Locker Presentation

PPE/5S Locker Internship Project

By: Christian Rupe

WCM

World Class Manufacturing

WO

About ProjectOrganize and clean out all PPE lockersLockers are to be maintained by 5s and WO standardsEach shelf is labeled, taped, and assignedEach locker will look the same based on the Team 13 modelBudgets will be set up for each team based on PPE needs

Will not be unlimited; will be reduced and cost savings will be achieved based on establishing PPE budget of $250 per week ($500 Biweekly)

Checklist will be implemented eventually. BUL’s will walk through once per week to make sure TL’s are sustaining their

lockersOPL’s will be created for lockers showing how they should not

look and how they should look

Team 13 Beverly BrownBeverly’s locker was used as a model for each team to go by

Before After

Overcrowding

Unorganized

No Labels

Very Organized

Divided up by size and NPM

number

Everything has a location

Each shelf has its own PPE pictures and labels based on NPM number

PPE Quantity Lists and Budget Lists:Each one of these are posted on the inside right door of each

locker based on that teams needsBudgeting List Team 13 Beverly Brown

Gloves Price Per Pair Price Per Bundle Min/Max (Pairs)

78-175-4821 $3.97 $47.64 12/24

78-175-4823 $3.97 $47.64 12/24

78-175-4825 $3.97 $47.64 12/36

78-175-4827 $3.97 $47.64 12/24

78-175-4830 $3.50 $42.00 12/24

78-100-0290 $0.70 $8.40 12/24

Total: $20.08 $240.96

Sleeves Price Per Sleeve Price Per Pair - Min/Max Min/Max (Pairs)

78-370-1530 $3.25 $6.50 - $65.00/$162.5 10/25

78-370-4744 $5.25 $10.50 - $52.50/$157.50 5/15

78-370-4747 $5.25 $10.50 - $42.00/$105.00 4/10

Total: $13.75 $27.50

Aprons Price Per Apron Price Per Max Min/Max

78-010-0215 $2.50 $12.50 2/5

Ear Plugs Price Per Box Price Per Max Min/Max

78-315-6171 $0.06 $0.12 1/2

Safety Glasses Price Per Pair Price Per Max Min/Max

78-385-0620 $0.62 $1.86 2/3

Total: $282.94

Estimated Weekly Budget: $300.00

Weekly: Biweekly: Monthly: Annually:

$282.94 $565.88 $1,131.76 $13,581.12

Weekly: Biweekly: Monthly: Annually:

$300.00 $600.00 $1,200.00 $14,400.00

*Subject to Change

PPE List Team 13 --- BEVERLY BROWN

NPM Number Type of Glove Size Quantity per Week (Pairs)

78-100-0290 White Cotton 10 6

78-175-4821 Hy-Flex 7 4

78-175-4823 Hy-Flex 8 6

78-175-4825 Hy-Flex 9 10

78-175-4827 Hy-Flex 10 8

78-175-4830 Kevlar Black Dot Large 2

Total per Week 36

NPM Number Type of Sleeve Size Quantity per Week

78-370-1530 Yellow Kevlar Standard 20

78-370-4744 Green M 8

78-370-4747 Green XL 4

Total per Week 32

NPM Number Type of Apron Size Quantity per Week

78-010-0215 Denum Full Standard 4

NPM Number Type of PPE Size Quantity per Week

78-385-0620 Safety Glasses Standard 2

NPM Number Type of PPE Size Quantity per Week

78-315-6171 Ear Plugs Standard 1

*Subject to Change

Saving Money

Cost Comparison & Cost Savings

Brown, Beverly $1,461.91

Fox, Paul $6,245.53

Gibson, William $8,518.65

Jomaa, Hayle $4,138.14

Schmidt, Keith $11,150.79

Umbrell, Mike $12,672.74

Willinger, Mark $9,954.20

Total $54,140.17

Six Month Sum Total Spending Comparison

Brown, Beverly $6,790.56

Fox, Paul $3,972.96

Gibson, William $4,876.32

Jomma, Hayle $4,800.00

Schmidt, Keith $6,790.56

Umbrell, Mike $6,261.60

Willinger, Mike $8,400.00

Total $41,892.00

Six Month Annually$0.00

$10,000.00

$20,000.00

$30,000.00

$40,000.00

$50,000.00

$60,000.00

$70,000.00

$80,000.00

$90,000.00

$100,000.00

$110,000.00

$120,000.00

$41,892.00

$83,784.00

$54,140.17

$108,280.34

Savings Visual Comparison

$108,280.34 $83,784.00

Annual Savings of:

$24,496.34 23%

-______CD Certified

Kaizens

Budgets No. 56714

CD Certified

Focused Improvement Page 12

CHRYSLER GROUP LLCPlan

Team leaders have unlimited access and spending on PPE and other items

Money is being wasted because team leaders do not keep track of their own spending

