DEARBORN, Mich. - Ken Halfacre, a Dearborn Truck Plant (DTP) Industrial Engineer, noticed there was a large waste and opportunity for cost savings with the lock set labels that DTP uses on Trim Line 1.
The Ford F-150 lock sets consist of six perforated bags to be separated throughout the process. In the past, DTP would install six 2"x6" one dimensional barcode labels per truck on the lock set bags for error proofing.
Halfacre noticed that after the team was done with the lock sets, the plastic bags, along with the 12” labels were thrown out.
He, along with Jim Bell from DTP’s IT department, created six 1”x1” labels with two dimensional bar code labels. The labels are no bigger than a postage stamp.
This special project resulted in an annual cost savings of approximately $69,000 for DTP and the company.