ShiftingGears

Sharonville Transmission Plant
ShiftingGears
A Message from Tim
National Safety Council Safety Survey Update
In August, I communicated the results of the National Safety Council Survey.
ISSU E
Overall, the 1376 employees who completed the survey responded favorably;
3
in fact nearly 90% of the questions were answered with a 50% or better
positive response.
Ma r ch
2014
Plant Leadership has consistently emphasized that Sharonville Transmission
strives to be the ‘Best in the World’ at what we do and when we benchmarked
our survey results against other leading companies, the data reflected a need
for improvement in many key areas. Since the survey, several actions have
taken place that aim to make improvements in those areas.
A Joint team was created and tasked to improve the 10 lowest rated questions on the survey. The first
action taken by the Joint Team was to gather direct input from employees across all shifts and crews
through focus groups. Employee contributions through these meetings significantly strengthened the
initiative and directly impacted the action items that are currently being implemented.
For example, employees’ specific comments led us to initiatives including:
This Issue
Safety
P. 2-4
Quality
P. 5
Delivery
P. 6
•
Improved cross-shift communication
•
Weekly safety walks by plant management and Health & Safety Rep
•
Improved issue escalation process
•
Reinforcement of the Near Miss process
•
Ergonomic audits of material handling work stations
The Joint Team is also reviewing a proposed method of recognition for teams that model performance to
safety standards. Another initiative under development is a process to more broadly communicate
Preventative Maintenance Operations and Corrective Maintenance actions.
On Monday March 25th, UAW International Representative Robb Miller and Corporate Safety Engineer
Sandy Kiers will be coming to Sharonville to review our action plans as well as tour the plant and to see
the progress we have made as a team.
Cost
P. 7
People
P. 8-9
Environment
P. 10
to Go Further, safely.
FPS
P. 10-11
Tim Boes
Thank you for your on-going contribution to initiatives dedicated to the Health and Safety of all
employees. Safety remains a priority at Sharonville Transmission and we will continue to work together
Sharonville Transmission Plant
Safety...
Near-Miss/Take Action Explained
Q. What is a Near-Miss/Take Action?
A. The "Near-Miss/Take Action" concept is simply a coordinated hazard spotting or risk observation
process where employees can actively participate in the identification, control and "self correction"
of those situations that might result in a harmful event. The emphasis of this program is for anyone to
identify and correct those conditions/acts within the team.
It's a little card that says, I noticed a potential for someone to get hurt and I did something about it; I took action.
On the Type of Issue portion of the card, you can categorize your observation by checking either Near Miss or Unsafe Condition
and then provide a brief description of the issue. When you're dealing with a Near Miss or Unsafe Condition, there is no space to
identify who's involved because it's not about blame; it's simply about taking care of your brother or sister. This Near-Miss is ANY
safety hazard or ANY unsafe act you or your co-worker may do.
On the Suggestions to Correct the Issue portion of the card you input your specific action taken to address what you have identified.
For example, in the case of a Near Miss; it might be as simple as catching yourself in a shortcut and righting your course of action.
So wouldn't it be beneficial if our brothers and sisters were willing to speak up when we put ourselves in harms way?
In the case of an Unsafe Condition it might require a little more time and work. The card is designed so you can document what
you've done to control the risk or where the necessary action needs to come from. For example, if the hazard control requires
maintenance support, the issue can be loaded into the Maximo for Maintenance system (MFM). Take note that any corrective
action requiring special licenses, certifications, etc… must only be performed by the appropriate employee.
Why
Q. Why should I make the effort to participate in the Near-Miss/Take Action process?
A. Because safety is truly everybody's responsibility, we all have an interest and if we leave the identification and correction of
hazards to a few select people then we will never be as efficient as we could be if everyone works together. If the entire
workforce is finding and correcting hazards or risk factors before harmful events can occur, we can realize our mutual goal of a
zero injury workplace.
