Today's edition is a 2nd shift update:
SECOND SHIFT UPDATE
As everyone knows, the entire plant is in the process of preparing for the kickoff of the second shift, which will be Jan. 3, 2012. There have been many questions about a wide variety of topics, and while all of them will not be answered here, we will give you the latest information we have.
Second shift split schedule: The first day back, Tuesday,Jan. 3, the start times for both shifts will be 6 am. This will be a 10.7 hour day. The build schedule is 0, although the line will obviously run some. This day will be dedicated to training. Wednesday, Jan. 4, the second shift employees will start 12 pm noon. The build schedule is 25 per shift. These shifts will be 10.7 hours. Thursday, Jan. 5, second shift will start again at noon and the build schedule is 50 per shift. These shifts will be 10.6 hours. There will be no production Friday due to the holiday on Monday. Then on Monday, Jan. 9, the second shift will begin at the normal start time of 5:30 pm.
Production acceleration plan: As mentioned above, the build schedule will begin low but accelerate rapidly. The target at the end of the first full week of two-shift production is 225 per shift. At the end of the third week it is 295 per shift. At the end of the fourth week (Feb. 9) it is 300 per shift. The plan is to reach full production at the end of February and begin March producing 317 units per shift with a net line speed off of the K-line of 34.3 jobs per hour.
Staffing for the second shift: Employees have already been brought into the plant in preparation for the second shift launch (there will be 444 hourly employees added). So far, there have been 16 people under the return to former community clause; 22 have come back that were laid off and had gone time-for-time; 84 temporary employees were hired; and 17 National Area Hire volunteers will be arriving next week.
Quality Metrics: For the first two weeks of January, we will have a direct run rate target of 70. The direct run loss target will be 202.44 and the GCA target will continue to be 50. Direct run target by the end of January will be 75 and direct run loss target will be 192. Direct run rate target by the end of February will be 81 and direct run loss will be 178. We will reach the ongoing plant target of 85 for direct run at the end of March. The direct run loss target will drop every month throughout the year, reaching 144 by the end of December.
Department staffing/training plan: All of the job bidding has been completed. Transfers are being honored based on the training time required for the particular job being filled. As new people are brought in, they are being trained on the jobs that will be vacated by the operators going to these long-lead-time jobs. There are still around 15 openings for team leaders after the latest application/testing phase.
Stamping: There will be approximately 30 people transferring to stamping. There are 13 jobs with a 6-week training requirement. Physicals and training are in progress.
Body shop: Training is already underway as all jobs have been filled. There are 22 jobs requiring 2 weeks of training. As more people come into the Body Shop we will continue to increase the number of people on second. The training on jobs will be done just as it is with any new operator. Training will take place with the Team Leader involved and utilize a revised JIT process that will assure the operator understands & can perform the job.
Paint shop: Paint Department will consist of 79 people when we have 2 shifts. 26 of those positions will be filled by people who are not in paint today. That number is direct and indirect labor. We are utilizing manpower that we currently have in the shop to train up to 9 people a day. We have 6 long lead time jobs that take at least 6 weeks to train on. These include Elpo/mixers, gun techs and final process repair. We had 11 sprayer positions open and so far there have only been 7 filled.
Material: There are 14 long-lead-time jobs in material. There are approximately 60 people transferring to material. Physicals and training are ongoing.
Quality: There are 13 long-lead-time jobs in quality. There are approximately 31 people transferring to the quality department. Training is ongoing.
Facilities preparation for second shift: There will be an enormous amount of rearrangement necessary to facilitate the new line speed and the addition of the second shift. As you may already know, a survey is circulating through the skilled trades to determine the availability of workers on weekends and holidays to perform this work, with the goal of having our trades people do as much of the work as possible. It looks like tentatively, we will need to work maintenance personnel most, if not all, weekends until Christmas break. There will most likely be maintenance personnel working the Thanksgiving weekend and Christmas week. Everything is dependent on how many skilled trades we can get to work and time needed to complete the different aspects of the work. Maintenance personnel are still putting the plan together based on the teams developing each of their scopes of work.
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