Car Woes

I love all the Engineering stuff. I am in awe how such productivity could be programmed into an assembly line. Is that 20 second Takt time still valid today? The post war Japanese generation made super human sacrifices to build a new industrial Japan. Are the present generations still willing to make the same sacrifice?

So what is the Takt time in a Michigan auto plant? Is it anywhere near 20 Seconds?

That is about what it takes to work up a good fart. If you had 100 assembly line persons and they had to fart every hour, you already lost 55 production units in a day. Imagine if you had 2000 workers! Japanese are not known to be farty people because their diet seldom includes dairy fat. We all know that those living up North consume lots of cheese and butter and a lot of meat.

The dream factory would be the one designed in Germany. Was that real? That was almost a 100% automated system. The entire building was a giant mechanized unit including floors and walls. Amazing what engineers can do.

They already have (in a smaller scale), self-perpetuating machines. Wow! Imagine if you could do this in major industries. But we may end up like "Matrix" or what was that Arnold movie about the future sending in prototype robots to kill the ancestor of a rebel?

Nothing important. Just oiling the old rusty brain.

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"Each worker pulled a box of parts from a computer controlled conveyor and must install the parts on the moving engine block for not more then 20 seconds. The line produced different engine models at the rate of 20 seconds per and based on the needs of the final assembly line in another part of the plant. Ā The final assembly plant was also a wonder.

Human beings were needed to install the various components of various models, from the smallest to the largest Crowns, also at the rate of 20 seconds each".

The 20 seconds time interval is called thetakt time. It's also called the "beat" of the production line because the conveyor carrying the engine, moves to the next station every 20 seconds. Whatever component that needs to be installed or added on to the engine at that particular station (and at every station throughout the entire length of the conveyor line, needs to be installed in less than or exactly 20 seconds. It also means that at the end of the line, there is one complete engine coming out every 20 seconds.

In 2006, I was part of the Operational Excellence team of my employer W.L. Gore and Associates that went to benchmark the assembly line of Apache attack helicopters in Meza, Arizona. The assembly process was in the form of a big U shaped assembly line running around the building. There was no traveling conveyor belt since the helicopters had wheels and they were just pushed around from one station to the next. The fuselage which was made in another adjacent building gets mounted on to it's wheels at the start of the U line. Other components are also attached to the fuselage. After three days, the first helicopter is moved on to the next station where the avionics are mounted. Meanwhile another fuselage is being mounted at the start of the line. After three days, these two helicopters move to the next stations and another new fuselage gets started. Meanwhile the first helicopter which is now on the third station is being mounted with propellers, and so on. The takt time was three days and there was a complete helicopter coming out at the end of the line every three days.

These helicopters were used extensively in the Persian Gulf war. We saw a white flag of surrender used by the Republican guards of Saddam Hussein. It was a souvenir that was displayed on the wall. According to the plant people, the Republican guards dreaded the Apache helicopters because of their deadly armaments and once it corners a group of enemies, it could hover over them and they don't leave until the US soldiers arrive to capture the enemy. Aside from US armed forces use, they are also supplied to US allies but these are not equipped with the latest instruments.

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You can add to your list the brand names: Nissan, Mazda, Volvo, Audi, Volkswagen, and soon Citroen.

Back in the 1960's, Lee Iaccoca headed Ford and, being concerned with the bottom line of his operations, he suggested to the Board that they install Mazda engines in some Ford models. Ā His timing was bad as the Board members were still very mad at the Japanese being that World War Two was just 16 years ago. Ā HIs reasoning of course was that Mazda could sell its engines at a profit for $ 300.00 each F.O.B. any point in U.S.A., a cost that no American engine manufacturer can ever match.

In 1976, with a group of 11 other Filipino Service managers from the Philippines, we toured the Toyota Engine Plant in Toyota City. After about 20 minutes of awe, one of our group asked the Japanese guide "Where are the workers?" After a few minutes of searching we came upon a trio in overalls in a tiny break room, one with his feet up on the round table was reading a comic book while the others were sipping soda with a lively discussion at another table. Another 20 minutes of resumed tour and we came upon the real workforce, the assembly line for the engines. Each worker pulled a box of parts from a computer controlled conveyor and must install the parts on the moving engine block for not more then 20 seconds. Ā The line produced different engine models at the rate of 20 seconds per and based on the needs of the final assembly line in another part of the plant. The final assembly plant was also a wonder. Ā Human beings were needed to install the various components of various models, from the smallest to the largest Crowns, also at the rate of 20 seconds each.