Who
Q. Who can submit a Near-Miss/Take Action card?
A. Anybody; all employees should participate. Only by working together can we ensure safety in our workplace.
Q. Who do I give the card to?
A. Your work team will decide how to collect the cards.
Q. Who will review the cards and who will discuss them?
A. Each week your Team Leader or Process Coach will review all of your Team's cards, summarize them, and discuss them with
the Team.
Continued...
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Sharonville Transmission Plant
Safety
Near-Miss/Take Action Explained continued...
When
Q. When should I use the Near-Miss/Take Action process?
A. Ideally, you should initiate the process every time you notice something that could lead to a possible harmful event. This is in
line with the zero tolerance or 100% compliance mind set that means, "I won't ignore or look away" but instead, "I commit to
take action in order to protect my brother or sister".
The process aims to focus on the smaller incidental safety improvement opportunities that would otherwise be forgotten by the
customary safety concern resolution process. But that said, the Near-Miss/Take Action cards can be used to initiate any of our
customary corrective action processes.
Where
Q. Where can I use the Near-Miss/Take Action process?
A. Anywhere, in the plant, office, or parking lot; anywhere your work may bring you. If together we can create a culture where all of
us are quick to point out hazards and talk about safety in a non-threatening manner, then together we can reduce risk factors that
cause harmful events.
However, no matter where you identify a Near-Miss and Take Action you need to turn the card back into your team
area, or you can submit the information using our on-line Near Miss reporting process. You can remain anonymous with
both processes but the added benefit of the on-line action is that it will generate an email to Leadership and both UAW
and Plant Safety departments. You can get to the on-line procedure through the local Sharonville webpage by clicking
on the below icon.
By using this process your team can grow by understanding what was identified as a Near-Miss and what Correction
was taken.
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Sharonville Transmission Plant
Health and Travel
Drug Addiction Awareness and Education
The recent death of the actor, Philip Seymour Hoffman, has highlighted the gravity in this
country of the continuing epidemic of drug addiction, and in particular, heroin addiction. The
US Centers for Disease Control have estimated that the rate of drug overdose deaths has tripled
from 4 per 100,000 population in 1990 to 12 per 100,000 in 2008. (http://www.cdc.gov/
homeandrecreationalsafety/rxbrief/) Approximately 38,000 overdose deaths have occurred in
2010, 75% of which may have been caused by opioids, including heroin.
UAW-Ford ESSP has collected a number of fact sheets on drug addiction and they are being
broadcasted on STP’s television monitors. In addition to these resources, a short educational
video can be accessed on the Sharonville Plant Facebook page.
As always, please do not hesitate to contact Mr. Jeremy Gordon (UAW-Hourly-ESSP, x7277)
or Dr. John Lin (Ford-Salary-ESSP) for additional information. Any inquiry will be kept
strictly confidential.
Expectant and Nursing Mothers-Did you Know….
STP provides a lactation site for nursing mothers. Located in the plant hospital, there is a private area dedicated to nursing mothers,
with access to a Madela Classic pump, along with a dedicated refrigerator for storage. In addition to a sign-up sheet and posted
procedures, nurses are available to assist with any questions you may have regarding this.
Used Insulin Syringes and Needles
Used insulin syringes and needles should not be discarded within the Plant, but rather taken home for proper disposal.
Waste management companies, including Rumpke, will generally accept used insulin syringes and needles for disposal if they are
placed in secure and sturdy containers, such as coffee cans with lids and capped detergent bottles. The containers must also be
clearly labelled as “SHARPS” or “INSULIN SYRINGES.” Please contact your municipal waste management company for any
differences in local regulations regarding biohazard disposal.
Plant Medical can provide you with a clean environment for insulin injections. If refrigeration is needed for your insulin supplies,
they can be stored in the Plant Medical refrigerator. Supplies such as alcohol pads and band-aids may also be supplied, but Plant
Medical will not provide syringes and needles for personal use. Please call Dr. Lin (x7535) if you have any questions.
