Lean Summit Nov.17
Category: Other
Updated: 25 Jan 2023
Contributors
Created byMaria Jose Davila
Attachments
Events
Safety Video for visitorsLean Steering Committee creationCH&L pilot areasBPD L1Skip level meetingsShopfloor standardization:
- Boards
- Timeline meetings
- Top 25
- 4 week challengesBPD L2ANDON in all areasLPAsSWEAdopt a PuppyTalent managementKaizenTCardsLeadership training (Oscar)
- Servant Leadership
- 4 day Lean trainingDelta Joint
DC Tool projectSelf- Funded LETs
Completion. Working teamsInspect
Phase 1Staff
TeambuildingBPD L 4/5
boardsOne day in the lineWorking Teams
in support areasStaff
Teambuilding5s training (1 day)Andon
(downtime tracking
and analysis)LETs training
-SWS
-Pillar Chart
-ScrollingRacks height
standardizationGreen TCard100% SWS/Pillar charts/ScrollingsLogistics 5s standardsVSM (Major areas)Traveler kit:
Door trim L2Teambuilding
Area (kick off)5s in officesRecognitions for employees
in Quaterly leaders meetingsTraining:
-STAFF doing OnboardingOnboardingBTL Lean ChecklistSTAFF as SMENaviSTAR
recognitions programBlue TCard +
LPA upgradeOpen House
with line runningVSM
(for Kaizen)5W done by operators
(620 total in FY17)Canopy: Subassembly
areaTraveler kit:
Engine L1Forklift reduction (14)Dock Audit
implementationMin/Max
for subassembliesWorking teams
recognitionsMP7 Supermarkets
(mini tote)BPD FY18 Session -
Setting Goals with LETsOne day in ELC
(Staff)Lean - Staff Calibration
(Observation process)1.94
FTE2.23
FTE2.402.44
FTE2.68
FTE2.772.82
FTE2.93
FTE2.983.023.073.133.20
FTE3.252.40
FTEVMV Campaign
(kick off)50% new
StaffProstar Daycab L1Lonestar MEXDe-rate L2
114 to 93De-rate L2
93 to 83HX Silverback
LaunchLT LaunchDe-rate L1
70 to 63A26 LaunchDe-rate L2
140 to 132Troy & Persio
VisitWorkstar rate increase L1De-rate
L1 88 to 70
L2 132 to 1221st Lean Summit
FTE¡550,000 trucks!
Celebration with Governor1st NIPA
L1 Durastar
0 defects88A LaunchCAT exitLean
Re-think Kaizen2nd NIPA
L1 Durastar
0 defects3rd NIPA
L1 Durastar
0 defects4th NIPA
L1 LT
0 defects5th NIPA
L1 Durastar
0 defectsDe-rate L2
122 to 114Quality Gate
ImplementationCost Recognition
EventTIP (Receiving
process in ELC)Electronic Pull System
in Cab shopFamily Day
EventPhil Christman
visitDe-rate L1
132 to 88 (Ford exit)Mexican Government
Safety RecognitionTroy VisitEAP PERFORMANCE1st 2pts Workstar
L2 NIPA1st 2pt LT
L1 NIPAHV/MV
LaunchHX Sleeper
LaunchLonestar Horizon
LaunchHX w/A26
Launch299 Durastar
Hydraulic Breaks
LaunchTC10 w/A26E38 Eaton
EndurantRe-rate
L1: 110 to 115Re-rate
L1: 63 to 74
L2: 83 to 96Continuous
Improvement
Walks3.253.25TIP (Empty Returns)Staff
Teambuilding6th NIPA
L2 Workstar
0 defects7th NIPA
L1 Workstar
0 defects8th NIPA
L1 Workstar
0 defects9th NIPA
L2 LT
0 defects10th NIPA
L2 LT
0 defects2nd Escobedo
Lean SummitBPD FY19 Session -
Setting Goals with LETsTraveler kit:
Engine L2787: HV/MV
with A26PCBL 17793: Clean CAE38 Endurant with A26E28 ISL Euro 5PCBL 17887: Snow Plow
PCBL: 17167 Batteries Inside of the CabCommunication Posters
for start up meetingsETADs Q1
Recognition3.233.32
(Revised Goal: 3.34)3.34Lean Score
FY19: 3.4811th NIPA
L1 MV
0 defectsCIMS buy off NNGVWalter Borst &
Samara Strycker
VisitBernardo Valenzuela
VisitTroy Clarke &
Phil Christman Visit3rd Escobedo
Lean SummitL1 Night Shift
start: 80Re-rate
L1: 74 to 79
L2: 96 to 103Re-rate
L1: 79 to 88
L2: 103 to 134Re-rate
L1: 88 to 110NNGV7 MV L1 PIPA
Cero defects
