ShiftingGears

Sharonville Transmission Plant
ShiftingGears
A Message from Tim
Each year, our country celebrates Labor Day. Labor Day, the first Monday
in September, is a creation of the labor movement and is dedicated to the
social and economic achievements of American workers. It constitutes a
yearly national tribute to the contributions workers have made to the
strength, prosperity, and well-being of our country. It began in the late
1800’s and has grown to a nationally recognized holiday. Sometimes, we
forget or overlook the purpose for some holidays so I wanted to take a
moment to say “THANK YOU” to each of you for your contributions of
labor that have helped make Ford Motor Company what it is today; a
prosperous, growing, and thriving contributor to the global economic
landscape.
ISSU E
8
Au g u st
2014
I would also like to take some time to review the 2014 Hourly Pulse Survey results. The Pulse
Survey is a voluntary, anonymous survey that measures employee satisfaction on selected topics.
The Pulse survey is administered to hourly employees every Spring and is currently being
administered to Salaried employees through September 26th. In 2014, hourly survey participation
increased by 41% (more than 900 hourly employees took the survey!) and thereby allowed
Sharonville to once again be the participation leader in the Transmission Region.
Thank you for taking the time out of your busy day to make your opinion count!
We had significant improvement in some key areas. Survey results showed that Sharonville’s areas
of strength are highlighted by the following:
This Issue
•
Safety/Health
P. 2
•
Delivery
P. 3
Cost
P. 4-5
•
•
•
People
91% of respondents feel that Company has clearly communicated to employees its values
regarding Quality.
84% of respondents stated that employees take collaborative efforts in order to complete work
assignments.
79% of respondents feel that Sharonville Management takes employee Health and Safety
seriously.
78% of respondents feel that Supervision provides employees feedback that facilitates improved
job performance.
78% of respondents feel that the Company has provided employees with an opportunity to
contribute to the Company’s business success.
P. 6-7
Thanks again for taking the time to take the survey, and we will keep working to improve.
Maintenance
P. 8
Environment
P. 9
FPS
P. 9-10
Extra Extra
P. 11-13
Lastly, please remember the upcoming Ford Family Fun Fest on Saturday, September 20th,
benefiting the Juvenile Diabetes Research Fund (JDRF). The events will include the traditional
favorites (Car and Bike shows, Corn Hole Tournament, Plant Tours and a Ford “Drive One”
opportunity) as well as a new “Kid Zone” specifically for the younger crowd to enjoy. The events
start at noon and continue until 4pm. I hope to see you there.
Have a safe Holiday!
Tim
Sharonville Transmission Plant
Safety
Why Take a Chance With Safety Risk?
Have you ever made a decision to break a safety rule? How long did it take for you to reach that decision? What did you gain by
taking a chance? It only takes a moment to decide to break a safety rule, yet that one moment could change your life forever. What is
your personal commitment to safety, and what you can do to keep that commitment strong.
Safety is ALL ABOUT YOU!
Do you always work safely? Are you 100% committed to the safety of
yourself, your coworkers, friends, and family? Are there times when your
commitment to safety is not as strong as it should be? Have you been taking
safety risks and getting away with it? Don't expect your luck to hold. No one
ever plans an accident. An accident, by definition, is an unplanned event. No
one wakes up in the morning and drives to work thinking, "I will have an
accident today so I'd better buckle up." No one ever climbs to the very top of a
ladder and knows for sure they won't fall. That's why it's so important to have
a personal commitment to safety; a commitment to do the right things to
prevent an accident--or minimize the damage done in case an accident does
occur.
What is gained by taking a safety risk? Think about a time when you've risked
your personal safety. Have you ever bypassed lockout-tagout procedures?
Have you ever driven a car after you had too much to drink? Have you failed
to use fall-protection equipment because it was just too much trouble? What
did you gain in that situation? A minute of time, an ounce of convenience?