Chikungunya Fever
As spring approaches, some, if not all of us, are looking forward to vacationing in the sun during spring break. For those of you who
may be traveling to warmer climates outside the states, there is an illness to be aware of called Chikungunya fever, which is
sweeping across Central American and Caribbean countries. Chikungunya fever is an illness caused by a virus, an Alphavirus,
transmitted by mosquito bites. It is often mistaken for dengue fever. Since December 2013, an epidemic has emerged with
approximately 10, 000 cases and 3 deaths having been identified in the following countries and islands: St. Maarten, Martinique, St.
Barthelemy, Guadaloupe, British Virgin Islands, Dominica, Anguilla, French Guyana, St. Kitts, Nevis, Yucatan as well as sections
of southern Mexico.
The illness is usually not fatal. Care is based on symptoms and there is no specific treatment for Chikunguya fever. Prevention of
mosquito bites is key – use insect repellents and protective clothing and stay in screened-in areas.
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For more information: http://www.cdc.gov/chikungunya/
Sharonville Transmission Plant
Quality
STP Awarded 2013 North American President’s Quality Award (NAPQA)
Pictured L to R: Mark Bender, Darrell Gildea, Jeremy Cornett, Rudy Schuh, Wes Malott, Byron Oliver, Mark Smearsoll, Jeremy Gordon, Kevin
Hogberg, Eric Gadd, Gene Warman, Greg Banks, Dave Mason, Rick Lawwill, Tim Boes, Steve Meisman, Rob Ralston, John Orlando, Ken
Taylor, Jo-Anne Neal-McKinnon, Alex Maciag, Mike Schulhoff and Denis Barry.
For the second year in a row, and the 5th time in eight years, the Sharonville Transmission Plant was recently recognized in a
company-wide presentation of the 2013 North American President’s Quality Awards. During the week of March 10th, the
Sharonville team was named as North America’s “Best Powertrain Transmission Plant” for the 2013 calendar year.
Led by the record-setting warranty performance of the 6R140 transmission in the SuperDuty vehicle, the plant’s field and vehicle
assembly plant customer quality metrics qualified the Sharonville team for this recognition.
on March 13th, Alex Maciag, Automatic Transmission Operations Manufacturing Director, presented the NAPQA Award to Tim
Boes, Dave Mason, and the plant leadership team in recognition of the great accomplishment.
Congratulations to each and every employee at Sharonville, for everything that you do each day to support delivery of high quality
transmission and gear products to our global customer base.
F DR
What does that Acronym Stand for?
ROS
ETV
OCM
DOS
Welcome to Ford Speak-Ford Speak is an unofficial database of the acronyms, abbreviations and terms in common use around
Ford Motor Company. We rely on company employees to keep Ford Speak up-to-date. Since such data is uncontrollable, this
database can not be considered official, although many consider it very useful.
Using menu tabs, you can search on several criteria at once using Advanced Search. You can also add terms, modify terms you
have previously added, or send us feedback on this site. For more information visit: http://www.rlis.ford.com/fordspeak/
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Sharonville Transmission Plant
Delivery
Pedestrian and Industrial Truck Safety Why are the pedestrian aisle ways and Fork Trucks painted yellow? What is the 2 foot
rule? Why do Fork Truck drivers wear Safety vest? Have you ever wondered why our PMHV and pedestrian safety rules have the above
mentioned requirements? Or the reason why these requirements/standards were developed? Well just like any other process, we must start with a
standard that will apply to all powered vehicles and employees in the company. The standard is designed to protect the health and safety of all
pedestrians and Powered industrial truck operators in the company and at our facility. These rules/guidelines/standards are an automotive standard
(AIAG) and they exist to improve the health and safety in the automotive industry working environment.
The standard is broken into 3 elements that have been strategically targeted: Physical facility layout, visual displays, and mental attitude. The
physical facility layout is targeted to physically separate the pedestrians flow from the powered industrial truck flow. The visual displays are
targeted to sensitize the pedestrian and industrial truck driver to potentially dangerous interaction situations within the facility. The mental elements
drive cultural change in our attitudes and perceptions to align with the standards and instructions integrated in our Pedestrian and industrial truck
safety program guidelines.. This cultural change begins with all of us reinforcing and coaching everyone when we are in and out of compliance
with the expectations/rules.
