heather r nacke industrial engineering manager kokomo transmission plant september 25, 2012...
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![Page 1: Heather R Nacke Industrial Engineering Manager Kokomo Transmission Plant September 25, 2012 Logansport, IN Teacher Enrichment Program](https://reader035.vdocuments.us/reader035/viewer/2022062404/551b82a1550346a10a8b5252/html5/thumbnails/1.jpg)
Heather R NackeIndustrial Engineering ManagerKokomo Transmission Plant
September 25, 2012 Logansport, IN
Teacher Enrichment Program
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CHRYSLER GROUP LLCMy Background
• Grew up in Cleveland, OH• Initially wanted to be a veterinarian due to love of science and math as well
as love of animals; found out the amount of schooling required and reconsidered other options.
• As a Junior in High school, developed a love of physics and was encouraged to look into Engineering (by Mrs. Dryer). Participated in a regional exceptional math & science student event where I was exposed to Nuclear Engineering.
• Attended Purdue University; began in Nuclear Engineering and switched to Industrial Engineering due to the human interaction. Earned BSIE in 1991
• Worked in Technical Sales (devised engineered solutions to material handling issues; i.e. conveyor systems) where I covered the West Coast and set up an office in Portland, Oregon (1991-1996)
• 1996 Joined Chrysler in Kokomo where I launched the new “greenfield” site called the Indiana Transmission Plant – varied assignments through 2004
• Moved as an IE Supervisor to deactivate the Indianapolis Foundry then returned to ITP
• In February, 2009 moved to Kokomo Transmission Plant as the IE Manager2
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CHRYSLER GROUP LLCCurrent Information• Married to the same man for over 20 years
• We have 2 lovely daughters, Devyn (14 and a freshman at LHS) & Piper (11 and a 6th grader at All Saints School)
• Worked while my husband stayed at home with our girls until they were in school
• Active in the choir at church
• Active church cantor
• Serve at the state level for Tri Kappa – a philanthropic sorority serving charity, culture and education in the State of Indiana
• Sit on the executive board for the Logansport Girls Softball Group Secretary
• Have Master of Science degrees from Kettering University in Manufacturing Management and Operations Management
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CHRYSLER GROUP LLCTraining / Skills Required• Good analytical skills (problem solving)
• Math, spatial relationships, COMMON SENSE
• Theory and hypothesis
• Computer skills (spreadsheet, simulation, presentations)
• COMMUNICATION!!!
• People interaction skills – all levels of people: Hourly floor workers, Salary supervisors & Business Unit Leaders, Plant Manager, Exec VP on occassion
• Ability to ask “Dumb” questions.
Specific to Industrial Engineering
• Time Study methodologies
• Motion Study methodologies
• Product flow understanding 4
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CHRYSLER GROUP LLCClass Focus for Success in IE• Algebra I, II and beyond
• Physics
• Ergonomics (Human machine interactions)
• Communications
• Debate/ Persuasion
• Interpersonal Skills – How to work in teams
• Time management – ability to prioritize many projects at a time
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CHRYSLER GROUP LLCThe Major Items of Work I Do…
