunch of standards to be followed –

it’s a company culture

Lessons Learned

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