Unlimited budgets give team leaders freedom to spend money on anything they want

Resulting in overspending, wasted money, and overcrowding of supplies

BROWN BEVERLY $1,461.91

FOX PAUL $6,245.53

GIBSON WILLIAM $8,518.65

JOMAA HAYEL $4,138.14

SCHMIDT KEITH $11,150.79

UMBRELL MICHAEL $12,672.74

WILLINGER MARK $9,954.20

GRAND TOTAL $54,140.17


CHRYSLER GROUP LLCDO

Create budget limit for each team leader based on current and future estimated spending

Each team leader will receive a maximum budget of about $250 per week that should be used for PPE and team purposes only

Whatever money is not used is money that isn't spent. This non spent money could be presented as a cost savings over a course of a year

Team Leader: Budget:William Gibson $250.00

Mark Cieniewski $250.00Martin Salas $250.00Hayle Jomaa $250.00Mike Umbrell $300.00Dennis Miller $250.00

Floyd Hollingshead $250.00Rob Majerowski $300.00

John Moore $200.00Paul Fox $250.00

Linda Cochran $250.00Keith Schmidt $300.00

Arnold Moreno$300.00

Beverly BrownMark Willinger $250.00


CHRYSLER GROUP LLC

CHECK

Based on the 6 team leaders that have TMS access as of right now*Over a 6 month & yearly spending period

Current: $54,140.17 ~ 6 mo. x 2 = $108,280.34 avg. per yr.

Future: $41,892.00 ~ 6 mo. x 2 = $83,784.00 avg. per yr.

$108,280.34 - $83,784.00 = $24,496.34 savings in 1 calendar year

($24,496.00 / $108,280.34) = 0.226 = 23% based on budgets


CHRYSLER GROUP LLCACT

Read AcrossIf all 15 team leaders have/had TMS access

*Over a 6 month & yearly spending period

15/6 = 2.5 NR$108,280.34 (6 TL’s) per yr. x 2.5 = $270,700.85 per yr.

$83,784.00 (6 TL’s) per yr. x 2.5 = $209,460.00 per yr.

$270,700.85 - $209,460.00 = $61,240.85 savings in 1 calendar yr.

($61,240.85 / $270,700.85) = 0.2256 = 23% savings based on budgets

Organization Time Reduction No. 56713

CD Certified


CHRYSLER GROUP LLCPlan

Team lockers are hard to maintain. Organization becomes difficult to keep up because of overcrowding.

Becomes costly for team leaders to check and reorganize lockers every day.

Team members throw PPE in locker for team leaders to organize every day based on WO/5S standards

Money that is spent for team leaders to organize lockers could be spent elsewhere such as writing suggestions and kaizens


CHRYSLER GROUP LLCDO

A checking/audit system will be put in place for each unit leader to make sure that team leader lockers are kept up to standards

Unit leader will audit the locker at least once or twice per week

Team leader would organize locker in the same time span (once per week) for about 10 minutes

WO/5T/5S locker would reduce organization time from 20 min down to 10 min


CHRYSLER GROUP LLC

CHECK

Current Organization Time:1 Day: 20 min per day x 7 day/wk = 140 x 52 wk/yr = 7280 min/yr(7280 min/yr) / (60 min/hr) = 121.33 hours per year

Future Organization Time:1 Day: 10 min per day x 2 day/wk = 20 x 52 wk/yr = 1040 min/yr

(1040 min/yr) / (60 min/hr) = 17.33 hours per year

121.33 hr/yr x $29.00 = $3518.57 per yr

17.33 hr/yr x $29.00 = $502.57 per yr

$3518.57 - $502.57 = $3016 savings per 1 calendar year


CHRYSLER GROUP LLCACT

Read Across to all 16 teams in BIW

Current: 7280 min/yr x 16 = (116,480 min/yr) / (60 min/hr) = 1941.331941.33 hr/yr x $29.00 = $56,598.57 per yr

Future: 1040 min/yr x 16 = (16,640 min/yr) / (60 min/hr) = 277.33277.33 hr/yr x $29.00 = $8042.57 per yr

$56,598.57 - $8042.57 = $48,256.00 savings per 1 calendar year

($48,256.00 / $56,298.57) = 0.857 =

86% savings based on time reduction

Other Locker Examples

Dennis Miller

Mike Umbrell

Mark Cieniewski

Linda Cochran

Red Gibson

Ways to Sustain Project

Weekly Check/Audit System

Unit leaders will check team lockers once per week according the weekly checklist provided for them Unit leaders must check for; organization (are the lockers being kept up to standard, is

everything in their place, are personal items put in other places besides PPE locker, is it neat overall), budgets being maintained (are they going over their weekly spending limit), and if min & max levels are being met (should not be over their locker limit based off of document)

Unit leaders will mark down “Y” meaning yes or “N” meaning no if any of the requirements are not met If any of the columns receive an “N” then they fail their weekly check

This is a standard that must be met and kept up on a weekly basis

Each examination should last about 10 minutes per locker If the locker is not organized or if personal/excess items are stored in, the TL

must spend time in front of the UL taking them outUL must report out weekly audit to the BUL

Weekly Check

Locker Presentation

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