1. 2015 Alcoa Summer Internship Program
Global Logistics Intern Cleveland, Ohio
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By: Alexander Flanagan
2. Introduction
Name:
Alexander Flanagan
Major:
Packaging
School:
Michigan State University
Senior Graduating in December
Hometown:
Lansing, Michigan
Alcoa Position:
Packaging Engineer
• (Steve Dominish)
Global Logistics
Supervisor:
Danielle Hurt
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Hobbies:
• Sports, Adrenaline, and giving Back
3. Last Year’s Returnable Dunnage Packaging Improvement
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Target Condition:
• New pallet pack with T-rings will cost less than current
dunnage.
• Will increase the capacity in a truck from 528 wheels to
672 wheels
• Potential for $356,388 in saving s for AWPM and CLE+
(DI# 106502 for CLE+, DI needed for AWPM).
Current 22.5’ Truck Load:
Target 22.5” Truck Load:
Results After One Year
35%
Improvement
4. CVW Ingot Pad
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Sink holes
forming
Preventing Tow
Motor
Drivers from
using
The bays.
Bay rails misaligned
No organization on how or where to
unload, and what to consume for
production.
5. CVW Ingot Pad Problems
Why is this an issue:
Production has run into the issue of ingot bars not being able to scan.
Either the sticker endure weather damage and are no longer able to
scan, or bars are being consumed for production before they have
officially been received in the system. This leads to bars being labeled
as DOES NOT EXIST, and placed into a QA Hold area.
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FIFO Plan:
The new ingot pad plan will allow for production to load and pull bars
for production in a first in first out matter.
July 4th Lot Fix:
During the July 4th outage, the ingot pad was able to be fixed of all
sink holes and damaged bays to implement the FIFO plan.
7. NAFTA (North American Free Trade Agreement)
What is NAFTA :
North American free trade agreements are implemented to help
companies avoid duties and fees while importing and exporting NAFTA
qualifying goods.
NAFTA qualifying goods include products that originate from the United
States, Canada, and Mexico.
Product that is sent back to warranty that did not originate in North
America is charged a duty fee of 2.5% of $250 which is a per wheel
price.
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Duty Fee No Duty Fee
8. My Role at Alcoa
Auditing of Canadian Imports to Warranty
Cross reference customer part numbers in Oracle
Check to make sure customer part numbers are matched with an Alcoa
part number.
Check is this part is NAFTA certified
If not certified print a Costed BOM (Bill of Materials)
Create an FTA organization worksheet to be further audited and
approved by members of the logistics team
Double check the part numbers on a master list to identify the country of
origin.
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Completed Chrysler and General Motors LLC
Sales order of Acknowledgements for daily shipments
Reorganization of trip planning and traffic notes for Daimler and
New Flyer shipments
TPM Participation
9. The Numbers Don’t Lie
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This chart identifies the duties and fees avoided on imported
NAFTA qualifying goods.
10. CLE
Forge
Palletize
• CLE HT
Wood Pallet
for Export
Ship to
TWI
Band
TWI
Export
Process Improvement
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Business Case: TWI spends $0.39/forging to repack forgings produced in Cleveland for export to Japan and China. The
double handling is unnecessary and ties up steel guarded pallets within the flow path until repacked at TWI.
CLE
Forge
• CLE
Palletize
• CLE Steel
Guarded
Pallet
Ship to
TWI
Unpack Repack
• HT Wood
Pallet for
Export
Band
TWI
Export
Future Trial with GA23917F in CVW:
Current Flow Path
Target Flow Path
Target Condition:
• Eliminates labor cost of $0.39/forging.
• Eliminates wheel handling / potential injury.
• Eliminates use of steel guarded pallets.
GA23917 2015 Production Forecast
30,816 Total GA23917:
• Steal guarded pallets fit 24 forgings per pallet.
• Heat treated pallets same dimensions
• Potentially free up 1,284 steal guarded pallets
for production.
11. Experience and Feedback
The Alcoa Experience:
This is my second year with Alcoa.
Work environment and atmosphere
Ability to challenge one self
Opportunity
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Internship Feedback:
Comparison to last summer
Lead team interaction
On boarding process
Career path counseling