• Protect the plant product capacity for NEW programs and Existing programs – Basically a BIG story problem
• Assign all manpower to each machining and assembly line including all support manpower to each production department and the overall facility – Hourly and Salary
• Determine timing required for new hire training (to facilitate movement of current employees to the new programs)
• Look at current state of process and devise method for improvement in overall cycle time, reduction of scrap, increase in output, etc. (improve profitability)
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Do the same output with less labor or do more output with the same labor
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CHRYSLER GROUP LLCMost Useful Knowledge from School
Carry Units through Equations• What machine cycle time do I require for each operation:
My projections show that I need to ship 450,000 transmissions annually
There are 294 straight time days in a year, with 2 crews of manpower per day
I have 10 hours per crew minus breaks of run timeI assume 92% throughput (scrap, rework, downtime)
• What is the cycle time in final assembly? Min/Unit (& Sec/Unit)
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Annual Capacity 450,000Units (Good)ST Days 294DaysCrews/Day 2Crews/DayThroughput % 92%
Hours/Crew: 9.083Hours/CrewAvail Minutes 600
-Breaks (Assy) 50-T/L Meeting 5
Total Run Minutes 545Minutes/Crew
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CHRYSLER GROUP LLCProblem Solution
8
Annual Capacity 450,000Units (Good)ST Days 294DaysCrews/Day 2Crews/DayThroughput % 92%
Hours/Crew: 9.083Hours/CrewAvail Minutes 600
-Breaks (Assy) 50-T/L Meeting 5Total Run Minutes 545Minutes/Crew
Solve for Minutes/Unit & Seconds/Unit:Units/Day = 1,530.7 Net Good (450,000 units/294 days)
Required Daily Production 1,663.9 Units/Day (1,530.7 (good units/day)/92% thruput)
Required Units/Crew832.0Units/Crew (1,663.9 (units/day)/2 (crews/day))
Required Hours/Unit0.0109Hours/Unit (9.083 (Hours/crew)/832.0(Units/crew))
Minutes/Unit = 0.6540Min/Unit (0.0109 (Hr/Unit)*60(Min/Hr))
Seconds/Unit = 39.24Sec/Unit (0.6540 (Min/Hr)*60(Sec/Hr))
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CHRYSLER GROUP LLCProblem Solution
9
Annual Capacity 450,000Units (Good)ST Days 294DaysCrews/Day 2Crews/DayThroughput % 92%
Hours/Crew: 9.083Hours/CrewAvail Minutes 600
-Breaks (Assy) 50-T/L Meeting 5Total Run Minutes 545Minutes/Crew
Solve for Minutes/Unit & Seconds/Unit:Units/Day = 1,530.7 Net Good (450,000 units/294 days)
Required Daily Production 1,663.9 Units/Day (1,530.7 (good units/day)/92% thruput)
Required Units/Crew832.0Units/Crew (1,663.9 (units/day)/2 (crews/day))
Required Hours/Unit0.0109Hours/Unit (9.083 (Hours/crew)/832.0(Units/crew))
Minutes/Unit = 0.6540Min/Unit (0.0109 (Hr/Unit)*60(Min/Hr))
Seconds/Unit = 39.24Sec/Unit (0.6540 (Min/Hr)*60(Sec/Hr))
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CHRYSLER GROUP LLCInteresting Example of Success
Visual Line Balancing (Story problem)
How to optimize total time available to work• Achieve the same output with less direct labor
• Achieve more output with the same direct labor
• In some cases, achieve more output with less direct labor
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CHRYSLER GROUP LLCTeam
• IE Department:
- Heather Nacke- Stan Kerstiens- Mary Chen- Becky Eagle- Dave Parker- Pat Pedone- Ryan Pritchett- Drew Ward
• Production Control
- Byron Gibson- John Day
• 9110 Assembly:
- Bryce Silvey- James Conley- Terry Thomson- Otis Green- Leslie Love
