Xxx internship daily log week of 5 18 09 monday

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Daily log week of 5-18-09

Internship

Monday

Investigated new shipment of TMC brake handles for REV change. Found no changes from previous shipment. Compared against technical data, metric thread pitch was supposed to be at metric 1.0. Found to be at .8, documented and took pictures, informed purchasing that change was not made because they have been involved with this since this part comes from Pakistan. Rejected the inspection lot for brake handles in SAP (Data Base) that tracks the vendor score, and transferred to quality block stock.

Logged into TEST mode for SAP to run different scenarios with creating inspection lots and adding characteristics with a task list. Created test purchase order and entered the goods receipt and observed the settings that were made in creating the inspection plan in SAP for part number 0201-00187. Added an inspection method that requires the use of a CMM to complete the inspection requirements.

Called to production line to investigate an issue with the side mirrors. Found that some side mirrors appeared to have a scuff mark in the end of the mirror. All side mirrors are packed individually with a bubble wrapped bag inside a sturdy box. The scuff is a vendor defect. Spot check entire stock on the production line and warehouse. Found 216 with the scuff mark and 400 with a lighter scuff followed with a small scratch. I suspect that the scuff was made during the process that removes the excess flashing from the plastic. Separated the stock from the production line and transferred in SAP to block stock. Took pictures and sent to Jon Cannon the account rep from gem for this product. The vendor is from Italy and our main contact is from New York. So it could be some time before we get some feedback.

Looked into adding an inspection method for the brake calipers. Required inspection tools will be the FARO CMM (coordinate measuring machine) and threaded hole gauge. Checking the flatness of the sealing surface and perpendicularity of the threaded hole to the sealing surface. GD&T is .004 for this feature. Sent price quote to Gage Crib Worldwide, from Grand Rapids, MI.

Daily log week of 5-18-09

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Tuesday

Called to production line on an issue with the rear hard doors, the complaint was that the sliding windows are being scratched when opening and closing. At first sight it appeared to be created by a raised circular area about the size of a quarter from the inside between the panels. Probably made from an injection point when creating the plastic door. The windows also rub up against a felt liner that covers the top edge of window opening. The scratches were very light; we looked at a couple more doors found some had like symptoms and some did not. Being that this was a very light scratch I used a cleaner called novis which is made for plastic windows. It leaves an almost like waxed smooth surface. After applied we operated the window several times with no issues. I suspect that the felt surface has some dust and or some particles causing the light scratches.

Spoke with a FARO technologies account manager about upgrading our current CMM to newer technology. I would like to see our quality department have an arm with the laser scanner attachment. Currently we use a FARO cmm touch probe. As of now it is not possible for us to upgrade because of Chrysler going through chapter 11. When Chrysler becomes stable it is a good possibility we will have to upgrade because of several reasons. 1- Our current arm is no longer under warranty, 2- If parts are needed to repair the availability will become hard to get parts and at a high cost, 3- Technology currently used is considered old in the industry, 4- This type of measuring device is essential for our business, and 5- Increases through put times of manufacturing the end product.

Called to production line on questions of quality standards on bucket seats. Worked with assembler so the he had a good understanding of what is acceptable with an issue of protruding objects from inside the frame.

Called to production line on issue in station 0 with attaching the trunk back frame jig to the main frame. Found a couple issues. 1- The stake pockets are not laying flat due to a design issue. 2- Assembler did not have the attachment rod aligned in the slot, and the biggest contributing factor was the latch plate mount was welding .3" lower than nominal according to print. #1 -Informed design engineer of issue. #2 assembler was shown that the alignment is slotted and can be adjusted accordingly. #3 Vendor was notified by email with a snap shot from print showing the part (latch plate mount) and nominal dimension. I followed that up with a phone call through my contact, no answer I will try again tomorrow.

Daily log week of 5-18-09

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Wednesday

Followed up with sliding window issue. The issue has not come back and final end of line inspection has no issue.

