Peterbuilt Summer 2001

Touch of Class
Summer 2001
Nashville
Wright Farms
A True Survivor Read on Page 3.
Frank Wright of the Test Department is proud to tell you he has been with the company thirty years and is the father of Kevin Wright who is a supervisor in the Paint Department. But his 200-acre horse farm is his “pride and joy.”
When Frank and Tina Wright married, she had horses, and he had cows. It wasn’t long until they decided to raise horses that would be bred to run on a racetrack or barrel race. Wright Farms currently has forty horses, which requires a lot of work. It involves many sleepless nights, but Frank and Tina love it. Frank says nature takes good care of the mares at foaling time, but they do need to be watched. At one time, the Wrights slept in the barn to watch the mares ready to foal. However, Frank has now installed a video camera in the barn and a monitor for the bedroom. Now, they have to listen to horses whining all night but they have been fortunate enough to see almost every foal born. Frank said Tina does most of the work and during the busy season they are in the barn till almost midnight.
One of their favorites is a stallion named Favorite Colours. He is an AAA race winner on the track and son of a World Champion, Triple Crown Winner, Special Effort, which is the only Quarter Horse in history to win the Triple Crown in Quarter Horse racing. The farm has both Quarter Horse and thoroughbred broodmares. Many of the mares are stakes winners on the track and have produced winning foals. One of the foals, Redalo, won the West Texas Futurity Conso- lation last year as a two year old and placed second in the race at Sunland Park, in New Mexico, on March 27, 2001.
Retirement isn’t in Frank’s plans for the near future even though he works long hours between work and Wright Farms. Visit their website at WWW.WRIGHTFARMS.NET
Tears and smiles mingled in the welcome given yesterday to Cpl. Tommy Caroland at Berry Field. On hand to great the returned prisoner of war were from left to right, his sister, Bruce Caroland holding his dog, Tiny. Mrs. Caroland, Cpl. Caroland, his father, Tom Caroland, holding his nephew, Mike Porter, and his half sister, Mrs. J. W. Porter of Clarksville.
Wright Farms . . . . . . . . . . . . . . . . . . . . . . 1 PlantManagerComments ...........2 Recognition . . . . . . . . . . . . . . . . . . . . . . . 3 Life After Peterbilt . . . . . . . . . . . . . . . . . . 4 Continuous Improvement. . . . . . . . . . . . 5 Customers . . . . . . . . . . . . . . . . . . . . . . . . 6 Volunteer Corner . . . . . . . . . . . . . . . . . . . 9 Six Sigma . . . . . . . . . . . . . . . . . . . . . . . . 10 Kaisen. . . . . . . . . . . . . . . . . . . . . . . . . . . 12 What’s Happening?. . . . . . . . . . . . . . . . 14 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clubs ...........................20
Frank, Tina and Chelsea with Favourite Colours
IN THIS ISSUE:


Touch of Class
Plant Manager Comments
When reading this edition of “Touch of Class”, one word pops into my mind - “Pride”.
Just look at some of the pictures of our equipment and customers on Pages 6 through 8. We build the toughest, best looking, and most desired vehicle on the road. Not only that, we cus- tomize them to the customers’ needs. From concrete mixers, to dump trucks, to over-the-road “long and talls”, we build the best!
Staying the best means change. Remember the 352? We made that better by coming out with the 362. Then the 359 took over when the length laws were changed. People said “you’ll never build a better truck than the 359”. Well, we did! The 379 is Nashville’s most popular truck ever, and it is still improving through con- tinued engineering updates. It’s easy to forget about how fortunate we all are in
being associated with Peterbilt. Not many people can point to their work each day while out with their friends, spouses, children, or grandchildren and say “I helped build that”, particularly when the person you’re talking to knows it’s the best. That makes us all proud. This same feeling comes from going by our facility on Myatt Drive. It looks “First Class” and well cared for.
The Nashville Plant and the sys- tems we use continue to evolve and get better every year. Some of you remem- ber when the back of the plant was at the rear of the plant cafeteria, when we used to cover the engines with plastic before we painted the chassis, or when we would mount the rear axles under the built up frames. How about when the Receiving Dock on the north side wasn’t enclosed. It was really cold out there in the winter. Wow, have things improved! Now, we have a paint sys- tem we can be proud of, a separate Test
building, and an air- conditioned facility. We have gone from paper systems to on- line computer systems everywhere. We have gone to calibrating all our critical tools and using standard processes to comply with I.S.O. The Nashville Plant and the trucks we build are better today than when each of us started to work here.
Much of this can be attributed to the “Pride” Peterbilt stands for and how all of us have striven to meet our own personal stan- dards of pride for many years. This requires coming to work each day and giving it our best. Often times, this
isn’t easy due to some personal con- cerns, part shortages, engineering is- sues, or other types of problems. But, each of us has done it, and Peterbilt Nashville is a better place because of it. So are we. We have great friends we have worked and played with for many years. Not everyone can say that. It’s something we should appreciate.
“Pride” is priceless. You can’t put a value on it; but people know what it is when they see it. Just remember the face of a small child when they accom- plished something as small as catching a fish. We need to take as much advan- tage of the pride we put into our efforts each day as possible. We want every customer to see it when they visit. Are we interested in every truck being the best it can be? Do we communicate that? Does our plant look “First Class”, well lighted, painted, cared for, and clean? Are we friendly to every cus- tomer who asks us a question?
There are a lot more questions like this that each of us can ask ourselves. We know these are difficult standards to meet on a daily basis; but meeting them has gotten us to where we are today.
The future, although difficult right now, is positive for Peterbilt Motors and us in Nashville. We have the best product, great people, and terrific deal- ers in the field working with us. Con- tinuing our tradition of “Pride” in everything we do is the key to continu- ously improving and beating the com- petition. I am not embarrassed at all to say I’m proud to be a part of what we have accomplished together here at Peterbilt Nashville.
I’m proud of the trucks we build. I’m sure each of you feel the same way. As I said before, it’s a difficult standard to meet each day; but we can do it. You’ll see this great potential as you read and look at the following pages.
Thank you for your time and your “Pride”.
2


