ShiftingGears

Sharonville Transmission Plant
ShiftingGears
In This Issue
December 2015
Message from Tim Boes, Plant Manager
Distracted Driving
2
GFPS: CROL Awards
3
Cost Objective Update
4
Team Receives Diversity/
Inclusion Award
5
Milestone Anniversaries
5
New Assembly Line
6
Hoskins Visits STP
6
Tim Boes in EPA Video
6
Personnel Update
7
Supporting Our ERT
7
New Prayer Box
7
Pink Honor Roll
7
Adopt-A-Child Gift giving
8
Bengals Tickets Winner
8
OSU Raffle Winners
8
Breakfast with Santa
8
Home Heating Safety
9
Anniversary Mustangs
9
Famous Fords
9
Application Upgrade
10
GM Supports Ford Family
10
Supporting Our
Ford Family
10
As 2015 quickly comes to
a close, I want to thank
everyone for a very strong
year. We achieved
improvement in every area
of the business! We
improved on Safety by reducing the
number of injuries that result in a
restriction or lost time, and I believe we
can do even better next year. In Quality,
we beat our warranty target in 5R110 and
saw significant improvement in our gear
business. We missed our target for 6R140
due to a design concern on the E Clutch,
but we were able to spot it quickly and
institute a fix. Every problem we encounter
provides a learning opportunity and
we really took advantage.
For Delivery, we are on
track to have our
highest production
year ever for both
6R140 and our gear sets, and we see
even more for next year! Cost is probably
the biggest story as we beat our cost
budget this year by $400K! GREAT JOB! In
the People category, we learned a lot
through the Pulse survey for both hourly
and salaried and will take that insight and
create improvement actions for 2016.
Thanks to all who took the surveys.
In Maintenance, our teams have done
an outstanding job of supporting
production and driving Preventive
Maintenance as a discipline that many
visitors have said is the best in the
company. In Environment, we are green to
every metric and know that there is much
more we can do to become even better in
conserving energy and reducing oil and
water usage.
I want to make special mention about
the folks who have worked to produce
5R110 transmissions for these many
years. Overall, we built 2,729,370 5R110
transmissions! These were very well
received by our customers and have done
a wonderful job in the field. Thank you to
all who played a role in producing this
transmission!
As I think about 2016, we will have a lot
on our plate as we continue the
capacity expansions for 6R140
and 6R80. In addition, we
expect very strong demand for
6F50/55 and steady production
for 6FMid. I am confident we will
meet our commitments and I look forward
to building on the successes we’ve had in
2015.
In closing, I hope each of you has a very
safe and blessed holiday season and get
to spend time with the people who mean
the most to you.
Thanks again for everything you do for
us every day.
— Tim
Safety
Sharonville
Transmission Plant
3000 Sharon Road
Sharonville OH 45241
Communications
Plant Page
@Ford Online >
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From Our Plants >
Sharonville
Facebook Page
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“Sharonville
Transmission Plant”
Email
STPfacts@ford.com
Shifting Gears
is a monthly publication
of the Sharonville
Transmission Plant,
a division of
Ford Motor Company
Please forward your
article ideas, photos, quotes,
department updates,
announcements and other
timely information to share
with your co-workers to:
Angela Osborne
Communications Coach
aosbor41@ford.com
782-7396
Employee
Recognition
All Sharonville employees have
the opportunity to nominate
co-workers for recognition for
outstanding performance.
Visit the Sharonville Reward
& Recognition website at
www.sharonville.ford.com >
Departments > Human
Resources > SQDCPME
Achievement Award.
Distracted Driving
A
n estimated one-in-four car
crashes involves cell phone use.
Many distractions exist while
driving, but cell phones are a top
distraction because so many drivers use
them for long periods of time each day.
Almost everyone has seen a driver
distracted by a cell phone, but when you
are the one who is distracted, you often
don't realize that driver is you.
Hands-free Not Risk-free
With some state laws focusing on
handheld bans, it’s no wonder people are
confused. They believe they are making
the safe choice by using a hands-free
device. It’s just not true. Your brain
remains distracted by the conversation.