• WCM Support:
- Jerry Skomp- Russ Dick- Todd Connolly
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CHRYSLER GROUP LLCInitial Line Layout
197 JPH
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CHRYSLER GROUP LLC
MODAPTS ANALYSIS
OPERATION: Station 10 1
MATE SHAFT AND INPUT CLUTCH HUB Date: 11/9/11
No. Task Description Code MOD's Freq Total
Install piston, spring and retainer in clutch
Get 637 IPCH out of kitting basket M4 G1 5 1 5.0000
Put pressed part on pallet M4 P5 9 1 9.0000
Get shaft W5 M4 G1 10 1 10.0000
Put shaft and 637 IPCH together M3 P5 8 1 8.0000
Get finished shaft and 637 IPCH out of press M4 G1 5 1 5.0000
Put shaft and 637 IPCH into press M3 P5 8 1 8.0000
Move to cycle start button M4 G0 4 1 4.0000
Depress cycle start press button M1 G0 1 1 1.0000
Press machine cycle ( 3.6 SECONDS ) 28 1 28.0000
Put shaft side in gage W5 M4 P5 J2 16 1 16.0000
Put hub side in gage M3 P5 8 1 8.0000
Move to Clamp M3 G1 4 1 4.0000
Clamp part in gage M2 P0 2 1 2.0000
Rotate part in gage M3 C3 6 1 6.0000
Read gage E2 E4 R3 D3 12 1 12.0000
Unclamp and get part out of gage (simo) M2 G1 M3 G1 7 1 7.0000
Total MOD's 133
Seconds 17.1570
MODAPTS ANALYSIS
OPERATION: Station 10 3
CLUTCH LINE PACK OUT Date: 11/9/11
Task Description Code MOD's Freq Total
Install piston, spring and retainer in clutch
Get bottom ring grove seal for center hub M4 G3 J2 9 1 9.0000
Put seal over assit then to bottom ring grove on hub M4 P5 9 1 9.0000
Get seal assit M2 G1 3 1 3.0000
Put on next pallet's hub M4 P5 9 1 9.0000
Get 6" seal for ID bottom grove M4 G3 J2 9 1 9.0000
Align and Put 6" seal in bottom grove (simo) M4 P5 M2 P5 J2 C4 22 1 22.0000
Get 2 seal for hub M4 G3 7 1 7.0000
Put top seal for hub M4 P5 J2 C3 14 1 14.0000
Slide over hub andPut 2nd grove seal in hub (simo) M2 P2 M2 P5 J2 C3 16 1 16.0000
Check 6" seal M2 G0 C4 6 1 6.0000
Check Bottom hub seal M2 G0 C3 5 1 5.0000
Check top seal M2 G0 C3 5 1 5.0000
Check 2nd seal M2 G0 C3 5 1 5.0000
Press foot pedeal W5 5 1 5.0000
Remove chips M2 G1 3 1000000/1500 0.0000
1 0.0000
Total MOD's 124
Seconds 15.9960
OPERATION: Phase 1 St 5; running 20,23, 28 WITH KITTING DEPT: ST: Date: 11/7/11
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 Get piston/retainer assy and place to hub M5 G3 M5 P2 J2 J2 J2 J2 23 1 23 AA Non Value Added - Reach
2 Press button for aligning tool M5 G1 M1 P0 7 1 7 A Non Value Added - Reach
3 Wait for aligning tool 0.0167 8 1 8 B Non Value Added - Reach
4 Use tool to align lugs M5 G3 M2 P2 M2 G3 M2 P0 19 1 19 AA Semi-Value Added
5 Press button for press M5 G1 M1 P0 7 1 7 AA Semi-Value Added
6 Wait for press 0.0333 16 1 16 A Value Added
7 1 0 A Semi-Value Added
38
Total MOD's 79
Seconds 10.2233
MODAPTS ANALYSIS
9110 5
CodeOPERATION: Phase 1 St 10; running 20,23, 28 WITH KITTING DEPT: ST: Date: 11/7/11
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 WAIT FOR PALLET;GET KIT PLACE TO PALLET INTERNAL TO PALLET TRANSIT 18 1 18 AA Non Value Added - Reach
2 GET PISTON; PLACE TO FIXTURE M3 G1 M3 P2 9 1 9 A Non Value Added - Reach
3 GET SPRING; PLACE TO PISTION M3 G1 M3 P2 9 1 9 B Non Value Added - Reach
4 GET TOP; PLACE TO SPONGE M4 G1 M4 P2 X4 15 1 15 AA Semi-Value Added
5 PLACE TOP TO SPRING M3 P2 5 1 5 AA Semi-Value Added
6 GET GAGE; PLACE TO CLUTCH; RELEASE GAGE M4 G1 M4 P2 M3 14 1 14 A Value Added
7 GET PISTON; PLACE TO CLUTCH M3 G3 M4 P5 15 1 15 A Semi-Value Added
8 SHAKE PISTION TO SEAT M2 M2 4 1 4 A Semi-Value Added