Now honestly ask yourself if those gains were worth it. Is a little bit of time or
convenience really worth chancing electrocution, a car accident, or a bad fall?
Don't sacrifice your healthy future by taking a safety risk. Every time you're
tempted to take a chance with your safety ask yourself if it's really worth the
risk. Your family and friends will thank you for making the right decision.
Health
It’s not just the hard hat, the safety glasses and the glove;
That bring you home safe to the people you love.
The safety valve feature on the high-pressure tanks;
The cave in protection on the vertical banks.
The well installed belt guard, the safety toed shoe;
The fire extinguisher- ready to use.
The safety belts that hold you inside your car;
The road signs of safety, wherever you are.
These are mere tools, like a carpenter’s plane;
They won’t produce safety, or minimize pain.
Your Health and Safety depend upon you;
On whether you think about things that you do.
So, think before acting, make thinking a rule;
Make use of your brain….your best safety tool.
Fall Events
Blood Drive: The fall blood drive is scheduled for October 1st
from noon – 6 PM. Blood supply has been critically short in the
Cincinnati area and your help is greatly needed.
In October of 2013, 108 cases were diagnosed compared to just
23 in 2012. ALL adults should have a booster immunization for
tetanus, pertussis (whooping cough) and diphtheria. You don’t
even need to see your doctor – just go to any pharmacy to receive
Influenza Vaccine Clinics: The flu vaccine clinics are scheduled the vaccine.
for October 29th (12-6 PM) and October 30th (4-11 PM). The
scheduled times should cover all 4 AWS shifts, as well as
While you are at the pharmacy, and if you are over 60 years of
traditional 1st, 2nd, and 3rd shifts. The vaccine is FREE to any
age, you should inquire about the shingles vaccine. Shingles is a
Ford employee with any Ford-sponsored insurance. The cost is
painful skin rash caused by the chicken pox virus which can
$22 for all others.
result in a very painful and debilitating condition called the postherpetic neuralgia. The vaccine is also effective in preventing a
second episode of shingles if you had a previous occurrence.
Speaking of vaccines...there has been a 4-5 fold increase in the
number of whooping cough cases in SW Ohio in the recent past. Again, all you need to do is to go to any local pharmacy to get the
2
vaccine.
Sharonville Transmission Plant
Delivery
MP&L Inventory Basics
Ford pays for all purchased parts and raw material that comes into Sharonville, and they consider that material an asset, just as you
would consider your bank account(s) an asset.
Ford expects that Sharonville will be responsible with the inventory assets that we are given, and not only refrain from losing it, but
in fact add value to it (by our manufacturing processes) and ship it on to our customers as finished products/end items.
Any parts that do not get converted into finished parts must be accounted for in some way to balance our inventory books, just as you
would expect the bank to account for all of the money you deposit, not just some portion of it.
Ford’s corporate materials management computer system, CMMS, is used by each Ford plant to account for all of our inventory
assets. Within CMMS there are ‘accounts’ for every part we buy, make or sell. Inventory transactions within that system add or
subtract inventory from these ‘accounts’. Examples of transactions are incoming receipts of parts from a supplier, production counts,
scrap entries, quality rejects, and bar code shipping labels. Over time all of the transactions should balance, just like you would
expect the bank to balance your account statements each month.
Sometimes when the timing of our transactions happens in the wrong order or we have incorrect or missing transactions, the
inventory balances get out of synch with reality. This can lead to part shortages which could stop production. Sometimes our
inventory can go even go negative (negative inventory is an obvious red flag). The company measures us on the number of
occurrences of negative inventory balances, because it is such an obvious red flag.
