end term presentation (actual)

Co-op Experiences

Kyle SpearmanGSM Co-opAugust 7, 2015

Copyright © 2014 BorgWarner Inc. 2

Background

Senior majoring in Business Management with an

emphasis in Operations

Graduating in December 2015

Always have had a strong interest in Trucks, Jeeps

and off-roading

Thought BorgWarner was perfect place for me to gain

additional knowledge of the 4wd platform as well as

manufacturing experience


Projects/ Responsibilities

Capacity Matrix Studies

Monthly Surcharge Report

Tooling Matrix

Supplier Day

Torq Day

Service Parts Trackable Sheet


Office Tasks

Assisted with tasks for GSM group to make them

more efficient

Teamcenter

Contacting Suppliers

Maintaining Documents

Part Files

Developed GSM standard work document

Co-op Power Points


Off-Site Supplier Visits

IMT Heat Treat

Went to analyze

possibility of new

supplier

Was able to learn more

about carburization

process

Aallied Die Casting

Attended APQP kick-off

for DT program

Learned about die

casting process


Capacity Matrix

One of the longest on-going projects I was involved

with

Managed supplier capacity data collection on ICE

P552, P558, Raptor

Communicated capacity templates for suppliers

Updated matrix when they were returned

Saved in part files and on ICE for records

Ran uplift reports in Matrix


9-Apr-14

Supplier Committed Capacity Report

Supplier: MultiTech Model Year 2013 2014 2015 2016 2017 2018 2019 2020 2021 Peak Volume

BorgWarner RFQ Quoted Volumes

Part #: 44-46-122-001

Part Description: Shift Shaft Ford P558 - - 182,197 218,636 218,636 218,636 218,636

36,439

P558 w/ 10% flex - - 200,416 240,500 240,500 240,500 240,500

40,083

Chrysler DJ (44-46, 44-47) 97,300 97,300 97,300 - DJ w/ 20% flex 116,760 116,760 116,760 - - - - -

TOTAL ESTIMATED USAGE Total Annual Capacity Planning Volume: - 97,300 97,300 279,497 218,636 218,636 218,636 218,636 36,439 279,497

Should plan to achieve these volumes on a standard 5 day work week

TOTAL ESTIMATED USAGE W/ OEM FLEX Total Annual Capacity Planning Volume (inclusive of % flex): - 116,760 116,760 317,176 240,500 240,500 240,500 240,500 40,083 317,176

Should plan to achieve these volumes on a 6 day work week

Supplier work shifts required to meet required capacity1 8 5 Buyer completes

1 Hours / Shift Days / Week

Supplier available Operating Pattern 0 8 5 Supplier completes

Shifts / Day Hours / Shift Days / Week

Parts/Day Parts/Week WKs/YR Peak Annual

BW Required Maximum Capacity: 1,282 6,408 49.5 317,176

Supplier Quoted Capacity: 2,000 10,000 48 480,000

Supplier Capacity Sheets


Capacity MatrixFiller Value

ANNUAL ASSEMBLY QUANTITY 264

PART NUM DESCRIPTION SUPPLIERANNUAL SENECA

PRODUCTIONANNUAL SUPPLIER

MAXANNUAL

SPACEWEEKLY SENECA PRODUCUTION

WEEKLY SUPPLIER MAX

WEEKLY SPACE Date Updated FRD_PN_44-68-000-003

10-00-012-002MAGNET 1000002

NATIONAL MAGNETICS GROUP INC.

1,642,900

1,542,240.00 -100660 32858 30844.8 -2013.2 4/3/2014 264

10-00-047-015

WASHER,FLAT (METRO # WG-43) K&K STAMPING

46,900

4,320,000

4273100 938 86400 85462 8/23/2014

13-00-016-002RING,SEALING 1300002

CONTINENTAL INTERNATIONAL

98,050

14,160,000 14061950 1961 283200 281239 8/22/2014

13-00-044-001SEAL, SHIFT SHAFT FNOK (MILAN)

1,443,400

1,375,000 -68400 28868 27500 -1368 6/19/2014

13-00-052-003PLUG, 1300003 SEAWAY BOLT

1,931,700

6,912,000 4980300 38634 138240 99606 2/26/2015 528

13-00-131-002Spacer- Pinion Needle

UNIVERSAL BEARINGS

227,763,000

240,000,000 12237000 4555260 4800000 244740 3/3/2015

13-00-139-012RING, RETAINING 1300012 YUSHIN

1,582,900

1,488,000 -94900 31658 29760 -1898 03/19/2015

13-00-139-027RING,RETAINING 1300027 YUSHIN

966,050

1,440,000 473950 19321 28800 9479 04/09/2015 264

13-50-100-001RAIL 1350001 NIAGRA LASALLE

337,900 -337900 6758 0 -6758

13-50-156-007SPRING 1350007 TWIST INC.