Summer 2001
Peterbilt Nashville Has True Survivor
Tomas Caroland, Jr. joined the Paint Department at the Peterbilt Nashville Plant on December 22, 1969 where he continues to report to work daily. At 70 years of age, he says he has no plans to retire from work.
Tom has survived 31 years of market fluctuations with the truck market, as have some other Peterbilt Nashville employees that joined Peterbilt Nashville at its inception. However, for Thomas Caroland, Jr., sur- vival has a much stronger meaning than for most peo- ple. He is a survivor in a much truer sense than that many associate with the popular “reality” TV show of recent months.
For Caroland, mind over matter has been a matter of survival. Survival has meant living through days and nights of 30 degree below zero weather. Survival has meant not losing hope while in captivity. Survival has meant having to live in an eight-foot square cubical with 13 other prisoners of war and maintain sanity.
Thomas Caroland Jr. volunteered for the US Army in 1949. He served with the Army until July 1953. Caroland found himself in the middle of the Ko- rean conflict in 1950. On December 13, 1950, while serving guard duty, North Korean soldiers sprayed ma- chine gun fire into the camp Caroland and other U.S. soldiers occupied. Most of his unit was killed by the at- tack. Thomas says he remembers his sergeant telling them “ we have to get out of here”.
The few remaining soldiers in his unit roamed the mountains in 30 degree below zero weather. Caroland states that his feet were actually frozen. Eventually they found a grass hut where they hid for four days be- fore being captured by the enemy. This capture was the beginning of 33 grueling months of captivity.
Tom and the rest of his unit were imprisoned in a small room where a bucket in the corner served as the bathroom. Bathing, shaving, clothing, and brushing teeth became luxuries that were not permitted. He eventually was able to find a small piece of rope with which he fashioned a toothbrush of sorts by fraying the end. Tom and the other prisoners slept on top of each other because of the cramped space and to stay warm. “You wanted to be in the middle to stay warm and you
did not want to be on the cold floor”, he says.
Heavily in- fested with lice,
the prisoners
were fed a diet
of millet, a small
grain from vari-
ous types of
plants including
sorghum. There
was little or no
opportunity for
the POW’s to
experience
physical exer-
cise. Caroland
says that there
was nothing else to do but daydream. “I got to where I daydreamed so much that when I was fed sorghum tops, I thought they tasted like turnip greens”, he said. Once a guard sneaked some dog for him to eat. Thomas, states, “not bad, a nice change from fish eyes and bones”.
After 13 months as a Korean prisoner, Caroland and others were placed under the control of the Chi- nese. This turned out to be a welcome change. The prisoners were given a change of clothes, a bowl of sugar each month, one cigarette a day, boiled whole fish, and roasted grasshopper. The change in command from the North Koreans to the Chinese also amounted to an opportunity to get some exercise. This was ac- complished by digging air-raid shelters and polishing cartridges from stray bullets.
Freedom finally came after almost three years cap- tivity. Caroland along with the other captives were taken by truck to an area called “Freedom Village”.
Thomas Caroland (Tommy to those who knew him) was given a hero’s welcome when he returned to Nashville’s Berry Field. He says he was overwhelmed
Continued on p.4
Thomas Caroland.
3


Touch of Class
Continued from p.3
that hundreds of people were there to greet him upon his arrival. He was further surprised how Robertson County residents showed their appreciation for his or- deal. The Springfield High School band helped make his “Welcome Home” ceremonies complete.
Over the years, Thomas has spoken little of his ex- periences as a prisoner of war. We are grateful that he has shared some of his experiences with us. He has re- ceived several medals for his service in the Army: the Combat Infantry Badge (CIB), the Prisoner of War (POW) Medal and most recently, a Major General of the Korean Army presented him the Korean Service Medal at Ft Campbell in Clarksville, TN.
One lingering result of Tom’s Korean War days that continues to remind him of his ordeal is the sensitivity of his feet, the result of having been frozen. “Still have to sleep with them out from under the cover, and still have to cut holes in my shoes for comfort” says Tom.
Today, Tom serves as Commander of the Prisoner of War Club (POW) of Middle Tennessee. Tom’s ex-
Thomas Caroland receives Korean Service Medal from Major General of the Korean Army.
periences should reinforce and remind all of us the many sacrifices and acts of heroism made by United States veterans and military personnel. To say, “Thank you” seems inadequate. We salute you!
Bubba Green – Life After Peterbilt
When James A. Green (better known as “Bubba”) drops by the plant for a visit before attending either a Bass Club or a Local 1832 Retirement Club meeting, there is one thing you can’t help but notice. Bubba never stops smil- ing. Why? Bubba retired on February 29, 2000. His career began with Peter- bilt on August 9, 1971 and spanned more than 28 years.
“Life is good” Bubba remarks with a smile. He and wife DeDe live just 10 minutes from Old Hickory Lake. He says that his favorite hobby is fishing. He stated that he goes fishing an aver- age of three times a week. However, he says, in the winter, deer hunting is added to his list of hobbies. Bubba also
Bubba Green caught a fish!
stated that his dog Gizmo goes with him everywhere including his fishing and hunting expeditions.
People are always calling Bubba and asking him to work for them. He tells them, “ I can’t. I’m enjoying retire- ment too much.” When asked what he
Green attending Bass Club Meeting
would like to say to the people at Peter- bilt, Bubba said “Tell them, retirement is good. Look forward to it and plan for it because their retirement will be here before they know it.” We offer best wishes to Bubba for continued good times for many years to come.
4


