christian rupe final
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Christian Rupe
Summer 2015 Fiat-Chrysler Internship
• Senior at Ohio Northern University
• Manufacturing Engineering Major
5 Things About Me
I have a 17 month old beautiful daughter named Ava
5 Things About Me
I run track for Ohio Northern University Qualified for the NCAA DIII National Championships in 2014 on the 4x100m relay I run the 60m, 100m, 200m, 400m, and lead leg on all of the sprint relays Multi-time conference OAC champion indoors and outdoors
I am a Philadelphia Eagles Fan I enjoy watching UFC, Football, Basketball, Golf, and Soccer My favorite colors are navy blue and light green
MY PROJECT
My Project
Over Cycle and Production Stops of top 5 jobs per BU in KL BIW In charge of tracking over cycle and production stops hour by hour of all four
business units Reports and graphs are presented every morning at 7:30 to Chuck Padden (complex manager),
Anthony Offredi (center manager), Waleed Almarayati (production manager), BUL’s, and management staff
Monitor operator over cycle Reach an absolute zero of zero operator over cycles minutes
Then break down process overcycle
Implement methods on how to correct the main issues Coaching, PDCA, Kaizens, WO, 3M (muri, mura, muda)
My Project Cont.
Team binders to organize PDCA forms per station
Top 5 ranked stations for over cycle per BU
Line graphs for visual increase/decrease in over cycle
My Project Cont.
Some jobs that I have made major improvements on: BO04 had stock issues where they were not getting stock to the line on time
Made improvements on the green stock routes by making them more efficient, got stock on board with overcycle, and rearranged some of the stock bin locations.
Had hooks placed on the pillar closest to the job as extra “safety” or “service” parts in case there were ever any driver issues.
Overcycle was taken to zero. *Kaizen
BI01 and BI02 had issues with sticking/greasy parts Had a small magnetic tool that was on BI02 (Team 7) read across to BI01 (Team 5). This brought the
over cycle down significantly. Operators had little problems after the fact. OC going towards zero. *Kaizen
231R issues with ball studs being placed into the wrong gun Had tips of guns changed so that ball studs and bolts could not be placed into opposite gun. Error mistake proofing for ball studs. Eliminating possibility of error. *Kaizen
My Project Cont.
RF30 had issues where the shot clock was not in line with the over cycle light and stock bins were too far away from the work cell Synced the clock as a visual for the operator. Stock bins were a couple steps too far from the cell. The stock bins were placed so that
they are conveyed inside the cell for easier access for the operators. OC went to zero multiple times.
All other stations I was able to reach zero by improving employee moral and coaching operators on importance of over cycle issues. Team leaders and operators understood the importance of no over cycle. Worked with
me well on jobs by presenting suggestions and ideas to fix jobs. As a unit we were able to reach zero many times.
Microsoft Excel Database
KAIZENS
#83130
BI01: magnetic tool to pick up parts
#83776
BO04 stock rack
#83242
231R: gun tip change
PROGRESS
MayJune
July
0
200
400
600
800
1000
1200
1400
1327
742
486
KL BIW Overall Overcycle in Minutes
Target is ZERO
How Much Does Overcycle Cost Us?
70 dollars per minute of overcycle Monthly vs Annually May 2015
1,327 min of overcycle = $92,890 x 12 = $1,114,680 June 2015
742 min of overcycle = $51,940 x 12 = $623,280 July 2015
486 min of overcycle = $34,020 x 12 = $408,240
63%
$1,114,680 $408,240
Ways to Sustain
Continuous improvement on communication with operators and management
Address issues as they come up and attack them thoroughly
Report out improvements, errors, and other issues daily
Monitor weekly progress
Daily who, what, and when about issues facing jobs
Conclusion (Things I've learned)
This internship has taught me great managerial skills Effective communication is key Making sure employees are aware of issues at their jobs Working well not only with management, but OP’s and TL’s too Attacking projects day by day Public speaking and presentation Creating databases and data analysis skills
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