2. About Project
Organize and clean out all PPE lockers
Lockers are to be maintained by 5s and WO standards
Each shelf is labeled, taped, and assigned
Each locker will look the same based on the Team 13 model
Budgets will be set up for each team based on PPE needs
Will not be unlimited; will be reduced and cost savings will be achieved based
on establishing PPE budget of $250 per week ($500 Biweekly)
Checklist will be implemented eventually.
BUL’s will walk through once per week to make sure TL’s are sustaining their
lockers
OPL’s will be created for lockers showing how they should not
look and how they should look
3. Team 13 Beverly Brown
Beverly’s locker was used as a model for each team to go by
Before After
Overcrowding
Unorganized
No Labels
Very Organized
Divided up by
size and NPM
number
Everything has
a location
4. Each shelf has its own PPE pictures and labels
based on NPM number
5. PPE Quantity Lists and Budget Lists:
Each one of these are posted on the inside right door of each
locker based on that teams needs
Budgeting List Team 13 Beverly Brown
Gloves Price Per Pair Price Per Bundle Min/Max (Pairs)
78-175-4821 $3.97 $47.64 12/24
78-175-4823 $3.97 $47.64 12/24
78-175-4825 $3.97 $47.64 12/36
78-175-4827 $3.97 $47.64 12/24
78-175-4830 $3.50 $42.00 12/24
78-100-0290 $0.70 $8.40 12/24
Total: $20.08 $240.96
Sleeves Price Per Sleeve Price Per Pair - Min/Max Min/Max (Pairs)
78-370-1530 $3.25 $6.50 - $65.00/$162.5 10/25
78-370-4744 $5.25 $10.50 - $52.50/$157.50 5/15
78-370-4747 $5.25 $10.50 - $42.00/$105.00 4/10
Total: $13.75 $27.50
Aprons Price Per Apron Price Per Max Min/Max
78-010-0215 $2.50 $12.50 2/5
Ear Plugs Price Per Box Price Per Max Min/Max
78-315-6171 $0.06 $0.12 1/2
Safety Glasses Price Per Pair Price Per Max Min/Max
78-385-0620 $0.62 $1.86 2/3
Total: $282.94
Estimated Weekly
Budget:
$300.00
Weekly: Biweekly: Monthly: Annually:
$282.94 $565.88 $1,131.76 $13,581.12
Weekly: Biweekly: Monthly: Annually:
$300.00 $600.00 $1,200.00 $14,400.00
*Subject to Change
PPE List Team 13 --- BEVERLY BROWN
NPM Number Type of Glove Size
Quantity per Week
(Pairs)
78-100-0290 White Cotton 10 6
78-175-4821 Hy-Flex 7 4
78-175-4823 Hy-Flex 8 6
78-175-4825 Hy-Flex 9 10
78-175-4827 Hy-Flex 10 8
78-175-4830 Kevlar Black Dot Large 2
Total per Week 36
NPM Number Type of Sleeve Size Quantity per Week
78-370-1530 Yellow Kevlar Standard 20
78-370-4744 Green M 8
78-370-4747 Green XL 4
Total per Week 32
NPM Number Type of Apron Size Quantity per Week
78-010-0215 Denum Full Standard 4
NPM Number Type of PPE Size Quantity per Week
78-385-0620 Safety Glasses Standard 2
NPM Number Type of PPE Size Quantity per Week
78-315-6171 Ear Plugs Standard 1
*Subject to Change
6.
7. Cost Comparison & Cost Savings
Brown, Beverly $1,461.91
Fox, Paul $6,245.53
Gibson, William $8,518.65
Jomaa, Hayle $4,138.14
Schmidt, Keith $11,150.79
Umbrell, Mike $12,672.74
Willinger, Mark $9,954.20
Total $54,140.17
Six Month Sum Total Spending Comparison
Brown, Beverly $6,790.56
Fox, Paul $3,972.96
Gibson, William $4,876.32
Jomma, Hayle $4,800.00
Schmidt, Keith $6,790.56
Umbrell, Mike $6,261.60
Willinger, Mike $8,400.00
Total $41,892.00
12. Page 12Page 12Focused Improvement Page 12
CHRYSLER GROUP LLC
Plan
Team leaders have unlimited access
and spending on PPE and other items
Money is being wasted because team
leaders do not keep track of their own
spending
Unlimited budgets give team leaders
freedom to spend money on anything
they want
Resulting in overspending, wasted
money, and overcrowding of supplies
BROWN BEVERLY $1,461.91
FOX PAUL $6,245.53
GIBSON WILLIAM $8,518.65
JOMAA HAYEL $4,138.14
SCHMIDT KEITH $11,150.79
UMBRELL MICHAEL $12,672.74
WILLINGER MARK $9,954.20
GRAND TOTAL $54,140.17
13. Page 13Page 13Focused Improvement Page 13
CHRYSLER GROUP LLC
DO
Create budget limit for each team
leader based on current and future
estimated spending
Each team leader will receive a
maximum budget of about $250 per
week that should be used for PPE and
team purposes only
Whatever money is not used is money
that isn't spent. This non spent money
could be presented as a cost savings
over a course of a year
Team Leader: Budget:
William Gibson $250.00
Mark Cieniewski $250.00
Martin Salas $250.00
Hayle Jomaa $250.00
Mike Umbrell $300.00
Dennis Miller $250.00
Floyd Hollingshead $250.00
Rob Majerowski $300.00
John Moore $200.00
Paul Fox $250.00
Linda Cochran $250.00
Keith Schmidt $300.00
Arnold Moreno
$300.00
Beverly Brown
Mark Willinger $250.00
14. Page 14Page 14Focused Improvement Page 14
CHRYSLER GROUP LLC
CHECK
Based on the 6 team leaders that have TMS access as of right now
*Over a 6 month & yearly spending period
Current: $54,140.17 ~ 6 mo. x 2 = $108,280.34 avg. per yr.