Multitasking is a Myth
Human brains do not perform two tasks
at the same time. Instead, the brain
handles tasks sequentially, switching
between one task and another. Brains can
juggle tasks very rapidly, which leads us to
erroneously believe we are doing two
tasks at the same time. In reality, the
brain is switching attention between tasks
— performing only one task at a time.
For example, a person who is talking on
a cell phone while driving has a brain
that’s dealing with divided attention. The
brain is overloaded by all the information
coming in. To handle this overload, the
driver’s brain will not encode and store all
of the information.
Some information is prioritized for
attention and possible action, while some
is filtered out. The driver may not be
consciously aware of which critical
roadway information is being filtered out.
Performance is impaired when filtered
information is not encoded into working
short-term memory. The brain doesn’t
process critical information and alert the
driver to potentially hazardous situations.
This is why people miss critical warnings
that can lead to potentially life-threatening
traffic accidents when engaged in cell
phone conversations while driving.
Why Drivers Miss Cues
All human brains have limited capacity
for attention. When there is too much
information, the brain must decide what
information is selected for encoding.
Some decision processes are conscious
and within a person’s “control,” while
other decisions are unconscious so we’re
not aware of them. Therefore, people do
not have control over what information
the brain processes and what information
it filters out.
Cell Phones Differ
Many people understandably wonder
how this risk compares to talking with
passengers or listening to a radio. Drivers
talking on cell phones make more driving
errors than drivers talking with
passengers.
Drivers are more likely to drift out of
lanes and miss exits than drivers talking
—Continued on next page
2
S h i f t i n g G e a r s | December 2015
GFPS
Driving continued from page 2
CROL Awards
C
with passengers. Why? Adult
passengers often actively help drivers
by monitoring and discussing traffic.
Passengers tend to suppress
conversation when driving conditions
are demanding.
Talking on cell phones has a different
social expectation because not
responding on a cell phone can be
considered rude. In addition, callers
cannot see when a driving environment
is challenging and cannot suppress
conversation in response. Passengers
can see the roadway and may moderate
the conversation.
Listening to music does not result in
lower response time, according to
simulator studies. But when the same
drivers talk on cell phones, they do
have a slower response time.
Researchers have concluded that voice
communication influenced the
allocation of visual attention, while low
and moderate volume music did not.
This discussion does not mean that
listening to music or talking with
passengers is never distracting. Loud
music can prevent drivers from hearing
emergency sirens. Some conversations
with passengers can be distracting to
drivers. Any task that distracts a driver
should be avoided.
ongratulations and thanks to the Converters Departments and
Department 576021 for their 100% attendance at all Starpoint
meetings since May. Keep up the good work Starpoints!
Converters Department: (left to right) Martha Mehl, Jeff Smith, Pam Benson, Tim
Angel, Mike Walters, Darin Lachenman, Harold Prindle and Tim Boes
Department 576021: (left to right) Martha Mehl, Greg Dickhaus, Sean Odell,
Randy Perry, Sean Morath, Joe Brueggemann and Tim Boes
S h i f t i n g G e a r s | December 2015
3
Cost
Sharonville L&O Performance Efficiencies
2015 Full Year Goal L&O Budget Efficiencies
Year-To-Date
L&O Budget Efficiencies
November 2015
Year-To-Date
= $18.4 M
= $17.1 M (Green)
L&O Budget Performance = $0.02 (Green)
L&O Budget Performance = $0.40 (Green)
November 2015 Average Daily (Mon-Fri)
Schedule Performance
6R140/
5R110 1,704 Actual vs. 1,610 Target
6R80 4,167 Actual vs. 4,237 Target
6FM 3,297 Actual vs. 3,600 Target
6F
1,887 Actual vs. 2,100Target
4
= 6% Better than Target (Green)
= (2)% Worse than Target (Yellow)
= (8)% Worse than Target (Red)
= (10)% Worse than Target (Red)
October 2015 YTD Hours Per Unit (HPU)
6R140
5R110
6R80
6FM
6F
3.29 Actual vs. 3.25 Target
3.88 Actual vs. 3.56 Target
0.63 Actual vs. 0.64 Target
0.81 Actual vs. 0.80 Target
1.45 Actual vs. 1.44 Target
=
=
=
=
=
(0.04)
(0.32)
0.00
(0.01)
(0.01)
(Yellow)
(Red)
(Green)
(Yellow)
(Yellow)
—Sam Madrigal, Controller, Finance
S h i f t i n g G e a r s | December 2015
Team Receives Ford’s
Diversity/Inclusion Award
C
ongratulations to STP’s 2015
Global Diversity and Inclusion
Award recipients! Six
employees recently received this Ford
national award for “Fostering a
Respectful & Inclusive Environment.”