520,750

2,400,000 1879250 10415 48000 37585 2/17/2014

13-52-127-001 BUSHING

PRIME ENGINEERED COMPONENTS, INC.

-

1,920,000

1920000 0 38400 38400 2/25/2014

19-00-014-003Plate - Front Carrier 1900003 MR. INFRAAUTO

141,550 -141550 2831 0 -2831

19-00-014-004Plate - Front Carrier 1900004 MR. INFRAAUTO

32,950 -32950 659 0 -659

19-00-014-005FILTER RETAINER PLATE 1900005BURKLAND

70,900

230,000 159100 1418 4600 3182 04/02/2015

19-00-014-006FILTER RETAINER PLATE 1900006BURKLAND

285,250

57,800 -227450 5705 1156 -4549 04/02/2015

19-00-016-004RING, Ext Sealing 1900004

FNOK (MORRISTOWN)

50,550 -50550 1011 0 -1011 264

19-00-016-009RING,SEALING 1900009

CONTINENTAL INTERNATIONAL

159,350

2,233,200 2073850 3187 44664 41477 3/3/2014


Surcharge Project

Manage payment to or from our suppliers regarding commodity Base rate price of each commodity is negotiated at

beginning of program Manual system now automated

Manual formulas entered into Excel spreadsheet that would be entered wrong or have human error

Use of Commodity Engine Helped with early development to fix base rates,

monthly rates, and part weights


Surcharge Report

Supplier PartnumMeta

l Comm.Desc Term Effective Date C/NCMetal

kgBase

USD/kgRate

Jan2014Act Vol Jan2014

Surcharge USD/kg Jan2014

AALLIED DIE CASTING 44-44-039-902 Al

Castings - Die - Raw - Aluminum (020)

840_Al_STD_Platts_MWA380ALLOY-2 USD/kg

Jan 1 2013 12:00AM C 4.91694 1.84200 2.24239 20,704 40,760

AALLIED DIE CASTING 44-44-039-903 Al

Castings - Die - Raw - Aluminum (020)

840_Al_STD_Platts_MWA380ALLOY-2 USD/kg

Jan 1 2013 12:00AM C 5.11650 1.84200 2.24239 1,401 2,870

22,105 43,630

Supplier Mar Apr May Jun SUM

ACUMENT / RING SCREW LLC -1299.039443 -1351.577837 -1297.741033 -1828.208486 -5639.340483

C & A TOOL ENGINEERING, INC. -5523.850529 -8808.454439 -9217.908493 -11357.86426 -41226.40614

CAMCAR LLC - BELVIDERE -937.7723688 -2138.125121 -2550.602283 -2686.401707 -9719.088754

CAPSTAN ATLANTIC INDUSTRIES (Wrentham, MA) -4453.0486 -5352.989547 -6218.169196 -5549.57948 -28555.28119

CONTINENTAL MIDLAND, LLC -64.30760995 -113.9837718 -87.70404368 -98.1644484 -425.5451653

DRIV-LOK, INC. -111.1443163 -183.0484219 -185.8814237 -220.1313636 -779.319247


Tooling Matrix

A universal tooling standard document used in RFQ

process with suppliers

All new and replacement tooling

States plainly what the supplier is responsible for

paying and what BW will pay for

I developed it by comparing Ford, Toyota, GM, and

Chrysler tooling matrices for BorgWarner tooling


Tooling Matrix


P552 Supplier Day/ Torq Day

Coordinated with P552

suppliers the date,

location, and schedule

for the event

Networked with

suppliers throughout the

day in a professional

setting

Given task to present

Carrier machining/

assembly on plant tour

Good practice

presenting to multiple

groups


Torq Day


Service Parts Tracking

Service Parts tracking document for better

communication between Materials and Purchasing

Established a document that allows materials to input

data onto in ICE On ICE

Displayed in Purchasing Office

Visual Management Tool


Service Parts

Printed on plotter- 34” x 44”


TTS Way Event- 5s

Participated in MRO stockroom Kaizan event

Went to Storage Room and learned how to organize

space efficiently

Became 5s certified

Related to coursework at Clemson


Other Tasks

Involved in the early goings of Silver Crescent Award Assisted in Change Management Participated in Angel Tree Program Audits:

Inventory- MRO Production Control Safety- GSSF11

Reported Minority Spending GSM office reconfiguration


My Takeaway

FIT

Functional Integrated

Teams

Communication

Internal

External

Professionalism

Supplier’s

Internally

Planning

New Programs

Manufacturing

Industry

Mentors

At work

Preparing for future


Questions?


Thank you

Fuel Economy Emissions Performance


Thank You For Your Attention

Fuel Economy Emissions Performance

Our Vision A Clean, Energy-Efficient World

Our Mission Deliver Innovative Powertrain Solutions that Improve

Fuel Economy, Emissions & Performance