Future: $41,892.00 ~ 6 mo. x 2 = $83,784.00 avg. per yr.
$108,280.34 - $83,784.00 = $24,496.34 savings in 1 calendar year
($24,496.00 / $108,280.34) = 0.226 = 23% based on budgets
15. Page 15Page 15Focused Improvement Page 15
CHRYSLER GROUP LLC
ACT
Read Across
If all 15 team leaders have/had TMS access
*Over a 6 month & yearly spending period
15/6 = 2.5 NR
$108,280.34 (6 TL’s) per yr. x 2.5 = $270,700.85 per yr.
$83,784.00 (6 TL’s) per yr. x 2.5 = $209,460.00 per yr.
$270,700.85 - $209,460.00 = $61,240.85 savings in 1 calendar yr.
($61,240.85 / $270,700.85) = 0.2256 = 23% savings based on budgets
17. Page 17Page 17Focused Improvement Page 17
CHRYSLER GROUP LLC
Plan
Team lockers are hard to maintain.
Organization becomes difficult to keep up
because of overcrowding.
Becomes costly for team leaders to check
and reorganize lockers every day.
Team members throw PPE in locker for
team leaders to organize every day based
on WO/5S standards
Money that is spent for team leaders to
organize lockers could be spent
elsewhere such as writing suggestions
and kaizens
18. Page 18Page 18Focused Improvement Page 18
CHRYSLER GROUP LLC
DO
A checking/audit system will be put in
place for each unit leader to make sure
that team leader lockers are kept up to
standards
Unit leader will audit the locker at least
once or twice per week
Team leader would organize locker in the
same time span (once per week) for
about 10 minutes
WO/5T/5S locker would reduce
organization time from 20 min down to
10 min
19. Page 19Page 19Focused Improvement Page 19
CHRYSLER GROUP LLC
CHECK
Current Organization Time:
1 Day: 20 min per day x 7 day/wk = 140 x 52 wk/yr = 7280 min/yr
(7280 min/yr) / (60 min/hr) = 121.33 hours per year
Future Organization Time:
1 Day: 10 min per day x 2 day/wk = 20 x 52 wk/yr = 1040 min/yr
(1040 min/yr) / (60 min/hr) = 17.33 hours per year
121.33 hr/yr x $29.00 = $3518.57 per yr
17.33 hr/yr x $29.00 = $502.57 per yr
$3518.57 - $502.57 = $3016 savings per 1 calendar year
20. Page 20Page 20Focused Improvement Page 20
CHRYSLER GROUP LLC
ACT
Read Across to all 16 teams in BIW
Current: 7280 min/yr x 16 = (116,480 min/yr) / (60 min/hr) = 1941.33
1941.33 hr/yr x $29.00 = $56,598.57 per yr
Future: 1040 min/yr x 16 = (16,640 min/yr) / (60 min/hr) = 277.33
277.33 hr/yr x $29.00 = $8042.57 per yr
$56,598.57 - $8042.57 = $48,256.00 savings per 1 calendar year
($48,256.00 / $56,298.57) = 0.857 =
86% savings based on time reduction
29. Unit leaders will check team lockers once per week according the weekly
checklist provided for them
Unit leaders must check for; organization (are the lockers being kept up to standard,
is everything in their place, are personal items put in other places besides PPE
locker, is it neat overall), budgets being maintained (are they going over their weekly
spending limit), and if min & max levels are being met (should not be over their
locker limit based off of document)
Unit leaders will mark down “Y” meaning yes or “N” meaning no if any
of the requirements are not met
If any of the columns receive an “N” then they fail their weekly check
This is a standard that must be met and kept up on a weekly basis
Each examination should last about 10 minutes per locker
If the locker is not organized or if personal/excess items are stored in, the TL
must spend time in front of the UL taking them out
UL must report out weekly audit to the BUL
Weekly Check