Summer 2001
Auto Shift Training for Test and Quality Assurance Employees
Eaton’s Scott Rains and Chuck Schippers on Thursday March 29th and 30th performed the Auto Shift training. Initially Scott and Chuck spent time on the floor reviewing our installation in Cab Trim and Engine Trim. They later did a one-hour presentation for Engi- neering and Q.A. representatives that included the systems configuration and operation. Scott then gave a classroom overview to the Test dept. with a fol- low-up review of a truck in the depart- ment. Test mechanics Jim Roy and Billy Lambert reviewed the system with Scott. The training was informative and gave our employees a good opportunity to increase their knowledge for im- proved customer satisfaction of this new product line.
Training class with Chuck Schippers – Eaton, Jim Roy– Test, Billy Lamberth - Test
Critical Process Documents on Plant Computers
In January 2001 Peterbilt Nashville process documents were placed on the intranet permitting employees to access them from any computer. In the pro- duction area this change nearly tripled the number of locations our employees can access those documents. On-line records are also much easier to keep up- to-date, which keeps the facility up-to- date on the latest Quality Standards.
Similar systems have been installed in other North American truck plants. Sharing this data between plant engi- neering groups to help PACCAR fur- ther improve customer satisfaction through the development of Standard Paccar processes.
Supervisor, Rod Watts, reviewing critical process with Ronnie Lay – Axle Department
5


Touch of Class
CSR Pleased With Pilot Review Process
On March 13, 2001, there was a Pilot review of the first truck produced as a result of a team effort over a two-year pro- ject between CSR (Rinker) and Peterbilt. The project started with the Year 2000 Millennium truck.
The initial goal for weight reduction of the trucks used by CRS was the direct result of the stringent requirements by the Florida DOT. To stay within the legal weight limit require- ments, CSR trucks may have to dump as much as 1⁄2 square yard of concrete, a costly loss on an annual basis. The team effort between the two companies resulted in an increased capacity of the CSR concrete trucks from 10 to 10.5 yards. The additional 1⁄2 capacity is equivalent to approximatly 3700 pounds.
The weight reduction was obtained by removing some items as simple as one sun visor from the cab and changing to a different type horn. More complex changes include CTIS (Dana’s Central Tire Inflation System). Traditional CSR trucks specified a 6x6 configuration which includes a heavy front drive axle. With the CTIS, better traction can be ob- tained using a standard 4x6 configuration where only two axles pull. The CTIS allows the driver to select on or off road condition and the tires are inflated accordingly. For off-road conditions, the tires are deflated which allows for a bigger footprint of the tire resulting in greater traction.
Richard Fritz, Maintenance Manger for CSR has been in the business for over 26 years. CSR is an Australian company that specializes in building materials and products. The com- pany is a dominant force in the concrete supply business in the state of Florida. During their most recent fiscal year end- ing March 2001, they supplied in excess of 6 million yards of concrete for various projects in that state.
CSR Pilot Review – Peter Barber, Pat Fagan, Gary Harrington, Richard Fritz, Don Koschmeter, and Mike Jones
The company operates approximately 1100 trucks in Florida alone. Company wide, they are operating 1600 trucks including Nashville where they have a drywall distribution center. They bought their first Peterbilt in 1986 and with the exception of 10 units, they have purchased only Peterbilt trucks since 1994.
Peterbilt is pleased to have been able to work with CSR on this project. Dealer support for customers is always a top priority and, the Pilot Review process allows customers an op- portunity to observe the final product before it leaves the plant.
The Arizona Super 18’s
The below is one of the Arizona Super 18 dump trucks Peterbilt Nashville built for Harvey Trucking. The photos were forwarded to our Southeast Region Sales of- fice along with compliments for a job well done from Landon Logan of the Peterbilt Springdale Dealership.
Since all federal bridges have a maximum weight limit of 80,000 pounds, the de- sign of the Arizona Super 18 allowing for maximum payloads is critical to Harvey Trucking. The chassis weight and configuration allows our customer to haul a 27/ton payload legally. This competitive engineering advantage and our reputation for durability helped sell Peterbilt.
Arizona Super 18
Logan says he appreciates everyone’s hard work and the time invested by our employees from the beginning stages through the completion and delivery to the customer. Thank you Peterbilt Nashville for making the customer and the dealership proud to be Peterbilt customers.
6


Summer 2001
U. S. Concrete Visits Our Facility
Jessie White, Region Field Service Manager, says one of the best sales tools Peterbilt Nashville has is customer visita- tion. Terry Green, Fleet Manager for U. S. Concrete and White hosted a two-day visit of the facility for the concrete company. Green is very familiar with our trucks because he has purchased our product for several years through his previ- ous employer. U. S. Concrete is a relatively new company that has purchased concrete companies all over the United States making them the sixth largest “ready mix” organization in the country within just a few years time. Because of the buyout of numerous other companies, they have inherited various brands of trucks but are looking to standardize their fleets. U. S. Concrete brought their managers in from all over the country to see our plant and examine our product with the potential of making Peterbilt their standard truck.
The visitors were impressed with our trucks and employ- ees. Impressing our customers during their visits with a friendly
U. S. Concrete
attitude, great product, and a clean plant helps sell trucks. As a result, U. S. Concrete purchased several trucks. This could well be an opportunity to make Peterbilt the accepted stan- dard truck for U. S. Concrete. Thanks to everyone!
Peterbilt Truck Helps Support Shuttle Program
Peterbilt Nashville employees build trucks that are used all over the country. Since the 1960’s Apollo Space Program, Russ Clantice’s company has used a Peterbilt truck to handle a trailer operation used to support all the space shuttle programs as well as other flight programs at Cape Canaveral Air Force Base and now the Kennedy Space Center. The tractor-trailer op- eration has a recharger on the back that converts liquid croginice to nitrogen which is super cooled and converted to high- pressure gas to pump into the shuttle.
Just recently, Clantice decided the older Peterbilt needed to be replaced. The original truck had been re-furbished several times and it was time for a new truck. Clantice chose Peterbilt because his company has been satisfied with the durability of the original 1960 Peterbilt. Peter Barber of the Palm Beach Dealership was happy to assist him in his choice of trucks. Clan- tice is pleased with his purchase and expects the quality of the new Peterbilt to be as good as the 1960 model.
Russ Clantice Peterbilt tractor and trailer operation.
7


