1. Co-op Experiences
Kyle Spearman
GSM Co-op
August 7, 2015

2. Copyright © 2014 BorgWarner Inc.
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Background
 Senior majoring in Business Management with an
emphasis in Operations
 Graduating in December 2015
 Always have had a strong interest in Trucks, Jeeps
and off-roading
 Thought BorgWarner was perfect place for me to gain
additional knowledge of the 4wd platform as well as
manufacturing experience

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Projects/ Responsibilities
 Capacity Matrix Studies
 Monthly Surcharge Report
 Tooling Matrix
 Supplier Day
 Torq Day
 Service Parts Trackable Sheet

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Office Tasks
 Assisted with tasks for GSM group to make them
more efficient
 Teamcenter
 Contacting Suppliers
 Maintaining Documents
 Part Files
 Developed GSM standard work document
 Co-op Power Points

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Off-Site Supplier Visits
 IMT Heat Treat
 Went to analyze
possibility of new
supplier
 Was able to learn more
about carburization
process
 Aallied Die Casting
 Attended APQP kick-
off for DT program
 Learned about die
casting process

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Capacity Matrix
 One of the longest on-going projects I was involved
with
 Managed supplier capacity data collection on ICE
 P552, P558, Raptor
 Communicated capacity templates for suppliers
 Updated matrix when they were returned
 Saved in part files and on ICE for records
 Ran uplift reports in Matrix

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9-Apr-14
Supplier Committed Capacity Report
Supplier: MultiTech Model Year 2013 2014 2015 2016 2017 2018 2019 2020 2021 Peak Volume
BorgWarner RFQ
Quoted Volumes
Part #: 44-46-122-001
Part Description: Shift Shaft
Ford P558
- - 182,197 218,636 218,636 218,636 218,636 36,439
P558 w/ 10% flex
- - 200,416 240,500 240,500 240,500 240,500 40,083
Chrysler DJ (44-46, 44-47) 97,300 97,300 97,300 -
DJ w/ 20% flex 116,760 116,760 116,760 - - - - -
TOTAL ESTIMATED USAGE Total Annual Capacity Planning Volume: - 97,300 97,300 279,497 218,636 218,636 218,636 218,636 36,439 279,497
Should plan to achieve these volumes on a standard 5 day work week
TOTAL ESTIMATED USAGE W/ OEM FLEX
Total Annual Capacity Planning Volume
(inclusive of % flex):
- 116,760 116,760 317,176 240,500 240,500 240,500 240,500 40,083 317,176
Should plan to achieve these volumes on a 6 day work week
Supplier work shifts required to meet required capacity
1 8 5 Buyer completes
1 Hours / Shift Days / Week
Supplier available Operating Pattern
0 8 5 Supplier completes
Shifts / Day Hours / Shift Days / Week
Parts/Day Parts/Week WKs/YR Peak Annual
BW Required Maximum Capacity: 1,282 6,408 49.5 317,176
Supplier Quoted Capacity: 2,000 10,000 48 480,000
Supplier Capacity Sheets

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Capacity Matrix
Filler Value
ANNUAL ASSEMBLY QUANTITY 264
PART NUM DESCRIPTION SUPPLIER
ANNUAL SENECA
PRODUCTION
ANNUAL SUPPLIER
MAX
ANNUAL
SPACE
WEEKLY SENECA
PRODUCUTION
WEEKLY SUPPLIER
MAX
WEEKLY
SPACE Date Updated FRD_PN_44-68-000-003
10-00-012-002
MAGNET
1000002
NATIONAL
MAGNETICS
GROUP INC. 1,642,900 1,542,240.00 -100660 32858 30844.8 -2013.2 4/3/2014 264
10-00-047-015
WASHER,FLAT
(METRO # WG-
43) K&K STAMPING 46,900
4,320,000
4273100 938 86400 85462 8/23/2014
13-00-016-002
RING,SEALING
1300002
CONTINENTAL
INTERNATIONAL 98,050 14,160,000 14061950 1961 283200 281239 8/22/2014
13-00-044-001
SEAL, SHIFT
SHAFT FNOK (MILAN) 1,443,400 1,375,000 -68400 28868 27500 -1368 6/19/2014
13-00-052-003
PLUG,
1300003 SEAWAY BOLT 1,931,700 6,912,000 4980300 38634 138240 99606 2/26/2015 528
13-00-131-002
Spacer- Pinion
Needle
UNIVERSAL
BEARINGS 227,763,000 240,000,000 12237000 4555260 4800000 244740 3/3/2015
13-00-139-012
RING, RETAINING
1300012 YUSHIN 1,582,900 1,488,000 -94900 31658 29760 -1898 03/19/2015
13-00-139-027
RING,RETAINING
1300027 YUSHIN 966,050 1,440,000 473950 19321 28800 9479 04/09/2015 264
13-50-100-001
RAIL
1350001 NIAGRA LASALLE 337,900 -337900 6758 0 -6758
13-50-156-007
SPRING
1350007 TWIST INC. 520,750 2,400,000 1879250 10415 48000 37585 2/17/2014
13-52-127-001 BUSHING
PRIME
ENGINEERED
COMPONENTS,
INC. -
1,920,000
1920000 0 38400 38400 2/25/2014
19-00-014-003
Plate - Front
Carrier 1900003 MR. INFRAAUTO 141,550 -141550 2831 0 -2831
19-00-014-004
Plate - Front
Carrier 1900004 MR. INFRAAUTO 32,950 -32950 659 0 -659
19-00-014-005
FILTER RETAINER
PLATE
1900005 BURKLAND 70,900
230,000
159100 1418 4600 3182 04/02/2015
19-00-014-006
FILTER RETAINER
PLATE
1900006 BURKLAND 285,250
57,800
-227450 5705 1156 -4549 04/02/2015
19-00-016-004
RING, Ext Sealing
1900004
FNOK
(MORRISTOWN) 50,550 -50550 1011 0 -1011 264
19-00-016-009
RING,SEALING
1900009
CONTINENTAL
INTERNATIONAL 159,350 2,233,200 2073850 3187 44664 41477 3/3/2014

