RDP Semester ReviewRotation #3

Sarah Brown, 12/07/15

Agenda

Introduction

Facts About the Rotation

Projects

Continues Improvement Initiatives

Lessons Learned

2

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

3

Facts About the Rotation

Rotation # 3

Core Field Operations

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

Site Manager Steve Holley, FAS-SMV Plant Manager & Mike Boerner, FAS-SMV Quality Manager

Location / Division Faurecia Automotive Seating – Simpsonville, KY

Objectives of the

Rotation

1. Participate in a New Plant Launch

2. Review and Apply Faurecia’s Core Procedures (FCP’s)

3. Training on Quality Lab Procedures and Requirements for Seat Acceptance

4. Attend Functional Training

Next Rotation Faurecia Automotive Seating – Vigo, Spain

4

Projects

Implementing 7 Quality Basics

Scope

Create necessary documentation & processes for

7QBs in the plant

Implement & train on documentation & processes

Actions & Results

Poka-Yoke

Created and implemented Poka-Yoke tags for

all lines

Trained on PY tag use and backup modes

OK 1st Part

Updated & standardized OK 1st

Part check sheets for all lines

Designated display area for

check sheet on lines

5

Projects

Implementing 7 Quality Basics

Self Inspection

Created defect tally sheets w/ thresholds & missed

defect charts for stations on all lines

Trained operators on Stop @ Defect

Final Inspection

Trained inspectors on final inspection process for all

lines

Administered FI Gage R&Rs to inspectors for all

lines

Completed 10/12 checks on FI validation form (9

needed for FES lvl3)

Completed mirror documents/setup for TQW

QRCI

Set up lineside QRCI areas for all lines

Trained personnel on lineside QRCI

6

Projects

Implementing 7 Quality Basics

Red Bin

Helped order red bins for main lines

and placed/zoned

Train line personnel on acceptable

defect identification

Rework Under Control

Developed rework & scrap flows for

all lines and QA cage

7

8

Projects

Control Plan & OK 1st Piece Updates

Updating control plan to reflect current

line setup and processes

Standardize control plan, Poka-Yoke list,

SCCAF, OK 1st Piece and other

documentation

Insert notes to guide those in charge of

‘official’ documentation updates

Kamishibai Audit

Created Quality kamishibai audit cards

based on initial items that can currently

be checked

Usability walks scheduled this week

149 quality kamishibai cards currently

created

9

Misc. Projects & Assignments

SAB Disposal System Quotes

Contacted several recycling & disposal

companies asking for quotes

Hosted a visit to the plant to discuss

capabilities

Lab testing for TT

Shaker Table testing and H-Point testing

training

Preliminary training on shaker table and

program

Learning through testing troubleshooting

Run@Rate Cycle Times

Collected cycle times on specific stations as

line run@rates were scheduled

Occur Monday-Thursday every week

Updated times in centralized Excel sheet

Assisted engineering in creating charts to

show needed trends

10

Misc. Projects & Assignments

20% S/R Fasteners – Presentation & PFMEA

Review

Chances to interchange S/R bolts and latches

in process

Opportunity for PFMEA improvement

Took pictures and notes, created presentation

to be distributed, and assisted in PFMEA

review meeting

Management reviews & final seat prep for

EPT/TT seats

Management review to look over final seat

assembly & appearance

Prep for shipping – completing “OK to Ship”

inspection sheets, attaching necessary alert

tags & Ford “New Model” stickers, taking

pictures of completed seats, etc.

Birth certificates for EPT & TT seats

As seats were built, filled out “birth certificates”

w/ relevant torques and serial numbers

11

Misc. Projects & Assignments

FES Games

Top 5 N-1 Responsibilities

Completed Quality KPIs

Report out on updates, AIMs issues, QA alerts

FUELS

Co-coordinated w/ Chastity Mazon

Reached 409% of goal (2,650 meals w/ goal of

648 meals)

Material feeding for fasteners to line

Working w/ FES and PC&L

Idea to mimic stations from main assembly plants

Concept created by Trilogiq

Next steps to order a kit and test

Building the Boundary Books & Documentation Binders

Binders on each line that contain the Ford Boundary

Book and copies of documents needed at Final

Inspection

Continuous Improvement Initiatives

12

Visit to Ford KTP

Visit to Toyota Production Plant

Visit to Corvette Production Plant

Involvement in Top 5 & Staff Meetings

See the application of some Plant KPIs & how they

integrate w/ other departments

Responsible for note taking during staff meetings

Boundary Book Documentation Instructions

Added instruction pages for the different documents

needed at Final Inspection & TQW

Added blanks of the documentation forms

to allow for easy copies

Idea to use FECT HSE Startup sheet

Easier to manage HSE Startup

Separate instructions and sign-off sheet

to closely monitor each safety measure

Time and work to create the FES standards usually already in place

Setting up correct the first time will make future production run much smoother

Opening a new plant is nerve-racking and rewarding

Plant Opening Lessons Learned

Line Layout and Future Seating Plants

Line should be designed to meet local safety guidelines (line currently not OSHA compliant,

stairs not usable)

Area for TQW/FI not built into layout

People on inside of line (Safety & material delivery concerns)

Line durability studies

OHP

1 UAP and 9 Supervisors for 459 MOD

Plant will fail FES Audit 2.1.1 Lvl 2

UAP max 200 & Supervisor max 25

1 Quality Engineer and 1 Process Engineer

Risk for high turnover and lack of development & improvement idea implementation

PFMEA importance and impact

Lessons Learned

13