Touch of Class
Peterbilt 379 NASCAR Winston Cup Hauler
The Caterpillar powered Model 379 Peterbilt was built at the Madison Plant in February 2001 for the Kodak/Morgan-McClure Racing Team. Built with a 280- inch wheelbase, the power train includes an 18 speed fuller transmission, Dana tan- dem rear axle system with 3.55 ratio. The truck was delivered through Peterbilt of Knoxville. The current driver of the car is Kevin LePage. Pervious drivers include two well-known drivers, Ernie Irvan and Bobby Hamilton.
Since taking deliver, the owners have made a few changes to their Peterbilt Truck. They changed from dual headlamps to single headlamps; added a custom chrome sun visor; had the dash chromed; and added lights under the cab/sleeper box.
Kodak Nascar Hauler
The 70” sleeper compartment is a genuine asset for cross-country trips such as
those to Sears Point Raceway in Sonoma, CA or California Speedway in Fontania, CA. The trailer is by Featherlite. It is basically a rolling machine shop that stores 3 engines and enough back-up parts to build an additional racecar. The trailer is not intended for work alone since it comes complete with a TV, stereo system, office, and a complete lounge.
The driver of the new, bright yellow Peterbilt is Randall Helbert who works for the Morgan-McClure Racing Team. He states that he “loves the truck and wouldn’t drive anything else”. He continues, “ once a Peterbilt man, always a Peterbilt man”. His en- thusiasm for his new “home on the road” implies that once again, the Madison Plant can boast of a job well done.
Construction Truck Certification Class Of 2001
Peterbilt Nashville gladly opened
there training facility on June 6 to the
Peterbilt Sales and Marketing group for
3 days of training for our dealership sales
personnel. There were 21 participants
from dealerships all over the U.S. and
Canada. The Construction Truck Certi-
fication Classes were an interactive and
hands-on approach to expanding and up-
dating knowledge of the construction
truck Class 8 truck market segments. At-
tention was given to how Peterbilt products play a significant role in the construction truck market segment. The salespeople that attended the class specialized in either the construction truck segment or wanted to diversify their highway truck skills.
Peterbilt Sales and Marketing staff which included Mike Jones and Kelly Bender along with component supplier personnel, and body manufacturing presented the training. At the end of the training the participants received certificates of completion.
Kelly Bender presenting to the group.
Mike Jones presenting to the group.
Peterbilt Nashville Hosts HVAC Course
Peterbilt Nashville played host to HVAC mechanics with Peterbilt dealer- ships from across the country. The Advanced Heating and Air Conditioning course was held in the Training Center at the plant. This was a two day event that provided a “hands-on” approach for the mechanics while continuing their study of maintaining and repairing the various components of the HVAC system.
The topics for this course focused on: Troubleshooting the HVAC electrical system, proper system maintenance, system evacuating and charging, and retrofitting R134 systems.
Mike Tenbush - Dealer Training Class
8


Summer 2001
Peterbilt Truck Is Big Hit At AMQUI Career Day
Every spring Amqui Elementary School designates a day as Career Day. Each year Peterbilt Nashville provides a “big” truck so the children can have a close-up look. The children are allowed to climb up into the cab and tour the sleeper before exiting through the pas- senger door. It is obvious by their excite- ment that the new Peterbilt is the most popular attraction at Amqui Elemen- tary School Career Day.
Along with the truck, four volun- teers from the Product Engineering De- partment assisted in the career day event. The volunteers included Mark Dyer, Pam Morris, Byron Markus and David Hudson. Chuck Beasley also helped by volunteering to drive the truck to Amqui. Thanks to everyone in- volved for making this annual event special for the children at Amqui Ele- mentary School.
Anxious children in line to see the truck.
Come on – Make My Day!
Field Day that is...and that’s exactly what Peterbilt Nashville did for the chil- dren at Indian Lake Elementary School in Hendersonville. The Model 379 Pe- terbilt truck with 63’’hi-cube sleeper was a huge hit with the 300 students, teach- ers, and parents who made their way into
the cab to sit in the drivers seat. The children especially enjoyed blowing the air-horns. Thanks to Bill Dayton, Horace Cron, Thomas Cooper and Peterbilt Nashville for “making their day” at In- dian Lake Elementary School.
Horace Cron poses with Whit Gray and Daniel Hart
College Students Benefit From Nashville’s Best
Recently Susanne Gross, Human Resources Training Manager, had the opportunity to volunteer as a workshop facilitator at the INROADS Leadership Development Institute in downtown Nashville. IN- ROADS is a national not-for-profit organization that partners with over 900 sponsoring corporations to provide paid summer internships and development opportunities for minority college students. The orga- nization has been recognized by The Princeton Review as one of America’s Top 10 Internships. Susanne facilitated two workshops on emotional intelligence and states that the students were very self motivated and eager to expand their experience and knowledge. “It was amazing to see 600 students with such ini- tiative. We would be fortunate to recruit a few of the students down the road!”
Susanne Gross
In the Spirit of Tennessee’s History as the Volunteer State
Dave Deacon, General Superintendent, chassis assembly, and Jason Brown, Superintendent, cab side assembly recently worked as volunteers on a new Habitat for Humanity home In Gallatin, TN. The project for the new home located on North Blakemore Street was coordinated by Sumner County Habitat for Humanity and was sponsored by First Presbyterian Church of Gallatin. The “blitz weekend” began on Friday, June 8th and the home was completely “closed in” and ready for plumbing/electri-
cal inspections by Sunday afternoon. Saturday saw as many as 72 volun- teer workers over the course of the day.
Jason Brown and several other volunteers (Dave Deacon not pictured)
Thank you, for volunteering your free time to worth while projects like these!
9