Amazing, what automation they had set up. Automation that the Americans first started and should be able to also do. That is the answer for the productivity of the American workers, for any product.

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Just a reminder

toyota, honda, hyundai, bmw build their cars in America and hire americans. In fact, they are better than ford which has plants in mexico, only the f150 is built in michigan. within the last 3 years American cars are a lot better and should have no problems going over 100k miles. i believe thats the recommended first tune up. the only problems with them seems to be the heavy use of plastics in the interior and exterior. that's the main complaint with the corvette, they should have the same interior as a german car specially with the zr1, over 100k and you can push the body at the back because of the plastics. on the mechanical side they are just as good if they they were produced after 2009. if you go to the car shows like the one in sf, thats the main complaint about American cars, they have cheap looking interiors and the choices are very limited. i believe the battery of the chevy volt is made in south korea funded by American stimulus funds.

The engines of the new mazdas with the skyactive, have good reviews.

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By comparison, my sixteen year old 1995 Toyota Camry has logged 128,000 miles when I got it back from my daughters in 2003. It now has 154,000 miles plus. Except for accident damages and regular oil filter changes with engine oil, the only parts replacements I have had were for front brake pads (twice), tires, timing belt (changed at 120,000 miles) and oil pan gasket which should not have failed had not a greenhorn mechanic over zealously tightened all the nuts under the car, resulting in the gasket having been squashed and so leaked. The engine's oil pan bolts must never be tightened, as they are supposed to be designed to last almost forever.

Toyota recommends that the spark plugs be changed every 90,000 miles, (compared to every 5,000 miles for regular plugs) but my mechanic asked me if the engine was misfiring and to my negative answer, he said I should just keep them until the engine misfires.

And my records show that my gas consumption is at about 32 miles per gallon for my (and my daughter's) total mileage, city and highway. At the time I bought it there was no american car that could match those records.

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The 2002 GMC Envoy XLT that I bought in December 2001 has about 110,000 miles, still runs good and also still looks good because I've been parking it inside the garage. The only major expense on it has been the replacement of the set of shock absorbers, change of the brake pads and change of tires. I'm very happy with it's quality and performance.

For the same price of an equivalent foreign car, you get the top of the line model with an American car complete with the bells and whistles. In my case, the SUV came with an a/c, sunroof, running board, leather seats, heated driver and passenger seat, dual temperature control, power seats and windows, Bose stereo system, automatic windshield washer that turn on as soon as it rains, and automatic adjustment of your driver seat and side view mirrors to their programmed positions as soon as you put your key into the ignition slot. It even has a small compressor so that you can inflate your own tires wherever you are and can also use it to inflate your bike tires and basketball or volleyball.

For a foreign car, it will cost you an arm and a leg assuming that they have the same features available. The best feature that sold my wife to it was that there is a covered vanity mirror embedded on the sun visor both on the driver and passenger side. As soon as she flips open the cover, the light turns on so that she could easily take a quick look at her make up even in the dark, before alighting from the vehicle. For her, this is the deal clincher. The foreign brands we looked at in 2001 don't have this feature. Approved and funds were released.

Denver Bronco QB Tim Tebow Helping the Philippines

If you are not a football fan, you will not know who Tim Tebow is. Here's an article we share with you about what he does outside the football fields. Please read on.

Tim Tebow, His Foundation and the Philippines: Fan’s Perspective
By Deborah Braconnier, Nov 26, 4:02 pm EST
　
Whether you like Denver Broncos QB as a football player or not, you can't deny that he and his foundation are doing a lot to help children all over the world. His newest venture teams the Tim Tebow Foundationwith CURE Internationalin the construction of a children's hospital in the Philippines.

Why the Philippines?

Before Tebow became the football giant that he is, he first had to move to the United States. Tim Tebow was born in Makati City in 1987 while his parents were Baptist missionaries. For this reason, the Philippines are very close to Tebow and he knows that many of the children in the poorest areas are unable to access medical care that they need.

