Walton Hills Press - Ford Motor Company

Walton Hills Press

Walton Hills Stamping Plant Volume 2, Issue 5

Leadership WHSP Employees Accept President’s Health & Safety Awards
Message
Pictured at the top left; UAW Safety Representative Berly Smith,
This is one of my favorite Area Manager Dick Showman, HR Manager Amy Adams, and Plant
times of year - warm but Manager Kevin Ford accepting WHSP’s Special Contribution Award
not so hot that you can’t get a good from Mark Fields, President of Ford Americas, for our effort to grow
night’s sleep. Recently, I got a new and sustain a culture of zero tolerance for unsafe acts and condi-
2013 Lincoln MKT. It has a lot of tech- tions. In addition, pictured to the bottom left, is our former Safety
nological features and it handles well on Engineer Alan Benefield accepting his award for the Health and
the Turnpike during my return trips to Safety Professional of the Year Award. Congratulations to the entire
Michigan twice per month. After having WHSP team that made these awards possible.
the vehicle for just over a month, I saw a
few quality issues and had to send the WHSP’s Excellence In Action Program
car back to the dealer for attempted
repairs. The things that were wrong This month’s Excellence in Action Recipients: used instead
included a seat belt that would not pull
out, some glue or excess sealer on the of being
inside of the liftgate window, and the
Sync system which consistently 276 Line — Deliver Results — Team Mem- scrapped, thus
froze. None of these things are a big
deal but none of us want to spend mon- bers: Bradley Nicodemus, Tonya Toth, Paul Staf- saving the
ey on an item that they have to take
back and have fixed. There are also ford, Wynora Hudson, Landis Bates, Shane Allen, plant/company
several sheetmetal issues that I see on
the quarter panels, liftgate, and doors Mike Hedge, Rob Harden, James Farmer: This team money. He
that I find objectionable. However, they
are not enough that I would take the car managed to deliver results on 276 Line the week of completes
back to have the dealer attempt repairs.
3/19/12 by delivering 31 of 32 standard green hours these build-
That brings to mind the quality of the
products that we ship to OHAP and and they ran at a rate of 102% of ECR for the ups in a rela-
other assembly plants. If we wait for the
customer to complain, we waited too week. This team has shown exceptional teamwork in tively short time as well.
long. We have proven processes in
place that when followed, allow us to order to exceed productivity targets while continuing
produce parts that the customer
wants. So when I see a “bad” part get to maintain quality. Scott Behrend, John Kunakowsky, and Terry Bur-
to the customer, it can only be due to
behavior or bad process. Bad process- gess: Job AC24-150220 was the worst performing
es are the easiest to trouble shoot and
correct. Behavior has to be corrected 277 Line — Own Working Together — Team Mem- job in 51 Line. Direct load into AGV’s and automa-
by proper work instruction, retraining,
and finally discipline. None of our cus- bers: Casandra Wenner, Candice Wartman, Robert tion failures were the constraints. Effective output
tomers deserve a bad part.
Galus, Doug Smith, Tom McNally, Mike Hedge, was 250 per hour.
(Cont. on the next page)
James Farmer: The 277 Line Team has managed to The Walton Hills

deliver performance results over the past two team decided to

weeks. Between April 30th and May 10th, this team move this job to 11

has averaged 85 parts per hour which is the ECR for Line. It was set and

this line. During this same timeframe, the team has launched the week

managed an uptime rate of 96.39% of ECR. The of April 14, 2012.

team has delivered these results with Safety and The first run pro-

Quality in mind. On Thursday, May 10th, the team duced an effective

broke a production record for this line by producing output of 440 per hour. This was accomplished on

626 LH Rear Cargo Doors in an 8 hour shift. The 3rd shift and the next day on day shift. The automa-

team’s average cycle rate for the shift was 86 pieces tion team that accomplished this task should be

per hour. This team has shown exceptional team- recognized for an outstanding job. The benefit to the

work in order to exceed productivity targets while plant will be felt on two production lines.

continuing to maintain Safety and Quality.