9 PRESS ACCEPT BUTTON TO RELEASE PALLET M1 P0 1 1 1 A Non Value Added - Reach
10 1 0 AA Semi-Value Added
11 1 0 AA Value Added
12 1 0 B Non Value Added - Reach
Total MOD's 90
Seconds 11.6100
MODAPTS ANALYSIS
9110 10
Code
MODAPTS ANALYSIS
OPERATION: Sta. 15
Install U/D Clutch Pack, Snap Ring and Thrust Bearing to Clutch Date: 11/08/11
I.E. Mary Chen
No. Task Description Code MOD's Freq Total
1Get and align & place u/d clutch pack in verifier & watch for green light M5 G3 J2 J2 M5 P2 E2 21 1 21
2 Install u/d clutch pack to clutch & adj. to position M2 G3 M5 P5 X4 19 1 19
3 LH Get snap ring & place snap ring to clutch M4 G3 M4 P5 16 1 16
RH Get screw driver & place snap ring to clutch M4 G1 M4 P5 14
4 Secure snap ring to position using screw driver M2 G1 M3 P2 8 2 16
5 Get thrus bearing and install to clutch M5 G3 M5 P2 15 1 15
6 Press accept button to release pallet M5 G0 M1 P0 6 1 6
Total MOD's 93
Seconds 11.9970
MODAPTS ANALYSIS
OPERATION: Sta. 1518
Install Reaction Plate, Snap Ring and Preposition of O/D Hub Date: 11/08/11
I.E. Mary Chen
No. Task Description Code MOD's Freq Total
1 Select reaction plate & place to verifier M4 G3 M4 P2 13 1 13
2 Press button & see green light to accept plate M4 G0 M1 P0 E2 7 1 7
3 LH Assemble reaction plate to clutch M2 G1 M5 P5 13 1 13
4 RH Get snap ring and position reaction plate M4 G3 M3 P5 15 1 15
5 Install snap ring M1 G1 J2 M2 P5 11 1 11
6 Secure snap ring to position using screw driver M2 G1 M3 P2 8 2 16
7 Get U/D Hub & install to nest M5 G1 M5 P5 13 1 13
8 Press accept button to release pallet M5 G0 M1 P0 6 1 6
Total MOD's 94
Seconds 12.1260
OPERATION: Phase 1 St 20 with kitting running 20,23, 28 DEPT: ST: Date: 11/7/11
N/A
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 Get (1) washer in Left Hand M4 G3 7 1 7
2 Get grease gun; squirt 2 X M3 P2 M3 P2 P0 10 1 10
3 Place washer to shaft M3 P2 5 1 5
4 Get (1) washer with right hand M4 G3 7 1 7
5 Place washer to underdrive M3 P5 8 1 8
6 Get over drive and place to clutch. M2 G1 M2 G1 M3 P2 11 1 11
7 Press accept button. M3 G0 3 1 3
8
9
Total MOD's 51
Seconds 6.5790
9110 20
Code
MODAPTS ANALYSIS
OPERATION: Phase 1 St 23; no shuffling of disks (pre-kitted)running 20,23, 28DEPT: ST: Date: 11/7/11
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 Press Button; Get stack (simultainiously). M4 G1 5 1 5 AA Non Value Added - Reach
2 Transfer stack left to right hand; Place stack to verifier. M3 G1 M4 P2 10 1 10 A Non Value Added - Reach
3 Visual pause to look at screen for green accept box. 24 1 24 B Non Value Added - Reach
4 Place stack to clutch M4 G1 M4 p2 11 1 11 AA Semi-Value Added
5 Shake stack into clutch. G1 M3 M3 M3 M3 M3 M3 M3 M3 25 1 25 AA Semi-Value Added
6 M3 M3 M3 9 1 9 A Value Added
7 A Semi-Value Added
Total MOD's 84
Seconds 10.8360
MODAPTS ANALYSIS
9110 21
CodeOPERATION: Phase 1 St 23; running 20,23, 28 WITH KITTING DEPT: ST: Date: 11/7/11
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 WAIT FOR PALLET 18 1 18 AA Non Value Added - Reach
2 CHECK SEATING M3 G0 M2 G0 5 1 5 A Non Value Added - Reach
3 GET PLATE TRANSFER TO OTHER HAND M3 P0 M2 G0 5 1 5 B Non Value Added - Reach
4 GET GAGE; PLACE ON CLUTCH M4 G1 M3 P2 10 1 10 AA Semi-Value Added
5 WAIT FOR MEASUREMENT 16 1 16 AA Semi-Value Added
6 PLACE PLATE TO VERIFIER M3 P2 5 1 5 A Value Added
7 WAIT FOR ACCEPT LIGHT 12 1 12 A Semi-Value Added
8 PLACE PLATE TO CLUTCH;VERIFY SEATED M4 P2 X4 10 1 10 A Semi-Value Added
9 PRESS ACCEPT BUTTON TO RELEASE PALLET M4 G0 M1 P0 5 1 5 A Non Value Added - Reach
