Paul Soukaseum completed an internship as a Manufacturing/Industrial Engineering intern at Oshkosh Corporation. During his internship, he worked on several projects including conducting a parts and bill of materials audit, designing a new build sequence for hydraulic lines, applying Six Sigma methodology to improve a fixture alignment issue, modifying existing fixtures, and creating new fixtures including an adjustable end stop, foot pedal redesign, and hydraulic valve lifting device. Through these projects, he gained experience in manufacturing engineering, process improvement methods, and supporting new product launches from a manufacturing perspective.

1. Paul
Soukaseum
ME/IE Intern
Automated Systems and
Robotics A.S.
Industrial and Systems
Engineering B.S.
University of Minnesota

2. • Oshkosh Corporation Classification: Unrestricted
What Is ME/IE?
Director: Todd Roughsedge
Team: Vijay, Ben, Peter, Camron, Dan, Sean, Sravan, Jigs/Fixtures
• Stands for Manufacturing Engineering/Industrial Engineering
• Design manufacturing jigs or fixtures
• Offer production support on new and existing product
• Standardize work
• Study capacities and utilization
• Cost justification
• Improve workflow
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3. • Oshkosh Corporation Classification: Unrestricted
Internship Project
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Prototype Support for Meridian
• Meridian Process Improvements
 Part and BOM Audit
 Build Sequence
 CI using 6 Sigma Methodology
• Meridian Fixtures/Jigs
 Modifying Existing Fixtures
 Creating New Fixtures

4. • Oshkosh Corporation Classification: Unrestricted
Observing Meridian Production
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5. Process
Improvement
Based off observations of the
Meridian

6. • Oshkosh Corporation Classification: Unrestricted
Fastenal Part/BOM Audit
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Problem:
To make sure Fastenal parts for the Meridian is stocked for production
Approach:
• Gather the all Fastenal/Aeroquip part numbers in PMPF
• Compare to Meridian BOM
• Find the “Missing Part”
• Create BIR for BOM mistakes
• Create locations for Parts Needed

7. • Oshkosh Corporation Classification: Unrestricted
Benefits from Part/BOM Audit
Improvement:
• BIR created to have R&D Engineering review parts list before
giving them a location (Cost)
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10,132 Total Fastenal Parts
337 Bins in PMPF
227 Fastenal/Aeroquip Unique Bins
377 Meridian Parts in PMPF
15 Meridian Fastenal Parts
w/ No Match

8. • Oshkosh Corporation Classification: Unrestricted
Hydraulic Line Build Sequencing
Problem:
To simplify the hydraulic line assembly. It’s difficult and
confusing.
Approach:
• Create build instruction
• Make it visual
• Label the hydraulic lines to correspond with build
instruction
• Implement Build instruction and audit the results
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9. • Oshkosh Corporation Classification: Unrestricted
Value in Build Sequencing
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• Improvement:
• Reduction in task time (Delivery)
• Simplification of task (Quality)
• Easier for the production worker (Morale)

10. • Oshkosh Corporation Classification: Unrestricted
Process
Improvement
Meridian improvement using 6
sigma methodology

11. • Oshkosh Corporation Classification: Unrestricted
DMAIC: Boomerang Alignment
Define:
Find the root cause of the poor fit when installing the ejector hydraulic
cylinder and to correct it.
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Define Non-Conforming as:
“If they have to use the tap or ream
out any of the holes”

12. • Oshkosh Corporation Classification: Unrestricted
DMAIC: Boomerang Alignment
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Measure:
• The fixture is also the boomerang part
• Measure parts to assure they are good
• Boomerang:
# 9,8,37,35,36 = 1.8 < Cpk < 10
• Laser-cut Sidewall:
Laser cut part is oversized to 0.81”
Bolts are 0.75”

13. • Oshkosh Corporation Classification: Unrestricted
DMAIC: Boomerang Alignment
Analyze:
• Solidworks Motion to study variance
Scenario 1 P{NonConf}= 85%
Scenario 2 P{NonConf}= 62%
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14. • Oshkosh Corporation Classification: Unrestricted
DMAIC: Boomerang Alignment
Improve:
From the Analyze step, there are reasons to believe that it is
the fixture or the oversize hole in the laser cut sheets
Design new fixture and use Hypothesis Testing:
• Introduce new fixture & use Bernoulli distribution function
(Discrete Event) to determine the p-value.
• H0: p<0.05 or <1 defect out of 20
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15. • Oshkosh Corporation Classification: Unrestricted
Value in DMAIC: Process Control
Improvements and Control:
• 62% reduction in the likely-hood of non-conforming alignment
(Quality/Delivery)
• Fixture is lighter (Morale)
• Error proofing for Scenario 1, lowers risk of 85% Non-Con (Quality)
• Production are not complaining about bad fit (Morale)
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16. • Oshkosh Corporation Classification: Unrestricted
Fixture Design
and Build
Based off the manufacturing
needs of the Meridian

