Denny Kramer, an engineering intern at Polaris Industries, gave a presentation summarizing his summer internship experiences. He utilized lean tools like A3 processes, spaghetti diagrams, and 5 whys to help reduce downtime on production lines. Some specific projects included redesigning material flow racks and station layouts to reduce non-value added time. Metrics showed improvements like an 11.5% increase in production and a 43% reduction in downtime. Kramer learned about lean principles and wants to do a design engineering internship next summer before graduating from Iowa State University in mechanical engineering.

1. Intern Final Presentation
Denny Kramer, Lean Manufacturing Engineering Intern
August 5th, 2015
POLARIS INDUSTRIES INC. Ɩ Spirit Lake, IA

2. 2
Background
Denny Kramer, Intern Presentation Summer 2015
College: Iowa State University – Mechanical Engineering
Graduation: December 2016
Hometown: Earling, Iowa
Past Work Experience: Kinze Manufacturing and Agriland FS
Hobbies: Sports, Boating, Outdoor Activities, Helping on
Family Farm

3. Lean Support – Day to Day
Projects
Problem Situation: Reduce Downtime
on the Slingshot line
Utilized Lean Tools (A3) and problem
solving methodology to identify Non-Value
Added Work Content
Worked with Operators to resequence
their Standard Work
Coordinated with cross functional team to
improve material presentation
Before After
Problem Situation: Reduce tapping
on Slingshot line
Kaizen Team Member - Helped collect
and analyze data
Problem Situation: Develop tooling
for MY16 Slingshot launch
Designed and implemented new battery
bracket holder
3Footer Here
Kaizen & NPI Support

4. A3 Process Utilized - Station 5711
Lean Tools (Spaghetti Diagram)
& Station Observations
Operator Input - what they did
not like about their process (5
why’s)
Created new material flow rack
and parts tray
Redesigned station layout
4Denny Kramer, Intern Presentation Summer 2015
ImplementationApproach
Before After

5. A3 Process Utilized - Station 5711
5Denny Kramer, Intern Presentation Summer 2015
Rebalance StationFollow Up on Results
Space & Time SavingsBefore & After PCT
Repeated A3 Process for 20 stations
Adjusted rack/layout until
operator was happy with
changes
Opportunity to rebalance more
Standard Work to the operator 0
100
200
300
400
500
600
Before After
Value Added Walking Unpacking PCT
0
100
200
300
400
500
600
Before After
Value Added Walking Unpacking PCT

6. Lean Manufacturing Team Results
Cost Savings
Before
After
Metrics May Avg. July Avg. % Improvement Annualized Savings
Delivery Incease 38.1 42.4 11.5% 4,367,833.80$
Downtime Reduction 80 46 43.0% 344,926.88$
Sum of Cycle Reduction 27204 24612 9.5% 202,494.23$
Labor Reduction 9,840.67$ 9,397.96$ 4.5% 110,677.98$
Total 5,025,932.90$

7. Dislikes
Likes/Dislikes
Fast paced work environment
Treated as valued team
member
Operators were open to
change
Rapid change process
Fun and exciting products
Change mentor halfway
through the internship
Never got opportunity to drive
any of the products
7Denny Kramer, Intern Presentation Summer 2015
Likes

8. 8
Lesson’s Learned/ Future Plans
Denny Kramer, Intern Presentation Summer 2015
Lean Principles:
Better understanding of Lean Manufacturing vernacular
Utilizing Plan, Do, Check, Act – Continuous Improvement
process
Identifying if issues are really problems – knowing the
standard to measure against
Need measurables when dealing with problems – can go
back and see if there is an improvement
Utilizing different problem solving methods – A3, 5 why’s,
fishbone diagrams
Data gives direction
Future Plans:
3 semesters left at Iowa State University
1 summer internship left – Design Engineering oriented

9. Questions?
9
Thanks Polaris for the opportunity!
Denny Kramer, Intern Presentation Summer 2015