To keep track of inventory, some companies do an annual physical inventory. We use a different system to prove to Ford (and
ourselves) that we are properly keeping track of the inventory assets we have been given. We use a cycle check program, to count
every part (on a rotating basis) every six months. This is somewhat similar to the bank sending you a statement monthly, quarterly or
annually to show you how they have accounted for all your money. When we are unable to account for all the inventory we should
have, the plant is charged for the missing amount. That charge is called a cycle loss. Cycle losses are by definition an unknown /
unexplained loss. In some departments, cycle losses could be greater than scrap losses. Using your bank account as a comparison to
our inventory records, you could compare scrap to an ATM fee on your bank statement. You may not like to see ATM fees on your
bank statement, but at least you know what those fees are, and you know what you need to do to not get charged with those fees.
Since cycle losses are by definition unknown losses, you could compare them to the bank being unable to explain to you what the
fees were that they subtracted from your account. You would not like that answer from the bank, and the company does not want to
hear from us that we can’t explain how we lost the parts.
Transactions out on the shop floor have a huge impact on both negative balances and cycle losses. Inaccurate, missing, or incorrect
production counts or scrap entries can cause cycle losses and negative balances which can cause down time and can cost the plant
significant financial loss.
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Sharonville Transmission Plant
Cost
Cost-Our Sharonville Transmission 2014 cost objective is to achieve $20.5 million in efficiencies, which includes recovery of our
$1.6 million miss to budget in 2013. Our base efficiency task is $18.9 million.
•
July cost performance was worse than budget by $(614) thousand. Efficiencies earned were $0.78 million at an efficiency rate
of 4.0%
⇒ This was largely due to the rust issue on 6R80 carriers $(0.4)million, cycle losses $(0.1)million and excess fluids cost due to
puck maker downtime
•
June cost performance was worse than budget by $(287) thousand. Efficiencies earned were $1.45 million at an efficiency rate
of 6.1%
⇒ This was largely due to lower than expected JPH performance on 6F/6FM component parts & end-items
•
May cost performance was worse than budget by $(263) thousand. Efficiencies earned were $1.57 million at an efficiency rate
of 6.3%
⇒ Though improved from April this was largely due to lower than expected JPH performance on 6F/6FM component parts & enditems
•
April cost performance was worse than budget by $(353) thousand. Efficiencies earned were $1.36 million at an efficiency rate
of 5.5%
⇒ This was largely due to lower than expected JPH performance on several 6-speed product end-items
•
March cost performance was better than budget by $9 thousand. Efficiencies earned were $1.38 million at an efficiency rate of
6.0%
•
February cost performance was better than budget by $18 thousand. Efficiencies earned were $1.06 million at an efficiency
rate of 4.4%
•
January cost performance came in at a $(137) thousand miss to budget. Efficiencies earned were $1.05 million at an efficiency
rate of 4.4%
⇒ This was largely due to cycle losses incurred in 2014 on balanced out parts in 2013
•
Summary: Year to date we are at a $(1.626) million miss to budget and efficiencies earned to date are $8.6 million.
Continued...
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Sharonville Transmission Plant
Cost
The Targets for August are:
⇒ Efficiencies of $1.802 million
⇒ Efficiency rate of 7.6 %
Below is the July actuals update of HPU (Hours Per Unit) performance to our July calendarized 2014 budget targets. Performance
was:
•
Green: 6R140 and FN
•
Red:
6R, 6F, 6FM and 5R110
If you have any questions regarding our performance or you have cost savings ideas for 2014 please don’t hesitate to stop by and
discuss with me.
Personal finance tip: Learn how to get out of debt and stay out of debt..…visit DaveRamsey.com
Todd C. Kraus
Controller - Finance
Sharonville Transmission Plant
2014 HPU PERFORMANCE
July Performance:
Product
6R140
5R110
FN
6R
6F
6FM
Jul
2014
Actual
3.20
3.54
1.46
0.67
1.47
0.82
Month
Budget
Jul (0+12)
2014
Target
3.35
3.42
1.43
0.66
1.42
0.78
Hours
Actual
B/(W)
Target
0.15
(0.12)
(0.03)
(0.01)
(0.05)
(0.04)
Performance
%
Actual
B/(W)
Target
4.5%
-3.5%
-2.1%
-1.5%
-3.5%
-5.1%
Rating
RGY
Green
Red
Red
Red
Red
Red
5
Sharonville Transmission Plant
Our People
Congratulations to the following individuals who
celebrated Milestone Anniversaries during
the month of August
The BIG 10!