Touch of Class
σ Six Sigma: σ Team Effort Pays Off for Materials Group
The Madison plant has long been recognized throughout PACCAR for its ability to identify problems and work together to create positive solutions. During the past six months, our Materi- als department has worked hard to im- prove receiving accuracy.
Last January, members of the Ma- terials department met to discuss the importance of accurate inventory records. In attendance were Eddie Shockney, Junior Keen, Joe Fromm, Tommy Gilbert, Gary Haskins, Richard Hudson, James Creecy, Toby Lewis, Tommy Duffy, and Gary Mudd. Every- one was in agreement that accurate in- ventory records impact our ability to deliver parts on time to our customers and the finished Quality of our trucks.
As discussion continued, concerns were expressed regarding receiving re- sults from the previous six months of business. These results reflected, on av-
erage, 159 unprocessed receipts per week, or 159 receiving defects per week. Following a healthy exchange of ideas and opinions, the group felt strongly that this key job part could be improved. It was agreed that a Receiv- ing Dock Action Form would be uti- lized to gather and track data that con- tributed to these receiving errors. The form would originate on the dock by a receiver, who would note the root cause of the receiving issue on the form and would pass it to a planner, who would communicate the issue to the supplier, note a corrective action response and return the form to the originator.
These Receiving Dock Action Forms were tracked for supplier fre- quency and total quantity over the next six months. For the first three weeks in June, the results indicate an average of 59 unprocessed receipts per week com- pared with 159 per week at the begin-
Materials Team
ning of this project. This is a 62% re- duction in unprocessed receipts.
The improved accuracy and timeli- ness of receipts not only helps materials deliver product on time to its’ internal customer, production, but also helps ac- counts payable improve invoice match- ing. This is a great example of what can be accomplished when people work together in a spirit of continuous im- provement.
Six Sigma Green Belt Training
The Nashville Six Sigma Group concluded another wave of training in June. The class included 12 participants from multiple departments, including; Human Resources, Materials, Product Engineering, Production and Account- ing. The total number of trained Six Sigma Green Belts and Black Belts in Nashville now stands at 43.
Training includes statistics, struc- tured problem solving techniques, and a large amount of information mixed with a little fun. The main objective of train- ing is to give Green Belts the needed tools to identify defects, reduce process variation, and implement controls for de- fect prevention. By the end of week 2, Green Belts have been exposed to the tools needed to complete their project.
The next step is to put the tools to use.
These newly trained Green Belts are working on projects that address quality issues and overall process im- provements. Projects include: paint overspray reduction, cab assembly pre- paint damage, materials ordering im- provements and administrative process improvements, just to name a few. Green Belts report on progress monthly and rely on strong teams to make im- provements to our processes. Teams are critical to providing effective changes that last. A project team’s goals are to eliminate defects, reduce variation, and eliminate waste.
With 12 new Green Belts trained, the Peterbilt Nashville Team is even more focused on delivering unsurpassed
May/June Green Belt Trainees
Craig Callis Dan Simmons Kevin Wright John Mattingly
David Dolan Susanne Gross Angie Wyatt Jim Overmohle
Steve Jones
Mike Phillips Margie McDannald Dee Sweatt
quality and competitiveness to our cus- tomers. Check out the displays around the plant to see what Six Sigma teams are working on in your department.
10


Summer 2001
Six Sigma - New Roof Drill Nest
for Cab Assembly
A recent Six-Sigma project completed by Launa Konyndyk replaced the old roof drill nest in Cab Assembly with a newer, color-coded version. The roof drill nest is used for drilling options such as ICC lights, air horns, and anten- nae in the aluminum cab roofs. Because of the design of the old drill nest, it could not include all of the roof drilling op- tions such as logger horns, omnitrac, and logger antenna. The new roof drill nest has every drill bushing clearly labeled and color-coded. The labeling and color-coding allow easy iden- tification of the drilling option and allows additional options to be drilled by the roof drill operator in Cab Assembly. There are no obsolete drill options included in the new roof
Launa Konyndyk and Charlie Hand
drill nest, which results in a much cleaner and less confusing drill nest. The roof drill operation in Cab Assembly accepted this new drill nest very positively in an effort to mistake proof the drilling of our aluminum cab roofs. Thanks to all for mak- ing this Six Sigma project a success.
Six Sigma Reaches Our Suppliers
This spring and early summer the paint department began seeing fibers on the cab doors below the sills in the paint. The Six-Sigma group was asked to investigate. After a process evalua- tion, no source could be found in the Paint Department or in Cab Assembly. Further analysis revealed that the fibers were pinched between the sill and the door panel in the assembly process at our supplier. Working with the supplier Quality Industries, the cause was nar
rowed down to two processes. The weld paddles were causing burrs on the sides of the door panels and then handling the doors with cotton gloves. The cot- ton gloves were catching the burrs and leaving lint. The weld paddles were modified to eliminate burrs and the cot- ton gloves were replaced with reduced lint gloves. Quality Industries and the Six Sigma group worked together to eliminate this defect and an additional improvement of Peterbilt paint quality.
Ken Webb explains improvements to Kenneth Finn
Low Noise Air Gun
A new low noise air gun has been installed in our bump and grind in the paint department. The gun is used to blow debris off the trucks prior to the painting process. This spe- cific gun was identified as a potential solution to reducing the plant noise level.
The low noise air gun is a new product from a manufac- turer named Silvent. They have patented safety nozzles de- signed to reduce the turbulence that is the primary cause of high sound levels associated with blowing operations with compressed air. Silvent’s nozzles easily fulfil the requirements that OSHA and the EU Machine Directive stipulate regard- ing noise levels and compressed air safety. In most installa- tions, the noise levels are cut in half, which means that noise
is reduced to a
level where the
risk of permanent
hearing loss is
eliminated. We
are currently pur-
chasing this equip-
ment for the areas
in Paint that use
compressed air for blowing off dust and debris in booths as identified by consultants.
Pictured is Fred Cothron using the new gun. Fred stated the noise level is definitely less and the gun is easy to use.
Fred Cothron
11


