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General Motors Powertrain, Romulus Transmission
Romulus Transmission, located at Romulus, Michigan requested a study to determine the correct amount of personnel required along with establishing truck routes in order to pickup, deliver and empty scrap buggies from machine centers to scrap wringers. All areas that produce aluminum, steel, iron and brass scrap were to be part of this program.

By using the current production volume at that time, each scrap buggy was identified by location using the bay or cafm numbers, type of scrap produced, established chip fill volume per buggy and the number of buggies to be delivered and emptied per shift/day.

By developing such a program, several determinations were made. Those determinations were:

  1. Verify and survey all scrap buggies located on site.
  2. Establishing walking time to replace and empty all buggies.
  3. Establishing truck moving time to replace and empty all buggies.
  4. Establish roll over truck time to empty all buggies.
  5. Establish truck routes to replace and empty scrap buggies for brass, aluminum, steel, iron, swarf and filter media.

Final product of this program was based on scrap volume produced in which truck routes, timelines and the identification of the number of people required to effectively staff and perform the tasks as identified above. Being that this program was volume sensitive, it was designed to be flexible, allowing for changes in the truck route schedule timelines in relation to the production schedule requirements.

By employing this program, estimated savings was $360,000.00 per year.
 
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