The elements for physical facility layout are definitions for Pedestrian aisle ways (both dedicated and shared), Automated guided vehicle paths,
restricted zones, and crosswalks.
•
•
•
•
Dedicated Pedestrian aisle ways have green lines with a minimum stripe width of 4 inches with an aisle way width of no less than 3 feet. These
aisle ways are as the name implies are designated for pedestrian traffic only. Any/all industrial truck traffic is prohibited on these aisle ways.
Shared Pedestrian aisles have yellow lines with yellow footprints with a minimum stripe width of 4 inches with an aisle way width of no less
than 3 feet. These aisles are shared with pedestrians and industrial truck traffic. Whenever possible, this aisle should be the farthest from
adjacent traffic or to the side that offers the best escape route.
Automated guided vehicle aisle way have orange lines with a minimum stripe width of 4 inches and an outside boundary 18 inches greater
than the AGV or the widest load intended load. Currently, Sharonville does not have any AGV’s installed in our facility.
Restricted zones have solid red lines with adjacent dashed red line with a minimum stripe width of 4 inches, with a total width of 12 inches. At
the boundary of a restricted zones, you will find signage stating; “Restricted Zone – Authorized Personnel only. Examples of restricted areas:
Receiving and Shipping docks, Material storage areas, and AGV pathways. Authorized personnel in restricted zones must wear high visibility
vests and have an appropriate business to conduct.
The elements for Visual displays for Powered Industrial trucks create an environment to maximize the operator’s ability to recognize potential
hazards and ensure the presence of the truck is easily recognizable for pedestrians and other industrial truck operators. The required features are:
•
•
•
•
•
The frame of all industrial trucks must be painted with high visibility color (yellow/orange).
The mast, uprights, and overhead driver guards of the truck must be painted non-glaring flat black.
All trucks must be equipped with key-on headlights.
The forward facing vertical edge of the mast/upright of high-lift powered industrial trucks should have a high-visibility stripe along the vertical
face of this edge.
All fork trucks (sit down and stand drive) should be equipped with a rearward facing drive light not to interfere with the operator’s vision,
which is activated when the truck’s directional control system is placed in the reverse mode.
The elements for addressing mental attitude are simply training and consistent, continual enforcement of the standard and policies by all levels of
the company. That approach will begin to create changes on a cultural level for our pedestrians and vehicle operators. As our cultural shifts, it will
create an instinctual response to all of our Safety guide lines:
•
•
•
•
•
2 foot rule
Driving backwards with load that creates obstructed view
Making eye contact with driver of industrial trucks and pedestrians before proceeding
Sounding horn when loading and unloading stands
Sounding horn when changing directions...just to name a few
It is important to remember that the Pedestrian and Vehicle Safety Guidelines involve more than "simply painting lines on the floor." It is a
comprehensive program and, to be effective, it needs the interaction among all of its elements. Embracing these aspects of the guideline has the
potential to significantly reduce, possibly eliminate vehicle and pedestrian accidents.
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Sharonville Transmission Plant
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.
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%.
Year to date we are $(119) thousand miss to budget and efficiencies earned to date are $2.109 million.
Improvement is expected to accelerate in March.
The targets for March are:
•
Efficiencies of $1.361 million
•
Efficiency % of 5.9% ( a 1.5% increase versus February rate)
Below is the February update of HPU (Hours Per Unit) performance to our 2014 targets. Performance was Red across the board
again, however, improvements were made in most products versus January where performance was hampered by the bad weather we
had during the month.
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.