Touch of Class
σ
σ
Six Sigma:
Critical Process Compliance Awareness
Jerry Anderson and Kenneth Jenkins – Paint
Critical processes are those procedures documented by Peterbilt as most impor- tant affecting the safety and quality of the vehicles purchased by our customers. In- cluding both mechanical and paint, there are more than 150 critical processes. Process documents serve as a reference guide for operator training and consistency of methods, particularly useful when jobs assignments change. Each critical process has a “Control Method”. Usually the “Control Method” is a periodic process audit per- formed by an auditor. To heighten awareness of our many critical processes, auditors often take a photo of the process operator(s) at the line location. When each of the process steps are followed, the audit result is “100% COMPLIANCE”. You may have viewed some of these photos as they ap-
pear for a few seconds on the plant moni-
tors as “100% COMPLIANCE”. Below
are two pictures from many displayed on
the plant monitor system. We all take
pride in demonstrating compliance to
these documented processes. Thanks to
everyone helping us to deliver consis-
tency to our customers by means of criti-
cal process compliance! Ray Banks and Claude Miles – Engine
Lloyd Manion and Ronnie Lay – Axle
Front Axle Kaizen
During a recent Kaizen event in front axle, process and time saving improve- ments were made. The front axle employees (Johnny Henson, Isaac Frierson and Joseph Thompson), working with manufacturing engineering (Tony Hopkins), de- termined that a 2.5” DC nut-runner socket, a back-off/alignment bar and a special socket for the DC nut-runner used on heavy duty axle brake assemblies were needed. By implementing the suggestions of the front axle employees, the process and qual- ity of the end product has improved. These improvements, will save both installa- tion time and improve the installation process in front axle. Thanks to the help and suggestions from the front axle employees, this Kaizen event has been a success.
Left to Right: Johnny Henson, Issac Frierson and Joseph Thompson
Engine Trim Kaizen
During a recent Kaizen event in engine trim, process and time saving improvements were made. Douglas Harris, Engine Trim, working with manufacturing engineer, Tony Hopkins, determined that a 45 degree 18mm ratcheting wrench could be used to tighten bolts on the mounting plate for fan hubs. This tool allows Doug to minimize the installa- tion time for plate and hardware while being ergonomically designed to allow for free rotation and a larger grip to improve grasping of the wrench. This tool will aid in both process im- provement and ease of installation. Thanks to the help and suggestions from Doug, this Kaizen event has been a success.
Douglas Harris
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σ Six Sigma: σ Kaizen Blitz Benefits Nashville Plant
Frame–Mike Elmore and Ted Thomas-Warehouse Test – Lynn Traughber (AIF) Tire Installation
Summer 2001
As part of Project Management training, the Nashville Six Sigma Group presented a class on Kaizen Blitz Methods to approximately 100 engineers, supervisors, and managers. This class resulted in a 5-week blitz campaign.
The application of the word “Kaizen” means continuous improvement. A Kaizen Blitz is the application of one or more quick improvements in a process that may come in small incremental steps. However, enough small steps can eventually add up to a valuable cost or competitive advan- tage relative to the total production process.
Within the first week the engineers, supervisors, and managers were divided into 13 teams. The teams then identi- fied 97 potential blitz opportunities. Each team, lead by a member of the Manufacturing Engineering Department, se- lected projects and began applying blitz methods. The fol- lowing are the results of a few of those projects.
Frame Department: The Mid-ship Plate project was ap- proached because of lack of space and congestion in the work area. The problem was resolved by removing obsolete parts as well as excessive inventory from the work area. Part number readability was also improved for quicker identification.
Test Department: Tire Label Elimination. Tire labels are commonly found attached to the tire tread. However, when these labels fall off the tire, they create a cleaning problem of the dynamometer machine as well as other areas in the plant caused by the residual adhesive on the back of the label. The Team contacted ASL, tire assembler, and they agreed to
Cab Trim – Mike Howell
remove the manufacturer’s label when tires are mounted prior to being delivered to the plant.
Cab Trim Department: This work area was congested be- cause of the placement of cabinets and worktables as well as the storage of parts that are seldom used. Rearranging and re- moving any extra cabinets and tables reduced congestion and clutter. Efficiency was improved by relocating low usage parts and replacing them with frequently used parts located closer to the employees work area. Air horn hoses were moved to a more convenient location as well.
13


Touch of Class
Peterbilt Nashville Scores “A” With Eaton/Meritor Clutch Audit
Our annually scheduled Clutch Audit was conducted on May 8th. Representatives from Eaton and Meritor clutch di- visions met to assess our handling and installation procedures as well as clutch measurements after the vehicle is com- pleted. The precision of a correctly adjusted clutch is a key concern for our customers.
Peterbilt Nashville, Eaton and Meritor perform several steps in the overall audit. They include in part; a review of the specifications; installation and adjustment of clutch com-
ponents prior to installation of the engine in the chassis, re- view of calibration equipment to insure torque specifications are compliant and a review of the operation of the clutch after the truck is completed.
This joint partnership audit is one of several that Peterbilt conducts with our suppliers to help promote optimal manufac- turing practices necessary for achieving top vehicle perfor- mance and durability. Our plant scored 95% conformance during the audit, an “A” rating in Eaton’s customer evaluation.
Matt Blomeke-Eaton, Johnny Davis-Test Dept., Greg Hunt-Meritor
Chuck Smith-Engine Dept, Matt Blomeke-Eaton, Richard Welch-Engine dept., Greg Hunt-Meritor
TRW Audit
Our TRW Steering Systems audit was conducted in Janu- ary. As with several of our other major suppliers, Peterbilt and TRW conduct routine partnership audits. Both company’s work together to identify specific good manufacturing prac- tices for factory installation of steering components to ensure customer satisfaction and lasting durability. Installation of gears, linkage, pumps, hoses, steering columns & shafts are monitored along with steering stop adjustment and gear purge. The plant scored 99% on the audit, attesting to our conscien- tious quality efforts. The TRW audit followed a visit the prior week by TRW’s Field Service Rep. for resetting gear poppets. Poppets are mechanisms inside the steering gear that relieve internal pressure just before maximum wheel turn in order to reduce system wear. Setting steering stops properly in Assem- bly II is key for correct poppet set inside the gear. Jarvis Bar- low, Jerry Callis, Harold Trammel, and Jim Roy comprised a
Andy Broughton TRW Representative and Jarvis Barlow Test Department
group of Test personnel participating in a hands-on training session for resetting poppets. Thanks to everyone involved for our successful audit results.
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Summer 2001
Nashville Plant Looks at Energy Efficiency
Nashville spends $1.2 million per year on electricity and $450,000 per year on gas. This equates to approximately $400 per truck at 16 per day. Many sales are lost to the competition for less than this. As a result, we are continually looking for ideas that will help reduce our energy costs. For example, when we re-roofed the plant, upgraded insulation is saving approximately $23,000 per year.
We have also asked for outside help. Recently, the University of Tennessee re- cently conducted an energy audit of the Nashville facility. During the audit, utility bills were reviewed for the last 12 months for potential cost savings. Also included was an inspection of the plant for suggestions that would reduce energy consumption.
Mark Spromberg demonstrates the Energy Manage- ment System to Dr Jendrucko, Allyson Hollier, and Matt Horn of the University of Tennessee.
The University was very impressed with our extensive energy management system as well as the excellent housekeeping in the plant. The energy management system controls and monitors over 900 points throughout the plant to reduce our energy usage including lights, A/C units, heaters, exhaust systems, and paint systems.
We expect to receive a report from them in 30 days outlining suggestions that we can consider implementing for further energy reductions. If you have any ideas, please bring them to Industrial Engineering attention.
European Group Visits Peterbilt-Nashville
PACCAR customers can be found all over the world. Such was the case on Monday, March 19, 2001, when Peter- bilt-Nashville played host to 39 European guests.
The coordinator for the tour was Leo Nuyens, owner and Chief Editor of “Transporama Magazine,” a European publica- tion. The visitors accompanying Mr. Nuyens are subscribers to his magazine and are transport operators including the owner of the DAF Truck of the Year Award. The guests began their visit by meeting with Joe Scattergood, Plant Manager, who presented an informative program featuring PACCAR and Peterbilt-Nashville. Following the presentation, engi- neering personnel escorted the European guests through the plant from the facility. The visitors were fascinated with the plant and had many questions. Answering questions posed by the Europeans proved to be interesting and challenging since some of them spoke limited English.
Lunch was served after the visitors were given an oppor- tunity to take photos of a new Peterbilt parked on the front lawn. The visit ended with a grand finale of a country music video featuring a Peterbilt Truck.
After leaving Nashville, the group headed for the Mid- America Truck Show in Louisville, KY. Peterbilt-Nashville enjoyed the opportunity to host such an interesting group.
Leo Nuyens (left) and visitors
Luncheon
15