FY20201 HV L1 PIPA
Cero defects
FY20206 MV L1 PIPA
Cero defects
FY202119 LTs L2 PIPA
Cero defects
FY202010 LTs L2 PIPA
Cero defects
FY2021E68: 2020 Cummins X15
Efficiency Series.E57 Aero Improvements787 HorizonE39: 2021 A26 -
LT/RH/HV Cert BuildE69: Cummins 2021
Emissions - B6.7/L9E74: Bendix 2.0Cummins L9 engine
HV at L2E63 Next Gen HX
- X15 & A26PCBL 18143.- Next Generation
HMX Suspension (HMX-EX)E92/PCBL 18168:
LT X15 Euro VIE88: ADAS 3.0 -
OGM LT/RH.E77: GHG Initiative -
TPMS HX/HV HD EngineE39: 2021 A26 -
LT/RH/HVE36: MV RefreshH07.- E- TruckE92: SFC w/MWM
I6 Euro VIE92: LT X15
Euro VIE63 Next Gen HX -
2021 A26 w/E39Rate
L1: 160
L2: 134De-rate L2
134 to 100De-rate L1
160 to 125
(one shift)De-rate
L1: 125 to 115
L2: 100 to 92De-rate
L1: 115 to 60
L2: 92 to 78Re-rate
L1: 60 to 75
L2: 78 to 81Re-rate
L1: 75 to 110
L2: 81 to 170
(Second shift launch)Re-rate
L1: 110 to 125De-rate
L1: 70 per day
(TCM shortages)Re-rate
L1: 70 to 125Visit: Industria Nacional
de AutopartesLast Ford truckFirst right hand
drive truckAlianza AntiCancer
(donation)PosadaCustomer: Penske
JOB 1LEAN Recognition20 YEAR
AnniversaryHalloweenAlianza AntiCancerLa Quinta
Quality AwardReforestaciónETADs
RecognitionsSchool - trash can
donationAdopt a treeCOVID Measures
at EAPDía de los
MuertosIP LineSanitiTRUCKJBHunt 5,000 truck
CelebrationLineX
Cab&PaintFirst Electric
TrucksBrigades in the
communityFirefighter department
donationsPeople:
Restrooms increase
in prod. linesViva Mexico
CelebrationCOVID Vaccine
in EAPAlianza
Anti-CancerLocal HighSchool -
Material donationPink OctoberLoyalty RecognitionsETADs
Objectives SettingVirtual
POSADAFord exitAustralian RHDMathias Carlbaum visitPink OctoberB-Box StoreNavibusWorking & WalkingCARPOOLPosada 2022Staff TeambuildingInfluenza vaccineLoyalty recognitionsFIFA WorldcupNAFIN visitNuevo Leon Governor visitL1
E36 MV Refresh JOB 1
L2
E39 A26 LT sleeper Job 1
E92 LT x15 Euro Job 1
E57 Aero improvements Job 1L1
E39 A26 LT/RH Job 1
L2
E39 A26 LT, HV, RH Job 1
E63 Next Gen HX Job 1
E57 Aero improvements fuel pump Job 1L1 & L2
E44 LT/RH Cert
E92 LT daycab Job 1L1
E81 MV/HV Intellipark Q
L2
E83 Bendix Safety Direct QL1
88N: Cooling Module Pahse 2Q
L2
88N: Cooling Module Pahse 2Q
E71: Linehaul fuel economy
E81: IntelliparkL1&L2
S22 Annual Update Job 1
L2
E90 Bendix Fusion radar replacementL1&L2
E76 Air bag module Job 1
E83 Bendix Safety Direct Job 1L2
S22 Annual Update 2022 Integrated Crossmember Job 1L1&L2
E92 SFC Euro VI
E99 CumX15 EPA
S23 Allison Gen 6 TCM
L1
E92 SFC Euro VIL3 Busses increaseUDEM Leaders10 LTs L2 PIPA
Cero defects
FY20223 MV L1 PIPA
Cero defects
FY2022New Fire truckLATAM VisitAFT LineDEF Tank LineCM Phase 1DCM LineCM Phase 2AFT E44 ScaniaMujeres Navistar
CDMX event170 new PlantsETADs
Objectives Setting 2022Convenio UANLChildren's Day CelebrationLine 2 2nd shift 1 YEAR celebrationMexican Independence CelebrationGoran Nyberg VisitFederico Rojas VisitChildren Anti-Cancer foundationLast alluminum
HX truckLast alluminum
cab produced in EAPPeriods
-----Porsche--------JSOP/McKinsey----------------------------------------- ELC Warehouse --------------------------------------------NGV Subassembly Main Line-------------------------------------------------Stamping-----------------------------------------------------------------Offlines increase due
to shortagesL1 Ramp up to 160COVID - Plant Down
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