I walk the production line a couple times a day to address various issues or questions with assemblers. I spoke with Wally in the roof station. He was repairing a roof rail that was scratched from the manipulator. I had him create problem log within the quality system navigator.

Followed up with Jon Cannon to see if any feedback was received for the side mirrors. He will give them a call later in the day.

Followed up with Voyager manufacturing about the latch plate mount being positioned lower than the print calls out. Spoke Jamie Schaffren that is looking into the problem. They are currently not producing this frame but are working on the EL frame. He said he will mock one up and talk with his welding assemblers about the issue. He will get back to me later today.

Set up brake calipers in SAP. Created inspection characteristic for flatness and perpendicularity. Updated the inspection plan with the new characteristic and assigned an inspection method with the CMM. Assigned target values with upper and lower limits. Sent quote to productivity quality in Plymouth MN for Solid Threaded Hole Location Gage.

Assisted in removing material from a vendor who chose to scrap here rather than sending back.

Daily log week of 5-18-09 Thursday Incoming inspection Verified rev change from sample of steering gear.

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Currently in process of changing the QC area to a more lean approach. During our Kazein event it was brought up the racks in the area are not bolted to the floor. This is a safety issue. I aligned the rack the best I could to get it straight then used the hammer drill to make holes in the concrete for the anchors. Installed concrete anchors 5 ?" long. Completed two racks which will leave one to go.

I outlined a square box with yellow tape for a couple carts that are used on a daily and weekly basis. Cleaned surface with alcohol and primed used a 3m primer as test to see if this will increase the longevity of the tape.

Friday OFF - Memorial Day Weekend.

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EXAMPLE 2 LOGS

Internship

Daily log week of 6-15-12

Monday:

I Met with Joe Kolo and we called Fisnar Dispensing Monday morning. I have sent numerous emails to their sales representatives, but have yet to get a reply. Phoenix International currently has two Fisnar 7400 series desktop dispensing units. We are looking to get an updated quote on the exact machine. I contacted Schuegenpflug because they dispense dow and that holds the control modules together. I would like to hear back from Fisnar within a week so I can compare prices between these two companies. I left my contact information, so they can have a conference call with us. I would also like to see if they can dispense the bergquist material. It's a highly abrasive gasketing material that allows for heat transfer from the circuit board to the aluminum casting. Schuegenpflug is currently the only company to successfully dispense bergquist. All of the other companies have trouble rebuilding the dispensing heads daily, while Schuegenpflug doesn't require any.

I am also getting ahold of another automation company called Ellison. They will send a sales representative out to quote our current crimp station. A formal quote from them would help us justify buying the equipment from them or other companies. Schuegenpflug is taking longer than we thought to get back to us on quotes for the crimp cell. Some of the delay is due to the fact we are communicating with a vender in Germany. Fargo Automation got back to us with a rough quote of $130,000 just for the crimp station. They are also a year out from building anything for us. The quote is too high, but we can still compare it to other companies when we present the quotes to corporate. I just learned today the flex box cell is another project that needs a formal quote by the end of July. We are going to have Fargo Automation come back again to quote the flex box cell and see if we can get a deal on grouping two projects together.

I've been working on proofing out the chamfer program. The push block I built last week is complete, but needs to be cleaned up around the edges, so no one cuts themselves when handling the part.

I talked with LeakMaster again to verify the quote we got last week included tooling. I sent a reply to get an additional quote without tooling, so we can break down the entire quote.

I set up a remote desktop conference with Brent Gernant from Waterloo, IA. He showed me how to import .iges files from Pro-Engineer. The feature recognition will allow me to create a duplicate drawings and machine out the specific part. This will save Phoenix International a substantial amount of money and there won't be any need to job out parts.

Tuesday:

I started the day off by working on the critical spares list. I am making my way through the online inventory to input into the crimp line spread sheet. Once we have all of the parts on hand into the

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