Touch of Class
Panza All-Plant Meeting
In February, Peterbilt Nashville was proud to welcome our General Manager, Nick Panza and Assistant General Manager Sales and Marketing, Dan Sobic for an all-plant meeting. The meeting consisted of Nick updat- ing us on the state of the Class 8-truck business by discussing Gross Market Share, Strengthen Customer Satisfac-
tion, New Product Investment, Best- In-Class Distribution System, Further Expansion of Six Sigma Processes, Achieve Cost Reduction Targets, and Leading in Industry Quality.
Dan Sobic provided information on sales, planned sales activities, and discussions on product introductions
present and future. Nick and Dan’s presentations were very informative and very much appreciated. After the presentations they were available for questions. Our thanks to both for tak- ing the time out of their busy schedules to present Peterbilt Nashville with in- sight as to the future for PACCAR.
Nick Panza Presentation Dan Sobic, Joe Scattergood, and Roy Biggs Nick Panza, Darryl Walters, and Ray Owen
Dan Sobic Visits Nashville Plant
Assistant General Manager – Marketing & Sales, Dan Sobic became a familiar face during his two-week stay between April 30 and May 11, 2001 in the Nashville plant.
Although very familiar with all aspects associated with marketing Peterbilt trucks, Sobic’s goal was to become more familiar with the assembly process as well as the peo- ple involved in the process.
Sobic spent at least one day in each department. He attended all daily produc- tion meetings and participated in the day-to-day operation of the business. The visit gave him an opportunity to talk with the employees and get to know the key rolls they play in building the trucks he markets.
Sobic attending daily production meetings.
Sobic touring the plant with Quality – Horace Cron and Don Smith
Sobic presenting $50 gift certificates to Ardell Brown and Brent Parks for the One-On-One Safety prize for April.
Sobic takes time from the plant to review Marketing and Sales
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Summer 2001
Modine Audit
Our semiannual joint supplier audit
with Modine was conducted during
April. Our plant scored an impressive
99% with assembly areas demonstrating
outstanding process compliance. The
audit represents a joint partnership effort
with Modine to help achieve a high
level of customer satisfaction. With the
customer in mind, Peterbilt and Modine
have established specific handling requirements for the HVAC components and A/C system hard lines. All connections re- quire o-ring lubrication and torque control for lasting performance. Thanks to everyone involved who help to make Peterbilt the most comfortable truck on the road.
Carol Wilson and Donnie Backhurst - Sleeper Hard- line CTF with Rod McLaughlin - Modine
Bessie Smith - Firewall Hardline Connections , CTF
Jason Brown, Joe Scattergood, Larry Vessels, Dave Logue, Brenda Copeland, Stephanie Rollins, and Bob Stroube
Bob Stroube, James Elrod, and Tommy Duffy
Btent Parks, John Southerland, Bob Stroube, David Haley, Bill Jenkins, Joe Scattergood, Danny Warren
Michael Pate and Joe Scattergood
Retirements
Once again Peterbilt says farewell and good luck to employees retiring from many years of support and good work. We thank each of them for their years of service and wish them the very best of “Life After Peterbilt.”
George Boguskie William Boyd Pat Dexter Martha Duke James Elrod James Gamble David L. Haley Paul Johnson Bobbie Koch Mike Leh
Dave Logue Michael Pate Leroy Scruggs John Sotherland Sam Weathers
Retirement Date
01/26/2001 03/16/2001 06/01/2001 06/01/2001 07/19/2001 02/28/2001 02/28/2001 04/27/2001 03/01/2001 01/31/2001 06/01/2001 03/30/2001 01/31/2001 02/28/2001 01/26/2001
Years of Service
24
29
29
24
30
31
29
30
24
15
26
27
28
30
28
Congratulations!
George Boguskie and Sam Weathers
Allen Butler, Bob Stroube, Leroy Scruggs, Paul Dalpe, and Danny Warren
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Touch of Class
One on One Safety Program
The One-on-One Safety Program is a safety awareness tool used in our facility. A pre-printed card is published each month with a current safety topic. The cards are then dis- tributed to the supervisors in each department. The One-on- One Safety card is handed out to the employees and there is a one-on-one discussion between the supervisor and each em- ployee about the safety topic. Employees then completes the card and deposits into one of the two cafeterias drop boxes.
A Monthly drawing from the entries is for a $50.00 dinner certificate for both the employee and their supervisor.
Recent winners are Ardell Brown – Cab Assembly and his supervisor Brent Parks, Freddie Belt – Warehouse and his supervisor James Creecy, and James Beard and his supervisor Bill Toliver. They each received a $50.00 dinner coupon from one of our local restaurants.
Dan Sobic presenting Ardell Brown and Brent Parks their gift certificates for April.
Larry Vessels presenting the May prizes to James Beard and Bill Toliver
Larry Vessels presenting Freddie Belt and James Creecy March gift certificate.
Run for Your Life?
Realizing today’s lifestyles often lack exercise, young and old Americans are turning to distance running to cash in on its benefits. Whether it is for weight loss, recovery from ill- ness, or just maintaining health, distance running is a great means to improve one’s quality of life.
This year two Peterbilt Nashville employees participated in Nashville’s Country Music Marathon. As a result of the marathon excitement, several other employees began per- sonal training programs. Seeing the large number of employ- ees sharing that excitement, a running group was established. While reaping health benefits short-term and enjoying the
camaraderie of co-workers, it is hoped that at least twenty Pe- terbilt Nashville employees will participate in the 2002 Country Music Marathon.
Though not everyone who runs wishes to compete in a marathon, many group members compete in public-sanc- tioned 5k races approximately once a month. So far, an in- formal training schedule at a local course helps to prepare for those events. Anyone interested in joining the running group may contact Nathan Meek. More information about the different runs follows:
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Summer 2001
Two Peterbilt Employees Run In Second Annual Music City Marathon
Nathan Meek, Manufacturing Engineer and Lonna Zeman, Sr. Technical Analyst, both competed in the Nashville 2001 Country Music Marathon on April 28th. This course is considered one of the more challenging and ranks in the top 10 U.S. Marathons. Nathan crossed the fin- ish line in 4:38:23 and Lonna finished with 5:13:36.
In addition to running the marathon, Lonna chose to contribute to a charity, linking her training and marathon performance to the size donation that she would contribute to Paralyzed Veterans of America.
According to Nathan, this race was the single toughest challenge in his life, but it was the most rewarding one too. Congratulations Lonna and Nathan!
Nathan Meek receiving his metal after crossing the finish line.
Lonna Zeman running in the Marathon
Five Peterbilt
Employees Run In
Memorial Day Dash
Five Peterbilt employees, Nathan Meek, Tommy
Duffy, Lonna Zeman, Larry Smolen, and John Mattingly,
all pictured below, participated in the Nashville Memor-
ial Day Dash on May 26th that covered 5K (3.1 miles).
There were over 300 other participants in the race that
began at Greer Stadium. The route took the runners through Fort Negley and on to the historic Nashville City Cemetery. Proceeds of the race are used to maintain the old historical cemetery. Thank you for your participation!
Nathan Meek, Tommy Duffy, Lonna Zeman, Larry Smolen, and John Mattingly
Peterbilt Well
Represented in
July 4th 5K
The excitement of running in competition is growing at Peterbilt Nashville. There were ten employees and two Pe- terbilt family members that participated in the Firecracker 5K (3.1 miles) race at the YMCA of Brentwood.
Angie Wyatt, one of the newest runners was the first of the Peterbilt group to cross the finish line.
Contact Nathan Meek if you are interested in joining the Peterbilt running group.
Lonna Zeman, Angie Wyatt, John Mattingly, Larry Smolen, Tommy Duffy, Nathan Meek, Dan Simmons, Dave Kaschner, Meredith Simmons, and Walt Simmons, (not pictured) Gary Mudd and John Tobin
19