Richard Back
Kevin Denton
James Favors
Kim Gilman
Deborah Hock
Mickey Padgett
Rachel Swanson
Bradley Weisbrodt
8.24.2004
8.24.2004
8.24.2004
8.24.2004
8.24.2004
8.24.2004
8.26.2004
8.24.2004
The BIG 15!
Robaline Brinkman
Priscilla Clay
James Cooper
Jeffery Curlington
Charles Dickerson
8.2.1999
8.16.1999
8.2.1999
8.16.1999
8.16.1999
Eddie Duvall
Ryan Enslen
Damon Fishback
Eric Gadd
Kimberly Green
Jamie Kuntz
Michael Lang
Jeremy Mullins
Terrance Prince
Paul Roberts
Danny Russell
Thomas Schappacher
Jeffrey Shiveley
Michael Short
David Snell
Ty Troxell
Carol Vaughn
Stanley Willis
8.30.1999
8.2.1999
8.2.1999
8.16.1999
8.16.1999
8.16.1999
8.16.1999
8.16.1999
8.2.1999
8.16.1999
8.16.1999
8.2.1999
8.2.1999
8.2.1999
8.2.1999
8.2.1999
8.2.1999
8.23.1999
Continued...
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Sharonville Transmission Plant
Our People
August Anniversaries cont’d...
Thank You for your Years of Service!
25
The BIG 20!
Ronald Rankin
Brenda Roberts
Terrence Sheets
8.1.1994
8.1.1994
8.11.1994
The BIG 25!
Kevin Pelko
8.15.1989
The BIG 30!
Anthony Kraft
8.13.1984
Pictured Above: Kevin Pelko was recognized for 25 years of
service. Congratulations!
A Tuskegee Airman and Father Remembered
It was the summer of ’04’ when The Tuskegee Airmen paid STP
a visit. One TA in particular was James Madaris Sr., whose son,
Daryl Madaris, was at the time and still is employed here at
Sharonville. While James spoke to crews throughout the plant,
Daryl was working Caseline at the time, steps from his father’s
speech but was unable to catch the words his father spoke until
his speech came to an end.
James Madaris Sr., was a Mechanic with The Tuskegee Airmen
and began his service in 1938 and served in Africa, Italy,
Germany and Sicily until 1944. On that day back in the summer
of ‘04’, a photograph was taken of James. Its whereabouts
became unknown and left Daryl to wonder where it had gone. In a team meeting on the morning of
Friday, August 15th, an unexpected surprise came from Addie Bonner, who has run the STP
cafeteria for 15 years, and was present during the visit. While randomly looking for paper work in
her attic, Addie came across the picture of Daryl’s father. The mystery of the missing photograph
was finally unraveled. In the team meeting, Daryl was presented with the framed photograph of his
father here at STP that summer, along with a cake paying tribute to James Madaris Sr.
Unfortunately, James Madaris Sr. passed away the December following his visit, but his presence will clearly be remembered and
Daryl now possesses that memory of his father. A big thank you to all who made this special event transpire.
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Sharonville Transmission Plant
Maintenance
from the FTPM Office…
It has been four years since Maximo for Maintenance (MFM) launched at Sharonville. There was a learning curve due to its
increased level of complexity compared to the previous maintenance program that had been in use here, but the benefits of MFM far
out-weigh those of its predecessor.
Maximo Reports
The customization of queries and reporting has allowed us to make data mining a much simpler process. Did you know that Maximo
has the ability to send information straight from its database tables to any user that has a company email address? This feature allows
preformatted information to be sent to users on a routine or scheduled basis; enabling the information they want to be at their
‘fingertips’ to review or share with others.
