1. RDP Semester Review
Rotation #3
Sarah Brown, 12/07/15

2. Agenda
 Introduction
 Facts About the Rotation
 Projects
 Continues Improvement Initiatives
 Lessons Learned
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3. Introduction
University Attended &
Majors/Minors
Indiana University – Purdue University Indianapolis (IUPUI)
Mechanical Engineering Technology
Technical Communications Certificate
Lean Six Sigma Green Belt
Organization Involvement
Society of Women Engineers
Engineers Without Borders
American Society of Mechanical Engineers
Society of Manufacturing Engineers
Engineering Technology Student Council
International Society of Automation
Engineering Technology Leadership Development Program
Study Abroad Experience
No International Experience - Yet
Travel throughout the United States with organizations:
- California, Michigan, Wisconsin, Florida, Ohio, Illinois,
Louisiana, New York
- Heard from many local engineers on their companies and
what they are doing in varying industries
Fun Facts about Yourself
- I play the violin and the piano
- I enjoy bourbon, beer, and wine tastings
- I like to cook/bake, read, draw/paint
- I love to travel & try to visit at least one new place per year
- I can speak some Spanish & Italian and am working to
become more fluent in both
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4. Facts About the Rotation
Rotation # 3
Core Field Operations
Executive Mentor Eddie Millington, Continuous Improvement Director, FECT - NAO
Site Manager Steve Holley, FAS-SMV Plant Manager & Mike Boerner, FAS-SMV Quality Manager
Location / Division Faurecia Automotive Seating – Simpsonville, KY
Objectives of the
Rotation
1. Participate in a New Plant Launch
2. Review and Apply Faurecia’s Core Procedures (FCP’s)
3. Training on Quality Lab Procedures and Requirements for Seat Acceptance
4. Attend Functional Training
Next Rotation Faurecia Automotive Seating – Vigo, Spain
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5. Projects
 Implementing 7 Quality Basics
 Scope
 Create necessary documentation & processes for
7QBs in the plant
 Implement & train on documentation & processes
 Actions & Results
 Poka-Yoke
 Created and implemented Poka-Yoke tags for
all lines
 Trained on PY tag use and backup modes
 OK 1st Part
 Updated & standardized OK 1st
Part check sheets for all lines
 Designated display area for
check sheet on lines
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6. Projects
 Implementing 7 Quality Basics
 Self Inspection
 Created defect tally sheets w/ thresholds & missed
defect charts for stations on all lines
 Trained operators on Stop @ Defect
 Final Inspection
 Trained inspectors on final inspection process for all
lines
 Administered FI Gage R&Rs to inspectors for all
lines
 Completed 10/12 checks on FI validation form (9
needed for FES lvl3)
 Completed mirror documents/setup for TQW
 QRCI
 Set up lineside QRCI areas for all lines
 Trained personnel on lineside QRCI
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7. Projects
 Implementing 7 Quality Basics
 Red Bin
 Helped order red bins for main lines
and placed/zoned
 Train line personnel on acceptable
defect identification
 Rework Under Control
 Developed rework & scrap flows for
all lines and QA cage
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8. 8
Projects
 Control Plan & OK 1st Piece Updates
 Updating control plan to reflect current
line setup and processes
 Standardize control plan, Poka-Yoke list,
SCCAF, OK 1st Piece and other
documentation
 Insert notes to guide those in charge of
‘official’ documentation updates
 Kamishibai Audit
 Created Quality kamishibai audit cards
based on initial items that can currently
be checked
 Usability walks scheduled this week
 149 quality kamishibai cards currently
created

9. 9
Misc. Projects & Assignments
 SAB Disposal System Quotes
 Contacted several recycling & disposal
companies asking for quotes
 Hosted a visit to the plant to discuss
capabilities
 Lab testing for TT
 Shaker Table testing and H-Point testing
training
 Preliminary training on shaker table and
program
 Learning through testing troubleshooting
 Run@Rate Cycle Times
 Collected cycle times on specific stations as
line run@rates were scheduled
 Occur Monday-Thursday every week
 Updated times in centralized Excel sheet
 Assisted engineering in creating charts to
show needed trends

10. 10
Misc. Projects & Assignments
 20% S/R Fasteners – Presentation & PFMEA
Review
 Chances to interchange S/R bolts and latches
in process
 Opportunity for PFMEA improvement
 Took pictures and notes, created presentation
to be distributed, and assisted in PFMEA
review meeting
 Management reviews & final seat prep for
EPT/TT seats
 Management review to look over final seat
assembly & appearance
 Prep for shipping – completing “OK to Ship”
inspection sheets, attaching necessary alert
tags & Ford “New Model” stickers, taking
pictures of completed seats, etc.
 Birth certificates for EPT & TT seats
 As seats were built, filled out “birth certificates”
w/ relevant torques and serial numbers

11. 11
Misc. Projects & Assignments
 FES Games
 Top 5 N-1 Responsibilities
 Completed Quality KPIs
 Report out on updates, AIMs issues, QA alerts
 FUELS
 Co-coordinated w/ Chastity Mazon
 Reached 409% of goal (2,650 meals w/ goal of
648 meals)
 Material feeding for fasteners to line
 Working w/ FES and PC&L
 Idea to mimic stations from main assembly plants
 Concept created by Trilogiq
 Next steps to order a kit and test
 Building the Boundary Books & Documentation Binders
 Binders on each line that contain the Ford Boundary
Book and copies of documents needed at Final
Inspection

12. Continuous Improvement Initiatives
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 Visit to Ford KTP
 Visit to Toyota Production Plant
 Visit to Corvette Production Plant
 Involvement in Top 5 & Staff Meetings
 See the application of some Plant KPIs & how they
integrate w/ other departments
 Responsible for note taking during staff meetings
 Boundary Book Documentation Instructions
 Added instruction pages for the different documents
needed at Final Inspection & TQW
 Added blanks of the documentation forms
to allow for easy copies
 Idea to use FECT HSE Startup sheet
 Easier to manage HSE Startup
 Separate instructions and sign-off sheet
to closely monitor each safety measure

13.  Time and work to create the FES standards usually already in place
 Setting up correct the first time will make future production run much smoother
 Opening a new plant is nerve-racking and rewarding
 Plant Opening Lessons Learned
 Line Layout and Future Seating Plants
 Line should be designed to meet local safety guidelines (line currently not OSHA compliant,
stairs not usable)
 Area for TQW/FI not built into layout
 People on inside of line (Safety & material delivery concerns)
 Line durability studies
 OHP
 1 UAP and 9 Supervisors for 459 MOD
 Plant will fail FES Audit 2.1.1 Lvl 2
 UAP max 200 & Supervisor max 25
 1 Quality Engineer and 1 Process Engineer
 Risk for high turnover and lack of development & improvement idea implementation
 PFMEA importance and impact
Lessons Learned
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