If you’d like to recognize someone or their efforts,

Tony DeGirolamo — Deliver Results : Many times forms are available online at our Plant Page: http://

throughout the year, Tony is called upon to build a bit.ly/WHSPAtFord or ask your supervisor or team

temporary or “re-hit” die to correct various quality leader for one.

issues that have occurred with multiple parts such as

missing pierce holes or distorted flanges. Our employees do a lot to help each other and per-

form great work. We want to give you an opportunity

Using his technical expertise and various pieces and to thank each other. Thanks to everyone for their

parts that he can use, he builds small dies that can hard work!!

pierce, trim, or restrike defective parts so they can be

(Continued from leadership message on page 1) tions. We need to work with them to keep the plant moving in
the right direction.
We recently had two of our long standing members of the
salaried team leave the plant for bigger assignments. Quality As always, keep safety as a top priority both at work where
Manager, Scott Stiff, is now the Production Manager for the we are all aware of the potential dangers and at home as we
newest Stamping Plant in Ford in Kansas City. Additionally, are enjoying the warmer weather and doing things outside
Mindy Brayo, from the Labor Relations office has left to go to that we might not normally do. Keep focused on safety and
Buffalo as their Labor Relations Supervisor. Both of these quality and the other items will take care of themselves. If
people were key parts of the Walton Hills team and we wish you have any ideas about how to improve the plant, let me
them best of luck and continued success in their careers. know.
Klaus Pleinies is our new Quality Manager and Jim Kelly has
rejoined the Walton Hills Stamping Plant team in Labor Rela- Kevin Ford,
Plant Manager

These Employees Are Celebrating Birthday’s This June

GILLES LAGACE RICHARD PARKS BRIDGETTE CHEARS
RONALD PERNELL STEPHEN FARKAS DAVID NELIS
LORENZO JACKSON RAY GIARDINA LANDIS BATES
LEO KELLY JOHN SHIMKO VALITA COLTON
WILLIAM H PHILLIPS GARY DUNEGAN TINA MARACZ
MICHAEL LIPINSKI DENNIS DEAMICHES MELANIE MEYER
RICHARD ARTIM KEM CARRINGTON CHARLIE DAIGEN
MICHAEL SPENCER ROBERT LARROW NANCY MIZERIK
DONALD SIMONIS JAMES CLYMER DENNIS PIECUCH
RANDY RUMSEY WILLIAM SMITH

Congratulations To These Employees Who Are Retiring July 1st

EMMET WRIGHT JR. TERRY BURGESS THANKS FOR ALL OF YOUR HARD
WILLIAM GRIFFIN ELMER GRAHAM WORK!!
DAVID YOUNG DAVID STAATS
DAVID ION BRUCE DOBBINS JR.
DAVID AHOLT

WHSP Employees Help Soldiers Call Home

Thanks for your recent participation in our Cell keeps valuable material

phones for soldiers drive. Cell phones for soldiers, out of landfills and incin-

a non profit organization, collects cell phones and erators, and conserves

accessories and uses the money from their recy- natural resources.

cling, as well as donations, to give calling cards to

soldiers. For more than 369,000 troops serving According to the U.S. Environmental Protection

overseas, making a call home is costly and a rarity Agency, electronic waste (e-waste) is accumulating

for many military professionals. almost three times faster than ordinary household

trash.

Each cell phone collected generates two calling

cards with 100 minutes each (200 minutes per If you still have a cell phone you would like donate

phone). In total, with donations collected between or would like to make a donation, visit http://

WHSP and OHAP, we were able to support the www.cellphonesforsoldiers.com/index.php

purchase of 512 calling cards with a total of 51,200

minutes. Thank you again for all of your support.

Recycling cell phones is also a positive for the en-
vironment. It reduces greenhouse gas emissions,

Heat Stress

As we look into the summer months upon us, temperatures will continue to climb. Understanding heat stress, heat injuries and how your body responds to heat
is the best proactive approach to prevention. Once again in 2012, the Company and the Walton Hills Stamping Plant will be implementing a Heat Stress
Program. We will continue to educate you and provide resources to ensure proper heat prevention within the plant and while you are at home.