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Surcharge Project
 Manage payment to or from our suppliers regarding
commodity
 Base rate price of each commodity is negotiated at
beginning of program
 Manual system now automated
 Manual formulas entered into Excel spreadsheet that
would be entered wrong or have human error
 Use of Commodity Engine
 Helped with early development to fix base rates,
monthly rates, and part weights

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Surcharge Report
Supplier Partnum
Meta
l Comm.Desc Term Effective Date C/NC
Metal
kg
Base
USD/kg
Rate
Jan2014
Act Vol
Jan2014
Surcharge USD/kg
Jan2014
AALLIED DIE
CASTING 44-44-039-902 Al
Castings - Die - Raw -
Aluminum (020)
840_Al_STD_Platts_M
WA380ALLOY-2 USD/kg
Jan 1 2013
12:00AM C 4.91694 1.84200 2.24239 20,704 40,760
AALLIED DIE
CASTING 44-44-039-903 Al
Castings - Die - Raw -
Aluminum (020)
840_Al_STD_Platts_M
WA380ALLOY-2 USD/kg
Jan 1 2013
12:00AM C 5.11650 1.84200 2.24239 1,401 2,870
22,105 43,630
Supplier Mar Apr May Jun SUM
ACUMENT / RING SCREW LLC -1299.039443 -1351.577837 -1297.741033 -1828.208486 -5639.340483
C & A TOOL ENGINEERING, INC. -5523.850529 -8808.454439 -9217.908493 -11357.86426 -41226.40614
CAMCAR LLC - BELVIDERE -937.7723688 -2138.125121 -2550.602283 -2686.401707 -9719.088754
CAPSTAN ATLANTIC INDUSTRIES (Wrentham, MA) -4453.0486 -5352.989547 -6218.169196 -5549.57948 -28555.28119
CONTINENTAL MIDLAND, LLC -64.30760995 -113.9837718 -87.70404368 -98.1644484 -425.5451653
DRIV-LOK, INC. -111.1443163 -183.0484219 -185.8814237 -220.1313636 -779.319247

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Tooling Matrix
 A universal tooling standard document used in RFQ
process with suppliers
 All new and replacement tooling
 States plainly what the supplier is responsible for
paying and what BW will pay for
 I developed it by comparing Ford, Toyota, GM, and
Chrysler tooling matrices for BorgWarner tooling

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Tooling Matrix

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P552 Supplier Day/ Torq Day
 Coordinated with P552
suppliers the date,
location, and schedule
for the event
 Networked with
suppliers throughout the
day in a professional
setting
 Given task to present
Carrier machining/
assembly on plant tour
 Good practice
presenting to multiple
groups

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Torq Day

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Service Parts Tracking
 Service Parts tracking document for better
communication between Materials and Purchasing
 Established a document that allows materials to input
data onto in ICE On ICE
 Displayed in Purchasing Office
 Visual Management Tool

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Service Parts
Printed on plotter- 34” x 44”

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TTS Way Event- 5s
 Participated in MRO stockroom Kaizan event
 Went to Storage Room and learned how to organize
space efficiently
 Became 5s certified
 Related to coursework at Clemson

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Other Tasks
 Involved in the early goings of Silver Crescent Award
 Assisted in Change Management
 Participated in Angel Tree Program
 Audits:
 Inventory- MRO
 Production Control
 Safety- GSSF11
 Reported Minority Spending
 GSM office reconfiguration

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My Takeaway
 FIT
 Functional Integrated
Teams
 Communication
 Internal
 External
 Professionalism
 Supplier’s
 Internally
 Planning
 New Programs
 Manufacturing
 Industry
 Mentors
 At work
 Preparing for future

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Questions?

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Thank you
Fuel Economy Emissions Performance

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Thank You For Your Attention
Fuel Economy Emissions Performance
Our Vision
 A Clean, Energy-Efficient World
Our Mission
 Deliver Innovative Powertrain Solutions that Improve
Fuel Economy, Emissions & Performance