Touch of Class
Without You —
We Couldn’t Make It Happen Many thanks to the contributors to this “Touch of Class” issue. They include:
Peterbilt Bass Club Celebrates 25 Years
March 2001 marked the 25th an- niversary of the Peterbilt Bass Club. With Kenny Baker as the first president of the club, membership reached 15 members. Frank Ford served as the sec- ond president, and James “Bubba” Green served as president until his retirement in February 2000. George Fox has served as president for the last two years. Over the years the club has seen its member- ship swell to 52 enthusiastic Bass fisher- men. Currently there are 26 active mem- bers. There are four members that have remained active from the inception of the club. They are; Ron Cotton, Bubba Green, Frank Ford, and Danny Whited. The members want to thank to every- one who has supported the Peterbilt Bass Club. They have also stated that they hope to be around
another 25 years.
Janice Bolling, Editor Lyle Bouslog
Judy Bracey
Stuart Brown
Doug Bryan Craig Callis Thomas Cooper Brenda Copeland Tim Cranford Horace Cron Steve Davis
Bill Dayton
Dave Deacon Susanne Gross Mark Gregory Burley Harris Tony Hopkins Mike Jones
Dave Kaschner Launa Konyndyk Toby Lewis
Mike Mabry Ann Means Nathan Meek
Gary Mudd
Jim Posey Stephanie Rollins Joe Scattergood Don Smith Randy Vaughter Pete Weatherford Ken Webb
Bryan Westlake Troy Wood
Jesse White
Peterbilt Madison is an Equal Opportunity Employer. Employment, Training and Promotion policies prohibit discrimination for race, color, religion, sex, age, national origin, disability, or veteran status. The Peter- bilt job line, 860-1608, is open 24 hours to reflect current job openings. Please encourage any referrals to use the job line.
Bass Club Monthly Meeting Bass Club Fishing Tournoment
Peterbilt Motors Company P.O. Box 487
Madison, TN 37115
PRESORTED FIRST CLASS U.S. POSTAGE
PAID
PERMIT NO. 989 NASHVILLE, TN
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