One way that this is information is practical is for use in Work Group team meetings. Throughout each week, scheduled maintenance
(PM) is performed on specific equipment within each department. However, with the advent of alternative work schedules, not
everyone in each team is aware of such maintenance. A completed PM report for each department assists in communicating what
scheduled maintenance was completed during the previous 1-2 weeks (depending on the work schedule). Searching for this
information takes time, but preformatted reports that are emailed to the department leadership make the data accessible quickly,
easily, and automatically. The reports arrive in their email as scheduled. They can be printed, distributed, and discussed.
Every Monday morning since the beginning of June 2014, Maximo has been scheduled to send PM completion information reports to
the company email accounts of Zone and department leadership, including Team Managers, Process Coaches, Work Group Team
Leaders, and Skilled Trade Team Leaders. Each report is specific to the department assigned to the leadership, and the information is
ready for communication during team meetings.
The intent: discuss and review completed scheduled maintenance, and ensure that team members understand and are aware of the
maintenance performed, even when they are not present. The assigned skilled trade representative is to come to each meeting with
this information (provided by the Work Group or Skilled Trade Team Leader beforehand) and review its contents. Feedback should
be documented in the meeting minutes and forwarded to the assigned Skilled Trade Team Leader for review and for PM updates/
modification as necessary. This is a small sample of what Maximo can do.
Over the course of the next few months, look for more benefits of Maximo for Maintenance to be highlighted in this column.
Brian E. Sturm
Sharonville FTPM – x7846
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Sharonville Transmission Plant
Environment
EnvironmentOver the past 4 years, STP has made a great deal of inroads in recycling oil for reuse by the plant. Wringing of wet chips from
broaching operations beginning in 2010 saved the plant 14,000 gallons ($140,000) per year in the purchase of new oil. Extrusion of
machining mud from operations in Depts. 877, 676 and 577 has yielded an additional 30,000 gallons plus of oil for reuse by plant,
and efforts to reclaim oil from mist collector ductwork throughout the plant has also yielded good results. As a result, STP has
reduced its oil usage 1,500,000 lbs. since the end of 2009, even though the plant has increased production over 40%.
Great job to all involved these past 4 years!
FPS...
CROL – Changing Role of the Leader
Shown below is the CROL attendance by zone through July. Congratulations to East 3 – Department 096/196 for 100% attendance
since February. Keep it going.
Jan
42%
30%
71%
46%
40%
61%
35%
44%
50%
43%
5%
16%
Feb
85%
100%
100%
100%
63%
61%
36%
58%
38%
37%
60%
31%
Plant Total
42%
56%
March
Data not Available
Zone
West 5
East 3
West 2
Central 2
Gear 3
Heat Treat 1
Gear 1
Gear 2
Gear 4
Quality
Engineering
MPL
April
49%
100%
72%
69%
60%
61%
43%
52%
61%
19%
48%
39%
May
30%
100%
74%
69%
38%
39%
35%
39%
52%
31%
40%
5%
June
60%
100%
79%
76%
44%
86%
34%
47%
44%
23%
33%
31%
July
41%
100%
78%
82%
44%
54%
32%
38%
39%
9%
31%
65%
53%
41%
49%
45%
Global Ford Production System Implementation
Last month we turned out attention to the Global FPS boards that are located throughout the plant. We reviewed the CI Continuous
Improvement Board. The purpose of the board is to house escalated issues from the Work Groups, Process Coaches and Team
Managers. A card (Red or Yellow) is issued to the appropriate responsible department or area by the Production Area Manager. A
daily meeting (Mt 104) is held by the Area Managers to review the status of each card.
This month we will review Process Confirmation-T Card
The purpose of Process Confirmation is to confirm adherence to standards through the identification of abnormalities to the process
and standards. It promotes stability and facilitates continuous Improvement. The process asks three basic questions:
• Is there a standard?
• Is the standard being followed, is it understood?
