The document summarizes Trevor Huggins' internship at JW Aluminum over the summer. Some of the major tasks he accomplished included creating an automated shift report using VBA, conducting time studies of the 11 casters, and designing a mechanical float system to indicate liquid levels. He also entered data, assisted with audits, and performed various other jobs. Trevor learned about consistency in production, data analysis, and the business aspects of engineering. He believes his work added value through increased efficiency and convenience. Some areas for improvement include focusing more on smaller tasks and departments. Overall, it was a valuable learning experience.

1. B Y : T R E V O R H U G G I N S
J W A I N T E R N
C L E M S O N U N I V E R S I T Y 2 0 1 6
Summer 2013 Internship
Reflection

2. WHAT I DID THIS SUMMER
•MAJOR TASKS ACCOMPLISHED
•MINOR TASKS ACCOMPLISHED
Section 1

3. Major Tasks Accomplished this Summer
 Studied the entire process of developing aluminum coils,
from melting to finishing, while familiarizing myself with
each individual component
 Created an automated shift report using Excel VBA that
pulls data from standardized workbooks and updates
automatically based on what the user clicks and inputs.
Can be emailed and cleared after usage and is “fool-
proofed.” Over 1000 lines of code.
 Learned about the capabilities of VBA, itself, and its
importance in the workplace with regards to data
analysis. Used this knowledge to create numerous Excel
workbooks for specific data analysis

4. Automated Shift Report Picture
Casting Analysis based on: Instructions: 1. Click the 'Create Report' button to request data
Day,Shift, and Crew 2. Select the date, shift, and crew from the user-boxes
3. Click the 'Email Report' button if you wish to email the data
Date 4. Click 'Clear Report' after you are finished analyzing the data!!!
Shift
Week Num Coil Type Caster Operator Scrap Weight Reason
Crew
Week Num Type Caster Holder Start Time (00:00) Finish Time (00:00) Minutes Reason
Caster # Planned Actual Caster # Planned Actual
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10 10
11 11
Total Total
Short Coil, Drainout, Scrap Coil Analysis
Notes
Production Yield [lbs]
Daily Goal: Shift Goal:
Cleaning and Equipment Information
Shift Log
Notes
Create Report Clear Report Email Report

5. Major Tasks Accomplished this Summer Cont.
 Study of communication within the
casting office and the communication
board
 Time Study of all 11 casters
 Complete study of the graphite spray
system
 Created Macros for sorting and
displaying data

6. Time Study Example
Date 6/11/2013 6/20/2013 Crew B
Time 1:35 3:40
Time Study # 1 2 2 2 2 2 2 2 2 2 2 2
Caster Number 10 1 2 3 4 5 6 7 8 9 11 10 1 2 3 4 5 6 7 8 9 11
Aisle Way 1
Behind Caster 6 1 1
Can't Find / On Break 13 1 1 1 1 1 1 1 1 1 1
Check Sheet / Desk 3 1
Gathering Supplies 1
HMI 4 1 1
Infinity Station 1
KPI Board 2 1
Oracle 0
Other 1 1
Sheet 4 1 1
Spray System Ctrl Panel 0
Spray System Tank/Stand 3 1
Talking with Operator 3 1
Talking with Supervisor 2 1
TPM Board 2
Trough 0
Winder 1 1
Number of Operators at Caster 41 0 0 2 2 0 1 1 0 1 0 0 1 1 0 1 0 1 2 0 2 1 0
Total # of Operators on Floor 0 0 2 4 4 5 6 6 7 7 7 1 2 2 3 3 4 6 6 8 9 9
Coil Buildup 0.75 0.25 0.00 0.25 0.50 0.50 0.75 0.50 0.50 0.50 0.5 0.75 0.25 0.25 0.75 0.5 0.75 0.5 1 0.5 0.75
Other 1

7. Major Tasks Cont.
 Used the design process to formulate, build, and test
a mechanical-float system that allows operators to
get a visual indication of the liquid level in the
graphite spray system reservoir tank. Process
included sketching, dimensioning, purchasing,
building, and testing the float system design.
4 3 2 1
Cost Durability Simplicity Accuracy Totals
Design 1 3 2 2 3 25
Design 2 4 3 4 3 36
Design 3 2 5 2 3 30

8. Minor Tasks Accomplished this Summer
 Entered data from over 100 German Shell Data Sheets
into an established database
 Served as the sorter and a “fresh set of eyes” for Brett by
analyzing hundreds of control plans and circling what the
operators need to improve on in regards to filling out the
control plans
 Stood alongside Jeff Thompson as he performed internal
audits, eventually performing one myself with assistance
 Sketched an entire tip to scale with dimensions
 Assisted the process engineers in everyday tasks
 Numerous other “odd-jobs” and, at times, secretary-like
work

9. WHAT I LEARNED THIS
SUMMER
Section 2

10. General Themes Learned
 While it would take hours to fully explained all that I
have learned this summer, here are some general themes
that I picked up working at JWA:
 The importance of consistency in the production industry
 DMAIC Process
 The collaboration of many departments within a plant to
ensure success
 A thorough understanding of the chemical properties of
aluminum and the omnipresence of chemistry and
material science in this plant
 Complete understanding of how data affects the
operations within a company

11. Themes Continued
 How the design process is applied in the workplace
 The versatility of an engineering degree
 The realization that JW Aluminum is, first and
foremost, a business and that each action taken by
process engineers or managers can affect the
financial welfare of the company positively or
negatively (updating casters story)
 The fact that engineers must often make
financial decisions

12. VALUE ADDED TO JW
ALUMINUM
Section 3

13. Value Added over the Summer
 It is very difficult for me to estimate or associate a
pecuniary amount with the value I added to the
company this summer; however, I firmly believe that
the positive effects of my summer projects will
manifest themselves in the long run
 Automated Shift Report Efficiency and Convenience
 Time study information provided

14. Value Continued
 By entering copious amounts of data into a database,
I saved the process engineers hours of time, which
they could devote to other tasks
 Float system: the visual indicator provided can save
time and effort by informing operators whether or
not the liquid level is low
 It is my hope that my assistance with the audits
added value to the process
 Excel spreadsheets created
 Investment by JWA

15. CONCLUSION
Section 4

16. Personal Improvements
 While I am satisfied with my work this summer,
there are some things I feel that I could have done
better:
 At times, I became so devoted to a single task that I avoided
undertaking other smaller tasks that were requested
 Became so involved with the affairs of casting and melting that I
neglected rolling and finishing at times. Am still slightly confused by
the finishing process due to lack of personal motivation to assist in this
department
 Should have spent more time talking with operators and supervisors as
to ways to improve general communication within the plant
 I wish I could have spent more time working with Infinity software

17. Suggestions
 Place a “SmartBoard” or computer monitors in the
casting office as a means of technologically updating the
communication board, rather than manually updating it.
Plus, some of the information displayed is not necessary.
 Ensure that each current or new operator is properly
trained as to how to fill out a data sheet and the
significance of each individual section he/she fills out. I
never encountered an operator who knew what a reaction
plan was when I assisted with audits
 More time to complete projects, if possible
 Mass Produce Float system

18. Smartboard

19. Final Remarks
 I would like to thank you all for giving me the
opportunity to work here this summer, you have all
assisted me and I have gained a tremendous amount of
knowledge that I will apply in my second year as an
engineering major
 Working with professional engineers in the workplace
will prove to be invaluable throughout my sophomore
year, as will having experience in a production facility
 I am very willing to continue working here next summer
or even over Christmas break if the opportunity presents
itself