Reduce Exposure Beware of Heat Injury Risks Such As:

⇒ Ensure proper location of man fans ⇒ Overweight
⇒ Use break rooms to cool down ⇒ Recent alcohol Intake
⇒ If possible, rotate between jobs ⇒ Prior heat stroke

Acclimatize Yourself ⇒ Skin rash over large area

⇒ On breaks, relax, hydrate and eat ⇒ Heart Trouble
properly ⇒ Alcohol or Drug Intake

Weigh Yourself ⇒ Fever from any cause

⇒ Weigh yourself in dry clothes before ⇒ Medications
and after work. If you are losing

weight, you may not be drinking Salt Intake
enough water. ⇒ An increase in salt intake is not

Clothing usually recommended because

⇒ Wear light comfortable light-color cotton clothing. of the high salt content of the

Increase Water Intake average American diet.

⇒ Develop a habit of drinking water frequently throughout the day. DO NOT ⇒ If you have high blood pressure or heart trouble, check with your

depend on thirst, because it is a poor indicator of adequate fluid intake. doctor before taking any salt

⇒ Utilize igloo coolers and water fountains. Take responsibility for your health. Drink plenty of water, get plenty of rest,
⇒ Know water fountain locations and use them. eat properly and let your supervisor know if you exhibit any symptoms
relating to heat stress and report it to medical.
.

Ford Driving Skills for Life Holds Summer Tour to Train Ohio Teen
Drivers to Avoid Tragedy

As summer activities heat up, Ford Driving Skills for Life (DSFL) is offering Ohio teen drivers free half-day driving clinics with some of the nation’s top
professional driving instructors designed to address the increase in life-endangering risks that teen drivers face on the road.

In partnership with the Ohio Department of Public Safety’s Office of Criminal Justice Services and Westfield Insurance, the clinics will be held July 15 and 16 in
Northfield Park in Cleveland.

Enrollment is available to the public through an online registration process at www.drivingskillsforlife.com. Drivers ages 15-19 with a driver’s permit or license are
eligible to apply for one of the free sessions. Enrollment is available to the first 1,200 eligible teens who register.

“This is a time of year when many teens are driving more miles, perhaps to work or summer activities,” said Jim Graham, manager, Ford Driving Skills for Life.
“Also teens frequently drive with other teens in the vehicle, adding to the risk for these less experienced drivers.”

Teen drivers, mile to mile, are in three times as many fatal crashes as other drivers, claiming the lives of nearly 3,000 drivers ages 15-19 each year. The under-
20 age group also has the highest proportion of distracted drivers involved in fatal crashes.

According to the Ohio State Highway Patrol, there were 327 Ohio teens killed in traffic crashes during the 2009-2011 period; 184 of them were driving. “We are
proud to partner with Ford, GHSA and Westfield Insurance on these incredibly important events this summer for a number of reasons,” said Karhlton Moore,
executive director of the Office of Criminal Justice Services. When a young life is needlessly ended or crippled, it affects people more than you can imagine.”

Ford Driving Skills for Life will address these risks by providing 1,200 Ohio teen drivers with advanced safe-driving skills training on a specially equipped course
that lets them experience the worst the road has to offer within a controlled and safe environment. The free half-day of driving exercises builds skills in four key
areas: driver distraction, speed/space management, vehicle handling and hazard recognition.

Developed with the Governors Highway Safety Association, Ford Driving Skills for Life is recognized as the nation’s most comprehensive driving skills program,
with free professional driver instruction, state grants, free materials for parents and educators, and a Web-based curriculum that includes “The Academy” on
www.drivingskillsforlife.com. Ford Driving Skills for Life has trained more than 500,000 new drivers through free online and professional hands-on driver
instruction

Slips, Trip and Falls in the Workplace

By Bob Duke, manager, Regional Safety and Security

The majority of workplace falls occur at the same level rather than from a height. A workplace must maintain order throughout the workday to
prevent accidents/injuries. Total engagement by all individuals is required to achieve success.

