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