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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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Presentation on theme: "Heather R Nacke Industrial Engineering Manager Kokomo Transmission Plant September 25, 2012 Logansport, IN Teacher Enrichment Program."— Presentation transcript:

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

2 CHRYSLER GROUP LLC My 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 Manager 2

3 CHRYSLER GROUP LLC Current 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 6 th 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 3

4 CHRYSLER GROUP LLC Training / 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

5 CHRYSLER GROUP LLC Class 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 5

6 CHRYSLER GROUP LLC The 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) 6 Do the same output with less labor or do more output with the same labor

7 CHRYSLER GROUP LLC Most 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 time I assume 92% throughput (scrap, rework, downtime) What is the cycle time in final assembly? Min/Unit (& Sec/Unit) 7 Annual Capacity450,000Units (Good) ST Days294Days Crews/Day2 Throughput %92% Hours/Crew:9.083Hours/Crew Avail Minutes600 -Breaks (Assy)50 -T/L Meeting5 Total Run Minutes545Minutes/Crew

8 CHRYSLER GROUP LLC Problem Solution 8 Annual Capacity450,000Units (Good) ST Days294Days Crews/Day2 Throughput %92% Hours/Crew:9.083Hours/Crew Avail Minutes600 -Breaks (Assy)50 -T/L Meeting5 Total Run Minutes545Minutes/Crew Solve for Minutes/Unit & Seconds/Unit: Units/Day = 1,530.7Net Good(450,000 units/294 days) Required Daily Production 1,663.9Units/Day(1,530.7 (good units/day)/92% thruput) Required Units/Crew 832.0Units/Crew(1,663.9 (units/day)/2 (crews/day)) Required Hours/Unit 0.0109Hours/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))

9 CHRYSLER GROUP LLC Problem Solution 9 Annual Capacity450,000Units (Good) ST Days294Days Crews/Day2 Throughput %92% Hours/Crew:9.083Hours/Crew Avail Minutes600 -Breaks (Assy)50 -T/L Meeting5 Total Run Minutes545Minutes/Crew Solve for Minutes/Unit & Seconds/Unit: Units/Day = 1,530.7Net Good(450,000 units/294 days) Required Daily Production 1,663.9Units/Day(1,530.7 (good units/day)/92% thruput) Required Units/Crew 832.0Units/Crew(1,663.9 (units/day)/2 (crews/day)) Required Hours/Unit 0.0109Hours/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))

10 CHRYSLER GROUP LLC Interesting 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 10

11 CHRYSLER GROUP LLC Team 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

12 CHRYSLER GROUP LLC Initial Line Layout 197 JPH

13 CHRYSLER GROUP LLC MODAPTS studies performed by IE to determine VA, SVA, NVAA and Unsaturation

14 CHRYSLER GROUP LLC Initial Chip Chart

15 CHRYSLER GROUP LLC 3M Analysis

16 CHRYSLER GROUP LLC Rebalanced Line

17 TL Seal install Kitting 18 people 210 JPH

18 CHRYSLER GROUP LLC Removed Kitters

19 TL Seal install Kitting 14 people 206 JPH

20 CHRYSLER GROUP LLC Rebalanced, No Kitters

21 TL Seal install Kitting 14 people 235 JPH

22 CHRYSLER GROUP LLC Rebalanced, 1 Kitter

23 TL Seal install Kitting 15 people 225 JPH

24 CHRYSLER GROUP LLC 3M Analysis

25 CHRYSLER GROUP LLC Results 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 25


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