10 1 0 AA Semi-Value Added
11 1 0 AA Value Added
Total MOD's 86
Seconds 11.0940
MODAPTS ANALYSIS
9110 23
CodeOPERATION: Phase 1 St 26; running 20,23, 28 WITH KITTING DEPT: ST: Date: 11/7/11
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 WAIT FOR PALLET 18 1 18 AA Non Value Added - Reach
2 GET (2) PLATES FROM KIT (SIMULTAINEOUSLY) M4 G1 5 1 5 A Non Value Added - Reach
3 PLACE (1) PLATE TO CLUTCH M4 P2 6 1 6 B Non Value Added - Reach
4 PLACE (1) PLATE TO CLUTCH M3 P2 5 1 5 AA Semi-Value Added
5 PRESS PALM BUTTONS TO PRESS PLATES M4 G0 4 1 4 AA Semi-Value Added
6 WAIT FOR PRESS 23 1 23 A Value Added
7 PRESS PALM BUTTONS TO ACCEPT AND RELEASE M2 G0 2 1 2 A Semi-Value Added
8 1 0 A Semi-Value Added
38
Total MOD's 63
Seconds 8.1270
MODAPTS ANALYSIS
9110 26
CodeOPERATION: Phase 1 St 28 with kitting running 20,23, 28 DEPT: ST: Date: 11/7/11
N/A
Mach Golden VA, SVA,
No. Task Description Cycle MOD's Freq Total Zone NVAA
1 Wait for pallet 19 1 19
2 Get snap ring M4 G3 7 1 7
3 Place snap ring to clutch M4 P2 6 1 6
4 Press snap ring with thumbs M2 M1 G0 X4 X4 11 1 11
5 hammer snap ring with screwdriver U2 U2 U2 6 1 6
6 pry up on snap ring M3 M3 M4 M3 M4 M3 20 1 20
7 gage 2x M3 M2 M3 M2 10 1 10
8 rotate gage in hand (juggle) J2 2 1 2
9 gage 2x M3 M2 M3 M2 10 1 10
10 Transfer gage to other hand M2 G1 3 1 3
11 gage top M3 M2 M2 M2 9 1 9
12 press button M4 G0 4 1 4
Total MOD's 107
Seconds 13.8030
MODAPTS ANALYSIS
9110 28
Code
MODAPTS ANALYSIS
OPERATION: Station 10 33
CLUTCH LINE PACK OUT Date: 11/9/11
No. Task Description Code MOD's Freq Total
Install piston, spring and retainer in clutch
Get 637 IPCH W5 M4 G1 10 1 10.0000
Put 637 IPCH on kitting basket W5 M3 P0 8 1 8.0000
Get Stamp M4 G1 5 1 5.0000
Stamp clutch pack M3 P0 3 1 3.0000
Put stamp back M4 P2 6 1 6.0000
Get finished Clutch from pallet and load on Clutch Cart M4 G1 M7 P5 W5 22
122.0000
Turn Clutch Cart 180º W5 W5 W5 W5 W5 W5 30 1/20 1.5000
Exchange Full Cart to Empty W5 5 1/2 2.5000
Total MOD's 58
Seconds 7.4820
MODAPTS studies performed by IE to determine VA, SVA,
NVAA and Unsaturation
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CHRYSLER GROUP LLCInitial Chip Chart
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CHRYSLER GROUP LLC3M Analysis
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CHRYSLER GROUP LLCRebalanced Line
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TL
TL
Seal install
Kitting
18 people
210 JPH
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CHRYSLER GROUP LLCRemoved Kitters
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TL
TL
Seal install
Kitting
14 people
206 JPH
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CHRYSLER GROUP LLCRebalanced, No Kitters
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TL
TL
Seal install
Kitting
14 people
235 JPH
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CHRYSLER GROUP LLCRebalanced, 1 Kitter
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TL
TL
Seal install
Kitting
15 people
225 JPH
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CHRYSLER GROUP LLC3M Analysis
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CHRYSLER GROUP LLCResults
Visual Line Balancing (Story problem)• Initial option: 18 people making 197 JPH = 10.9/person
• Rebalance Initial: 18 people making 210 JPH = 11.7/person
• Remove Kitting: 14 people making 206 JPH = 14.7/person
• Remove 3 Kitting: 15 people making 225 JPH = 15.0/person
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