Heather R Nacke Industrial Engineering Manager Kokomo Transmission Plant September 25, 2012 Logansport, IN Teacher Enrichment Program.

Heather R NackeIndustrial Engineering ManagerKokomo Transmission Plant

September 25, 2012 Logansport, IN

Teacher Enrichment Program

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

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

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

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

CHRYSLER GROUP LLCProblem Solution

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-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))

CHRYSLER GROUP LLCProblem Solution

9



-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))

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

CHRYSLER GROUP LLCInitial Line Layout

197 JPH

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


CLUTCH LINE PACK OUT Date: 11/9/11

Task Description Code MOD's Freq Total


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



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


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


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



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



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




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




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



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


CLUTCH LINE PACK OUT Date: 11/9/11



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

CHRYSLER GROUP LLCInitial Chip Chart

CHRYSLER GROUP LLC3M Analysis

CHRYSLER GROUP LLCRebalanced Line

TL

TL

Seal install

Kitting

18 people

210 JPH

CHRYSLER GROUP LLCRemoved Kitters

TL

TL

Seal install

Kitting

14 people

206 JPH

CHRYSLER GROUP LLCRebalanced, No Kitters

TL

TL

Seal install

Kitting

14 people

235 JPH

CHRYSLER GROUP LLCRebalanced, 1 Kitter

TL

TL

Seal install

Kitting

15 people

225 JPH

CHRYSLER GROUP LLC3M Analysis

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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Heather R Nacke Industrial Engineering Manager Kokomo Transmission Plant September 25, 2012 Logansport, IN Teacher Enrichment Program.

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