STP’s recipients were recognized for
demonstrating “Working Together”
behaviors by building a collaborative
environment that inspires and involves
employees, and leverages diverse
perspectives inside and outside of the
team.
STP’s team of Al Incerpi, Russell
Carter, Darlene Oakes, Jeffrey
Pridemore, Joseph Sabato, Mark
Bender and Ricky Monhollen received
the award for the plan they developed
to aid hearing-impaired employee/plant
security communications. STP currently
has three hearing-impaired employees.
The plan came about after a situation
last winter, during an extreme cold
snap, in which one of the plant’s
hearing-impaired employees was
having trouble getting into the plant
because of a badge/gate malfunction.
They were unable to communicate
with plant security via the gate
intercom to ask for assistance.
To prevent that problem in the
future, the team created a process
that allows hearing-impaired
employees in a similar situation to
send a text message to a dedicated
number that will indicate the
employee’s name and current gate
location. The employee presses the
Call Box button at the Security Gate
and then plant security can manually
open the gate. In addition, plant
security also added the capability for
deaf employees to receive emergency
plant pages via text.
This is the 16th year Ford has
recognized the “Go Further” efforts of
the One Ford team for contributions
related to diversity and inclusion. As
one team together, we go forward!
Congratulations to
Phillip Robbins who marked
his 40th anniversary in
November working at Ford!!
December Milestone
Anniversaries
25 Years
Peter Beltramo
15 Years
Elizabeth Kachele
Congratulations to Peter
Beltramo who marked
his 25th anniversary
working at Ford!!
January Milestone
Anniversaries
20 Years
Jeffrey Jackson
15 Years
Robert Schubert
(left to right) Russell Carter, Joseph Sabato, Rick
Monhollen, Darlene Oakes, Jeffrey Pridemore and
Al Incerpi (Not pictured: Mark Bender)
S h i f t i n g G e a r s | December 2015
Thank you for your
service and dedication!
5
STP Launches New Carrier Assembly Line
S
TP’s newest production line is going well. A South
Korean team from Hanwha was here last summer
to install equipment for a new carrier assembly
line and teams have been training on it for several
months. As the 5R110 line gradually ceases in early
2016, this new line will be launching a new product
6R100 and additional capacity for the 6R80. This will
allow STP to produce 100,000 more 6R100s per year
and 200,000 more 6R80s in annual volume.
It normally takes 3-4 months after an install to work out
the bugs and go full volume. So far the team seems happy
with the launch. “We’ve got a long way to go before full
volume,” said Sean Nguyen, team manager, Manufacturing
Engineering. “It’s a good start.”
These new lines are designed to be flexible so technicians
can make either the 6R80 or the 6R100. STP has been
making 6R80 transmissions since 2006 and sends these
out to go in F-150s, Expeditions, Navigators, Raptor SVTs,
Mustangs and Transits.
STP has just started making the 6R100s. “We’re in debug
mode,” adds Nguyen. These new transmissions should start
going out in March 2016 to the Kentucky Truck Plant in
Louisville for the F-250s.
“The process is pretty much the same as the other
equipment,” said Nguyen. “It’s just a different supplier.”