17. • Oshkosh Corporation Classification: Unrestricted
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Fixture Improvement Process
Production needs a solution to a problem
Collect Input from Shop and Cross Functional team
Validate Loading Sequence
Validate Clamping Plan vs Actual Jig
Develop Concept for Cross Functional Team Approval
Detail Design, Drawings and Part Order
Build and System Integration, Update Work Instruction
Setup the Jig to Nominal and Build Part for Quality Validation

18. • Oshkosh Corporation Classification: Unrestricted
Requirement Analysis
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Analysis:
• Problem Statements
• Needs/Functions
• Requirements to Functions
• Load Seq. and Clamping Plan
• Designs/Revisions to Design
My Designs:
• Tower 1 Adjustable End stop
• Winnebago Roof Fixture
Modification
• Riceville Rotating Weld Fixture
Foot Pedal
• Hydraulic Valve Lifting Device

19. • Oshkosh Corporation Classification: Unrestricted
Winnebago Fixture Upgrade
Problem Statement:
The contract manufacturer contacted us
with an opportunity to improve the roof
fixture.
Revision to Design:
• 3 Panel End-Stops
• 10 Extended bracing
• 2 Clamps and brackets
• 4 Rack and pinion covers
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20. • Oshkosh Corporation Classification: Unrestricted
Value in Winnebago Upgrade
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Improvement:
• Contract manufacturer issues are addressed (Morale/Delivery)
• Additional end stops and clamping hold parts securely (Quality)
x10 x3
x2x4

21. • Oshkosh Corporation Classification: Unrestricted
Tower 1 End Stop Upgrade
Problem Statement:
Tower 1 needed end-stops for the
Meridian and I saw an opportunity to
consolidate the end-stops and lower
variability.
Revision to Design:
• 1.5” Wider roller
• Threaded end with locker
• Extra offset hole
• Longer Pins
• 4X for all sides
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22. • Oshkosh Corporation Classification: Unrestricted
Tower 1 End Stop Upgrade
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Improvements:
• 42.2% Reduction in Setup Time (Delivery)
– Increase capacity
– Increase production efficiency
• Setup Process Simplification (Quality)
• Additional Error proofing (Quality)
• Adjustability for Yearly Calibration (Quality)

23. • Oshkosh Corporation Classification: Unrestricted
Riceville Foot Pedal Upgrade
Problem Statement:
The foot pedal could be activated
accidently, which is a safety issue.
Revision to Design:
• Remove current pedal
• New pedal to the outside of active
working area
• Add a drive shaft
• 2X for similar fixture
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SAFETY ISSUE

24. • Oshkosh Corporation Classification: Unrestricted
Benefit from Foot Pedal Upgrade
Improvement:
• 98.2% Reduction in Risk Priority Number in the function (Safety)
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Oshkosh PFMEA

25. • Oshkosh Corporation Classification: Unrestricted
Hydraulic Valve Lifting Device
Problem Statement:
Operator must lift and manage the
175lb Meridian hydraulic valve, OSHA
requires a lifting device
Design
• Pivot bearing to rotate valve
• 20mm threaded attachment
• Safe for lifting 175lb valve
• Test with a 5x safety factor
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175lb
Hydraulic Valve

26. • Oshkosh Corporation Classification: Unrestricted
Value in Valve Lifting Device
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Improvements:
• Dennis uses it and Safety approves (Morale)
• Reduction in physical exertion (Safety)
• Safety hazard prevention (Safety)
• Tested “Homemade Tool” (Safety)

27. • Oshkosh Corporation Classification: Unrestricted
Take away

28. • Oshkosh Corporation Classification: Unrestricted
The Take Away
What I learned:
• Process of new product launch from the manufacturing perspective
• Hands on person
• School of common sense
• More knowledge about all the roles of ME/IE
• Application from what I’ve learned in school
• More about Oshkosh and McNeilus
• How to ride a long board
McNeilus Benefits
• Improve areas of: Safety, Quality, Delivery, Cost, Morale
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29. • Oshkosh Corporation Classification: Unrestricted
The Take Away
Future Goals:
• Finish last year of schooling
• Get more involved with Automation/Engineering
• Get more Involved with Process Improvement (Stats/DFSS)
Overall:
• Great people (interns and employees)
• Great experience
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30. • Oshkosh Corporation Classification: Unrestricted
Acknowledgements:
• Director/Mentor: Todd Roughsedge
• Everyone in ME/IE, Vijayakumar Kittuswamy, Peter Howard and
Ben Horejsi
• Jigs and Fixtures: Jim, Brian and Dave
• Quality Team
• PFMEA: Jim Luraghi
• Safety: Ross Coberly
• Materials: Justin Carlson
• Production: Seng and Eli
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31. • Oshkosh Corporation Classification: Unrestricted
Presentation
Over