What’s my role?
Plant Leadership:

Set a good example for others by maintaining good housekeeping throughout your plant
Ensure periodic workplace inspection (GRASP) are conducted to identify slip, trip and fall hazards
Establish a process to handle spills to ensure they are cleaned-up/contained immediately
Ensure appropriate training is provided for all employees who will be working in high-risk areas where slip, trip and fall hazards are
prevalent
Stress the need for preventive efforts, maintenance of walking surfaces and proper footwear
Use Periodic Job Observations (PJOs) to ensure employee compliance with safe work practices

Production, Skilled Trades, MP&L Employees:
Adhere to the recommended housekeeping practices and other safe work practices to prevent slip, trip and fall related incidents. This
includes cleaning up spills immediately or adequately marking spills/wet areas, to alert other individuals of the potential hazard. In your
work area, sweep debris from floors, remove obstacles from walkways and keep your work area free of clutter
Report potential hazards to supervisor immediately

Emphasize good housekeeping. Good housekeeping includes keeping work areas neat and orderly, maintaining floors free of slip and trip
hazards and removing waste materials (e.g. paper, cardboard, shrink-wrap, banding material). Without good housekeeping practices other
preventive measures will never be fully effective.

UAW-Ford Spring Quality Conference:
Influencing Change

By Wendy Tuma, program service representative, National Quality Committee

The UAW-Ford Spring Quality Conference was held at the Walter and May Reuther UAW Education Center. It included Quality
personnel from all manufacturing operations. Leadership from the National Quality Improvement Steering Committee kicked off
the week long conference with inspiration and guidance for "Influencing Change" to deliver enhanced quality improvements.

Building upon previous training in team building and temperament styles, participants were asked to complete a pre-assessment
to determine their 'influence style.' They learned how to better gain support for necessary change to improve quality by using
different styles of influence, through a simulation and other exercises at the workshop. By the end of the conference they were
developing team strategies on how to better communicate customer concerns at base operations utilizing different styles. The
teams showed a lot of enthusiasm and knowledge in using the Customer Pareto and Health Charts and learning more about
CCC 6-Panel and Quality College topics in order to focus on workstation robustness back at their respective facilities.

Participants left the conference re-energized, armed with new information and skills and recommitted to do the best job in quality.

AXZ Plan Usage

A/Z-Plan provides the very best price on the Ford and Lincoln products to you
and your eligible family members. X-Plan allows you to give the next best price
on these same great brands to your friends.

The plans are also a tremendous advantage to Ford Motor Company. They
provide you the tools to Go Further, tell the Ford story, and encourage the people close to you to Drive One. However, with this
privilege comes responsibility. To whom, and the manner in which you offer the privilege is very important. Plan sales must
always be in the best interest of the company and should not substitute for normal retail sales.

Continued on the reverse side

A X Z U s a g e (continued)
Examples of Prohibited Activity:

Not knowing the individuals you are sponsoring
Sponsoring PINs to customers referred to you by a dealership or a dealership employee
Selling PINs to a dealership or dealership employee or profiting by the acceptance of cash, gifts or discounts
Providing A/Z-Plan PINs to ineligible customers (see AXZ-Plan Rules for details)
Reselling an AXZ-Plan purchased vehicle within six months of the original sale date
Failing to provide proof of your relationship to the customer you sponsored on A/Z-Plan, when requested by Vehicle Programs, Human
Resources or the General Auditor's Office
Random audits are performed routinely and violating the rules of AXZ-Plan is a serious matter, even for a first offense. Employees who are non-
compliant with these expectations may be subject to disciplinary action, up to and including, suspension of program privileges, and/or termination
of employment.
You are responsible for your plan eligibility and how it is used. Please take a few minutes and visit our website, www.axz.ford.com, and
familiarize yourself with the AXZ-Plan Rules. It is up to you know the rules before you offer the plan to your friends and relatives.

FPS Integration into Global Standards

By Everett Samuels, FPS Strategist

The Ford Production System Continuous Improvement Model and 10 Critical Processes are KEY within the Global Ford Production System.
To support our new and launching plants and the development of structured and integrated operating systems, the following key processes will be standardized
and implemented: Policy Deployment, Standardized Work, Visual Management, Process Confirmation, Continuous Improvement Tools, Time & Data

Management. All of these processes are supported by an aligned and capable organization.
These Key Unifying Processes:

Are NOT new in concept, but include the FPS CI 10 Critical Processes in the
Global Ford Production System Key Unifying Processes
Will be the unifying elements, processes and standards that guide and support
the way we run our business everyday
Will integrate the Operating Systems into ONE Integrated System