Hoskins Visits STP
Jason Reynolds (in back) and Darron Reynolds work on the new
carrier assembly line
Jason Reynolds, a technician on the line, is happy with
the new line so far. “We’re running good parts,” said
Reynolds.
Next up will be three more Hanwha lines installed in
March to build more 6R140s.
Watch Tim Boes talk about STP's conservation
efforts in the Ohio EPA video on YouTube.
www.youtube.com/watch?v=Ylav5AJ2zL0
Anthony Hoskins, our new Director of Manufacturing
Powertrain Operations, learns about STP
manufacturing operations from Jamie Kuntz in
Department 578 during his Dec. 4 visit to the plant.
6
S h i f t i n g G e a r s | December 2015
Personnel
Update
Supporting Our ERT
STP’s Emergency Response Team (ERT) recently received a new
stretcher to help them help us! The ERT wishes to thank the
management team and plant nurse Robin Dickhaus for help in getting
it here. Special thanks
to Nik Johnson for
arranging the purchase
and Tim Boes for
helping to expedite the
entire process.
Kelly McCartney joined STP as a
layout engineer on Dec. 7. He worked
at Ford’s Batavia Plant and has many
years of manufacturing experience.
Pictured (left to right)
are Sean Nguyen, Jonne
Messer, Jeff Fisher,
Mike York, Denny
Messer and Tim Boes.
Wood Shop Team Creates
Prayer Box for All Faiths
Check out the new prayer box in front of the union office!
A huge thank you to Doug Messer, Dennis Messer, Tim
Towe and Carl Bohl. Please place your prayer requests in
the top slot. Paper is available below the box. The box is
always locked for confidentiality and only opened by the
STP Chaplain.
C
ongratulations to the members of the 2015 Pink
Honor Roll, which recognizes the top Race for the
Cure fundraisers. The 2015 Pink Honor
Roll members raised more than $112,000 for the Race
for the Cure! STP has four of those top 100, raising a
total of $7,800. Congratulations and thanks to these
hardworking fundraisers!
We have already begun our 2016 fundraising — all of
the OSU raffle tickets funds will go into the 2016 bucket.
11
13
14
79
Anne Leung
Stephanie Huffman
Darlene Oakes
Yolanda Burns
$2,183.50
$1,962.00
$1,962.00
$462.50
(Left to right) Doug Messer, STP Chaplain Harold Walters Jr.,
Carl Bohl, Tim Towe and Doug Messer
S h i f t i n g G e a r s | December 2015
7
Supporting Our Community
Adopt-A-Child Holiday Thanks
Volunteers Kim Durgan, Jessica
Meadors and Betty Meadors
bring in their sacks of goodies.
Volunteers Tina Sukup, Cheryl Holland, Tim
Meadors, Tanya Frierson and Roberta Mitchell
organize the gifts.
Rachel Rivera and Rachel Morrissey
pack up gifts to make their delivery.
Thanks to everyone who contributed and helped with our Adopt-A-Family
programs this year. Your generosity is greatly appreciated.
Bengals Tickets Winner
Congratulations to Cindy Maybury!
Breakfast with Santa 2015
She won STP’s Race for the Cure
Bengals Raffle — two tickets for the Dec.
13 Bengals vs. Steelers game. Thanks to
everyone who participated! The raffle
raised $310 for Race for
the Cure! Who Dey!!
OSU Raffle Winners
Thank you to everyone who participated in the
OSU Raffle. The $670 proceeds will be split
between the Race for the Cure Greater Cincinnati
Affiliate and the AFCA/FBI National Child
Identification Program. Winners of the signed
Urban Meyer football and helmet are:
▪ Helmet – Angela
Osborne (drawn
by Kim Matthys)
▪ Football – Jeff
Busam (drawn by
Jim Whitlock)
Jim Whitlock,
Kim Matthys
and Anne Leung
8
S h i f t i n g G e a r s | December 2015
Be Prepared: Stay Safe this Winter
Carbon Monoxide and Home
Heating Safety
▪ Carbon monoxide is an invisible, odorless, colorless gas
created when fuels (such as gasoline, wood, coal, natural
gas, propane, oil, and methane) burn incompletely.