Todd C. Kraus
Sharonville Transmission Plant
Controller - Finance
2014 HPU PERFORMANCE
February Performance:
Product
6R140
5R110
FN
6R
6F
6FM
FEB
2014
Actual
3.49
4.13
1.48
0.66
1.46
0.82
Vol Adjst'd
FY Fcst
2014
Target
3.31
3.34
1.44
0.63
1.39
0.77
Hours
2014 Actual
B/(W)
2014 Target
-0.18
-0.79
-0.04
-0.03
-0.07
-0.05
Performance
%
2014 Actual
B/(W)
2014 Target
-5.4%
-23.7%
-2.8%
-4.8%
-5.0%
-6.5%
Rating
RGY
Red
Red
Red
Red
Red
Red
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Sharonville Transmission Plant
Our People...
Employee Recognition Each month the employees at Sharonville Transmission Plant go above and beyond
the call of duty. Below are just a few examples of the hard work and dedication happening around the plant!
The Assembly Skilled Trades Team and Management Celebrate Joanie Cable!
This is Joanie Cable, an Electrician here at STP. Joanie was diagnosed with stage IV breast cancer
three years ago this month and was given two months to live...clearly, she surpassed that
prognosis! Joanie is celebrating not only the milestone of outliving her two month prognosis, but
celebrating another birthday! On March 7th, Joanie and her department were having a team lunch
for what she thought was a going away gathering for a co-worker. It was not. This get-together
was a special occasion to celebrate another year of life, as well as her dedication to what she does
here at Sharonville Transmission. Joanie was not only stunned by this surprise from her coworkers, but stated in her own words, ‘I love my job and the people I work with every day!’
Joan’s team presented her with a lightning bolt cake (being the electrician that she is), along with
gift cards to Home Depot for flowers to plant-just in time for Spring! She was also given a 2013
Ford Race for the Cure T-shirt and a Ford Warriors in Pink scarf commemorating her battle
against breast cancer. Happy Birthday Joanie! Here’s to many more...
Machine Repair employees, Jim Goodrich and
Terry Tomes were recognized for repairing down
6R80 184 Peener, which was jeopardizing parts to
assembly. Jim and Terry worked above and beyond
the call of duty and were able to maintain assembly
operations.
Pictured L to R: Jim Goodrich, Randy Branham,
Terry Tomes and Keith Holmes.
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Sharonville Transmission Plant
Our People...
Thank You for your Years of Service!
25
35
Pictured: Dan Huening (top left) was recognized for 25 years of service, along with Mike Richmond (top left).
Two T’s celebrating 35 years of service, Theresa Wheeler (bottom left) and Teresa Pingleton (bottom right).
Not pictured, bur recognized for March’s 25 years of service was Larry Proctor! Congratulations!
Congratulations to the following individuals who celebrated
Milestone Anniversaries during the month of March
The BIG 15!
Jason Ferguson
The BIG 25!
3.15.1999
The BIG 20!
Abdulqaadir Henry
3.21.1994
The Big 35!
Daniel Huening
3.13.1989
Teresa Pingleton
3.26.1979
Larry Proctor
3.6.1989
Theresa Wheeler
3.19.1979
David Richmond
3.28.1989
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Sharonville Transmission Plant
Environment
Recycle, Recycle, Recycle!
Just a small reminder…please place all small batteries (NiCad, alkaline, lithium, et al) and aerosol
cans in their appropriate containers so that these materials can be properly recycled/disposed. If you
have a container in your Dept. where you collect old batteries, make sure the container has the words
“Used Batteries or Spent batteries” on it. Also, please mark the container with the date the first battery
was collected. State environmental regulations require that the container be sent for recycle within a
year of first battery collection.
Spent aerosol cans should be deposited into specially marked yellow “kick cans” located throughout the plant. Any cans deposited at
kick can locations will be collected daily by our Total Waste Manager, MPS Group and taken for storage/accumulation in a 55 drum
located at General Stores. Kick can locations can be found on the STP website. Pull down “Departments” tab and select
Environmental to access STP’s environmental webpage. Select “aerosol staging locations map” on right hand side of webpage to
access locations. Check out the work instruction and single point lesson sections of the Environmental website for further detail.
