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2/6/2017
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Cummins TWI Journey
Dana Sims
Amanda Couch
Clyde Martin
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“We understand the fact that we must give a
machine the best care and the best treatment if
we are to receive from it the best work. We have
sometimes shied away from the similar fact that
we must give a person the best care and the best
treatment if we are to receive from him the best
work.” – J.I. Miller
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Who is Cummins CMEP
• ISB 6.7L engine – assembly & block machining – 200k annual capacity
• Customer: FCA (Fiat Chrysler Automobiles) - RAM Truck 2500 & 3500 series
• TS 16949 certified
• FCA Powertrain Supplier of the Year award - #1 globally of 1,300 powertrain suppliers in 2013
• 3 million engines shipped as of Jan 2017
• 850 Employees
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Our TWI Story
• Standard Work Implementation
• Development of our Training and Development Department
• Certifying our Group as Train the Trainers
• Developing Our team trainers
• Speeding Tickets
• Focus after JI
• # of Visitors to Learn what we do
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Standard Work Implementation
• 176 engineered stations
• Process documentation vs.
Standard Work
• 2.5 years to implement
• Hurdles
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Creating Standard Work Sheets and JIB’S
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Development of Training Department
• Department size and growth
• 10 hour JI
• Speeding Ticket
• JITT
• JITT=4 JMTT-2 JRTT-2 JSTT-3
• Problem Solving Trainers=3
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Development of Shop Floor Trainers
• Number of trainers needed
• Old process versus New process
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23 Teams Supported
2 Assembly Production shifts
3 Materials Shifts
3 JI Certified Trainers per Team
138 JI certified trainers needed to launch new process
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OLD TRAINING METHOD
Training using Job Instructions
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E= Trainer/ Red Dots T= Trainee/ Blue Dots
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MFG Defects 2013 - 2016
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754
114
613
127
382
223 179
345
0
330
142
89
70 86 85 76
0 0
200
400
600
800
1000
1200
Jan Feb March April May June July August September October November December
MFG Defect Before/After STD Work
2013 2016
Manager’s View of JI
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Speeding Ticket
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Focus After JI
• JOB METHODS, JOB SAFETY, JOB RELATIONS, PROBLEM
SOLVING
• Certified Trainers (shop floor employees) as of January 20, 2017
• JI=325 JM=50 JR=41 JS=94
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Manger’s View of Job Methods
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Job Methods in the Office
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Kaizen Line Balance
Kaizen Training
Kaizen Team Plan
TPM Kaizen
Kaizen TPM Strategy
Kaizen Line Balance
3000 Ideas from the shop floor since 2013 to make the business better!
Contact Information
• Dana Sims
• Amanda Couch
• Clyde Martin
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