• Is the standard sufficient? Are we getting the results we expect? Can the standard be improved?
Continued...
9
Sharonville Transmission Plant
FPS
Process Confirmation-T Card cont’d...
There is a Roll Up Matrix located next to the T Card boards for
recording Red items that cannot be resolved during the shift. In
addition to the Team Leader T Card boards, there are Leadership
T Card boards, which are mounted on the Zone boards (we will
review Zone boards in the future). Leadership T Card boards
contain one type of T Card one for each Team Leader in the
Zone. Both Team Leader and Leadership T Cards are very
At the start of each month, Team Leaders shuffle their cards and similar. Team Leader cards focus on specific SQDCPME
place them in the left side blue holder by scheduled working day requirements like the one shown below (left) for Monday
for that month. When they have completed Process Confirmation, confirming that there are no Slips and Trip hazards compared to
they place the card in the right blue holder indicating completion. the Leadership card on the right looking for Slip and Trip
hazards. Leadership T Cards look at the health of the SQDCPME
Operating systems while the Team Leader cards ensure they are
The cards contain specific Safety, Quality, Delivery, Cost,
in place.
People, Maintenance, and Environment (SQDCPME)
requirements/standards laid out by the day of the week (Monday
– Sunday) that must be in place on that operation. When
requirements do not meet the standard, the Team Leader
indicates this by turning the T Card Red dot side out and Green
dot side out, if in compliance.
How does Process Confirmation work? Each Team Leader in the
plant has a Process Confirmation (or T Card) board. The board
has the days of the month labeled between 2 blue T Card holders.
Team Leader T Cards exist for each operation in the department
and for general areas like cribs, storage areas and market places.
Pictured below is a photo of a Team Leader T Card showing both
sides and a photo of a Process Confirmation board.
Cards are linked
Next month we will review Process Verification which is performed by the operator.
For questions about Global FPS, please contact me.
Martha Mehl
Plant GFPS Facilitator – x7393
10
Sharonville Transmission Plant
Extra Extra...
Electrical Vehicle Charging Stations are Coming to STP
STP will be installing two EV charging stations during the month of October. They will be installed
by the 15th of the month and will be located in the corner of Lot D.
The EV charging stations are available to all full time, part-time, supplemental and agency employees.
The stations may be used to charge only Ford-manufactured vehicles.
Charging Station Fees
After registration is completed, the Ford private network will be provided free-of-charge for the first
four (4) hours that the vehicle is connected. After four hours, a $1/hour fee will be assessed to the
employee. This is designed to encourage drivers to move their vehicles and allow other EV drivers the
opportunity to charge their vehicles. The payment structure may be modified in the future.
Station Usage Etiquette and Safety
All users for the Ford network stations are expected to be courteous to others and follow these simple rules:
•
Monitor your EV charging and move the vehicle from the charging station soon after charging is complete. This will provide
access to others waiting to use the station.
•
Do not park in the station with a non-EV or with your EV vehicle disconnected.
•
When charging, do not leave excess charging cord lying where others may trip or drive over it. Please tuck the cord under your
vehicle.
•
When finished charging, please neatly rewind the charging cord or retract the cord on to the holder. Leaving the cord on the
ground may become a tripping hazard, is impolite to the next user, and may damage or cause faulty or in-operable equipment.
•
Only use stations designated and marked as employee EV charging stations. Stations marked for Product Development use are
not available for employee use.
Policy Violations
All EV charging is subject to audit. Failure to comply with the guidelines set forth in this policy may result in the loss of Ford
Network electric vehicle charging privileges, restitution for unauthorized expenses, and/or other disciplinary action.
Electric Vehicle Charging Station Program Disclosure
The Company reserves the right to disable charge access for employers that do not comply with the program
guidelines and to modify any part of this policy, including pricing, at any time without notice.
11
Sharonville Transmission Plant
Extra Extra...
12
Sharonville Transmission Plant
Extra Extra
13