1. 2014 Alcoa Summer Internship Program
Packaging Intern Cleveland, Ohio
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By: Alexander Flanagan

2. Introduction
 Name:
 Alexander Flanagan
 Major:
 Packaging
 School:
 Michigan State University
 Senior
 Hometown:
 Lansing, Michigan
 Alcoa Position:
 Packaging Intern
 Supervisor:
 Steve Dominish
 Mentor:
 Daniel Smink
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 Hobbies:
• Sports, Adrenaline, and trying new things

3. Returnable Dunnage Packaging Improvement
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 Business Case:
• Total spend for transportation from TWI and AWPM to
ASL locations is $2,164,268 ($1,414,713 + $749,555).
Current dunnage creates inefficiencies.
 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:
• Current dunnage designed to fit 19”- 24.5” wheels.
• 80% of shipments to ASL are 22.5” wheels.

4. T-Ring Trials
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Extruded T-Ring Trial
Molded T-Ring Trial w/
Stretch warp
Molded T-Ring Trial
banded w/ stretch wrap
Pros:
• Eco Pack cover
Cons:
• Clips came apart
• Cloth created separation
• wheels sliding on pallet
Pros:
• Shipment from Mogador
to Chillicothe
• Eco Pack cover
• Stretch wrap
Cons:
• T-Ring movement
• Wheel movement on pallet
• wheels sliding on pallet
• Damaged T-Rings
Pros:
• Shipment from Mogador
to Chillicothe
• Eco Pack cover
• Stretch wrap
• Banding
Cons:
Plastic Pallet
• T-Ring movement
• Wheel movement
• Sliding on pallet
• Damaged T-Rings
Wooden Pallet
• No physical damage
• Not reusable

5. CLE
Forge
Palletize
• CLE HT
Wood Pallet
for Export
Band
CLE
Export
CLE
Forge
Palletize
• CLE HT
Wood Pallet
for Export
Ship to
TWI
Band
TWI
Export
Forging Improvement
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 Business Case: TWI spends $0.39/forging to repack forgings produced in Cleveland for export to Japan and China
(projected volume is 115,000 forgings from CLE to Asia in 2015). 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
 Successful Trial with GA23906F in FSW:
Future Recommendations
 Current Flow Path
Target Flow Path
• Will need
containers in CLE
and Oracle enabled
• Need new
equipment in
CLE
 Target Condition:
• Eliminates labor cost of $0.39/forging.
• Eliminates wheel handling / potential injury.
• Eliminates use of steel guarded pallets.

6. AWTP Experience
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