Help the STP go green!
Ford Production System...
Work Group Development
CROL – Changing Role of the Leader
Listed below is the CROL Starpoint attendance for February 2014. Please note that the
only Starpoint meeting held in February was Safety.
Global Ford Production System Implementation
In this issue we will continue our discussion of Global FPS (Ford Production System)
Principles, Systems and Standards.
This month GFPS training continues for all Team Leaders, Skilled Trade Team
Leaders, Process Coaches, Senior Process Coaches and Team Managers training and
will be completed on March 28.
Zone
Jan
Feb
West 5
42%
85%
East 3
30%
100%
West 2
71%
100%
Central 2
46%
100%
Gear 3
40%
63%
Heat Treat 1
61%
61%
Gear 1
35%
36%
Gear 2
44%
58%
Gear 4
50%
38%
Quality
43%
37%
Engineering
5%
60%
MPL
16%
31%
Plant Total
42%
56%
During the week long training Leaders are taught how to implement standard tasks in their Work Groups during their shift.
Last month we reviewed the first activity- Issues Escalation (CI Improvement Board). The purpose of Issues Escalation is to
provide Team members a process to escalate issues to leadership requesting help in resolving issues they cannot close
themselves.
This month we will review the second activity for Leaders Process Verification / Confirmation.
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Sharonville Transmission Plant
FPS
Global Ford Production System Implementation cont’d
Process Confirmation – you might not realize it but Process Confirmation is in your
department in the form of T card boards. At Sharonville we have been using Process
Confirmation – T card boards since 2006. The purpose of Process Confirmation is to “confirm adherence to standards through the
identification of abnormalities to the process or standards”. Example: are working surfaces free of slip, trip and fall hazards (i.e.
fluids, mats, uneven surfaces, debris, bolts, parts, etc.)? All Team Leaders, Process Coaches, Team Managers, Area Manager and the
Plant Manager will conduct Process Confirmation at standard times of 11:45 am for day shift and 9:00 pm for night shift. Using
global blue T card holders and pre- printed global T cards, they confirm standards at each operation, work station, storage areas,
market places and cribs throughout the plant. If abnormalities are found the T card is turned Red Dot side out. If the issue cannot be
resolved at the Work Group level it can be escalated through the CI board process.
Process Verification- are physical checks on equipment, tooling, and procedures to ensure they meet the standards. Process
Verification is performed by the operators using a Verification Check sheet. Examples of items on a check sheet are:
•
Error Proofing devices has been challenged
•
Weld tips have been changed
•
Parts are tagged
•
Temperature has been verified
•
5S Housekeeping is completed
•
All gaging and sign off has occurred
•
Operation is ready for the next shift
•
All parts have been tagged properly
As a plant we will implement Process Confirmation across all Work Groups before implementing Process Verification. Both
processes will be fully implemented by the end of the year.
Martha Mehl
FPS Plant Facilitator
2014 Hourly Pulse Survey You know how things are going in your work area, and now it’s your chance to tell us. In the next month,
you’ll have the opportunity to take Ford’s Pulse survey, and let us know how we are doing in areas like training and development, supervision,
workplace obstacles, quality, safety, and the One Ford plan.
What’s in it for you? The Pulse survey helps our company learn about and understand issues and concerns that you may have. It’s your direct line to
upper management. It also acts as a basis for developing new plans to improve how employees work together as a skilled and motivated team,
which is the foundation of One Ford.
Pulse also gives each of us the opportunity to voice our opinions about relationships, the work environment, Safety, Quality, and Communications.
The survey consists of 26 multiple-choice questions and takes less than 10 minutes to complete. The survey will be open from April 14 – May 23.
Our focus in 2014 continues to be on the implementation of the Ford Production System. The systems and standards within FPS exist to evolve the
culture within our plants and create an empowered, aligned, and capable organization, and ultimately, the best manufacturer in the world.
Your feedback provides us a baseline for continuous improvement and is much appreciated!
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