DEARBORN - Employees at Dearborn Truck Plant (DTP) have taken the challenge to Go Further everyday by working together to make sure they produce a high- quality vehicle. An example of this is DTP employee James Jean, a Team Leader in the Trim Department. He reported an issue with the robot cell that decks the windshields. Operators were noticing at the start of their shift that the robots were decking too high or low on the vehicles.
This was not the first time that Jean has reached out to maintenance, noted Automation Engineer Gilbert Johnston, “[James] is very conscientious and notices everything when it pertains to quality glass installation. He always contacts maintenance and works with us to solve the issue”.
Although the maintence team had to shut down one side of the robot cell to make repairs, the glass operators had to share the same side of the cell and coordinate who had to load the glass each time.
Typically, operators have their own side of the cell, so the odd rotation glass is on the east side and the even glass is on the west side. Glass operators in the past might only have to work together on one side once a week, in this instance, the operators had to switch five times in one shift because there were decking issues on both sides of the cell.
Once the trucks left the robot cell, Jean worked with Junior Chrislip, Chris Byrdsong (pictured in photo on left), Russ Boudrie and Rolanda Bynum, all team leaders on Trim Line 3 & 4, to see that every single windshield was correct before leaving the Trim Department.
After safely locking out ECPL (Energy Control Power Lockout), the crew was able to isolate power to one side of the cell. Locator cylinders, aligned perimeter light screens and edits to the robot programs for decking and urethane paths were all completed while production was still running. This is a huge undertaking, especially when some of these issues occurred on both sides of the cell. Joe Roop and Mark Militello (Machine Repair); Jeff Salo, Jeff Prince, Brad McCarthy, Larry Bochenek, Mike Domine (Pipe Fitters);and Alan Bachert, George Boyer, Randy Loy, Tim Bergerand Dale Smith (Electricians) were all instrumental in this project.
All the employees that worked on this project are a prime example on how Ford employees at DTP Go Further!