▪ Each year, carbon monoxide poisoning claims
approximately 480 lives and sends another 15,200
people to hospital emergency rooms for treatment.
▪ Each year more than 200 people die from carbon
monoxide produced by fuel-burning appliances in
the home, including furnaces, ranges, water
heaters and room heaters.
▪ A person can be poisoned by (1) a small
amount of CO over a longer period of time
OR by (2) a large amount of CO over a
shorter amount of time.
▪ Carbon Monoxide can have different
effects on people based on its
concentration in the air that people
breath, and the person’s health
condition.
▪ CO poisoning can be confused with flu symptoms, food
poisoning and other illnesses with symptoms including
shortness of breath, nausea, dizziness, light
headedness or headaches. High levels of CO can be
fatal, causing death within minutes.
▪ Consumers die when they improperly use gas generators,
charcoal grills, and fuel-burning camping heaters and
Looking for a
Holiday Gift?
50th Anniversary Mustangs
are still available for $10
each or two for $15. Sales
benefit JDRF. Contact
Sherri L. Mullen at
513.782.7677 or
smullen@ford.com.
S h i f t i n g G e a r s | December 2015
stoves inside their homes or in other enclosed or partially
enclosed spaces during power outages.
▪ Install a carbon monoxide (CO) alarm (also called
detectors) in the hallway of your home near sleeping
areas. Avoid corners where air does not circulate.
▪ Follow the manufacturer’s instructions to test the CO
alarm every month.
▪ Do not use a CO alarm in place of a smoke alarm. Have
both.
▪ Make sure all household appliances are installed
according to manufacturer’s instructions and local
building codes. Most appliances should be
installed by professionals.
▪ Have heating systems (including chimneys
and vents) inspected and serviced
annually, checking for blockages,
corrosion, partial and complete
disconnections.
▪ Only burn charcoal outdoors, never
inside a home, garage, vehicle or tent.
▪ Always make sure to turn off any gas-powered engine,
even if the garage door is open.
▪ Do not use gas appliances such as ranges, ovens or
clothes dryers for heating your home.
▪ Treat the alarm signal as a real emergency each time. If
the alarm sounds and you are not experiencing any
symptoms described above, press the reset button. If the
alarm continues to sound, call the fire department.
Famous Fords:
Name the Car
Answer to
November’s
Famous Ford:
It was a 1973 XB
GT Ford Falcon Coupe
from “Mad Max.”
9
Attention Employees
Application Upgrade Begins
Friday, Dec. 18
Beginning at 9 p.m. on Friday, Dec. 18 and
continuing through 6 p.m. on Saturday, Dec. 19, the
Maximo for Maintenance (MFM) Application will be
brought down to perform MFM Scheduler Production
launch for release 2.3.0.
Production Impact
The MFM application will not be available to users
during that time. The application is expected to be
available starting at 6 p.m. on Saturday, Dec. 19.
(Please note that the planned outage may extend
through 9 p.m. in the event the upgrade is not
successful and a rollback is required.)
UAW Brothers & Sisters Support Ford Family
STP Chaplain Harold Walters Jr. (third from left) is pictured
with the GM parts plant local 686 plant manager, their
chaplain and others during a pancake and sausage lunch
fundraiser for Kyler Bradley and family. Thanks to our many
UAW brothers and sisters for supporting our STP family!
Supporting Our Ford Family
Thank you to everyone who came out to support and helped
with the Kyler Bradley Fundraiser on Dec. 13. You raised
more than $38,000 to help pay hospital expenses.
Darth Vader (with Kylo Ren) is challenged to a duel
by a young padawan
Hot potato was a popular activity
To see more photos, visit STP’s Facebook
page at “Sharonville Transmission Plant.”
Lisa Hill (far right) represented The Cure Starts Now
10
S h i f t i n g G e a r s | December 2015