Type of Hospital

The hospital is set to be built in Davao Cityand they hope to break ground in January 2012 with construction being completed in mid-2013. It is estimated to cost around $3 million and costs will be shared by both the Tim Tebow Foundation and Cure International. It will be a 30-bed surgical facility that will focus on treating conditions such as club foot and bow legs. While these are simple surgeries, the families in this area do not have access to this type of care. They hope to be able to treat at least a third of the patients free of charge. In addition to providing medical care, they hope to provide the message of faith, hope and love while spreading and teaching Christ's Gospel.

Other Projects in the Philippines

This hospital will not be the first operation the Tim Tebow Foundation supports in the
Philippines. Uncle Dick's Home, an orphanage founded by the Bob Tebow Evangelistic Association also receives support. This orphanage is located in Lamsugod, Surallah, South Cotabato, Mindanao, Philippines and is currently the home to 49 orphans, according to the Tim Tebow Foundation.

The Real Tebow

While the critics may call Tebow a joke when it comes to his play as an NFL QB, his devotion to his religion and helping those in need is something to be admired. He brings this belief, strength and determination into everything he does, including on the field. His teammates and coach agree that he is the real deal.

Coach John Foxsaid, "He's real. He walks the walk. A guy like that in today's society, in my mind, ought to be celebrated, not scrutinized to the level that he is." Teammate Eddie Royasays, "He really is genuine and the emotion and the passion that you see him out there playing with, he has the same passion off the field with those type of things, the charity things and the missionary things."

Tebow is making a difference so far this season with the Denver Broncos both in the way he plays and the fact that there are now wins on the board. However, I think the biggest difference Tebow will make in the long run will be off the field and in the lives of many

American vs. Foreign products

ONE AT A TIME

This probably sounds crazy, but just yesterday I was in Wal Mart looking for a wastebasket. I found some made in China for $6.99. I didn't want to pay that much so I asked the lady if they had any others. She took me to another department and they had some at $2.50 made in USA. They are just as good.

Same as a kitchen rug I needed. I had to look, but I found some made in the USA and they were $3.00 cheaper. We are being brain washed that everything that comes from China and Mexico is cheaper. Not so. That is also why I don't buy cards at Hallmark anymore. They are made in China and are expensive. I buy them at Dollar Tree....50 cents each and made in USA.

One Light Bulb at a Time

A physics teacher in high school, once told the students that while one grasshopper on the railroad tracks wouldn't slow a train very much, a billion of them would. With that thought in mind, read the following, obviously written by a good American . . .

Good idea . . .. One light bulb at a time . . ..

Check this out. I can verify this because I was in Lowe's the other day for some reason and just for the heck of it I was looking at the hose attachments... They were all made in China .

The next day I was in Ace Hardware and just for the heck of it I checked the hose attachments there.
They were made in USA. Start looking ...

In our current economic situation, every little thing we buy or do affects someone else - even their job. So, after reading this email, I think this lady is on the right track.. Let's get behind her!

My grandson likes Hershey's candy. I noticed, though, that it is marked made in Mexico now.
I do not buy it any more.

My favorite toothpaste Colgate is made in Mexico... Now I have switched to Crest. You have to read the labels on everything....

This past weekend I was at Kroger . .. . I needed 60W light bulbs and Bounce dryer sheets.

I was in the light bulb aisle, and right next to the GE brand I normally buy was an off-brand labeled, " Everyday Value ." I picked up both types of bulbs and compared the stats they were the same except

For the price . . . The GE bulbs were more money than the Everyday Value brand but the thing that surprised me the most was the fact that GE was made in MEXICO and the Everyday Value brand was made in - get ready for this - the USA in a company in Cleveland , Ohio.

So throw out the myth that you cannot find products you use every day that are made right here...

So on to another aisle - Bounce Dryer Sheets... Yep, you guessed it, Bounce cost more money and is made in Canada... The Everyday Value brand was less money and MADE IN THE USA! I did laundry yesterday and the dryer sheets performed just like the Bounce Free I have been using for years and at almost half the price!

My challenge to you is to start reading the labels when you shop for everyday things and see what you can find that is made in the USA - the job you save may be your own or your neighbors!

If you accept the challenge, pass this on to others in your address book so we can all start buying American, one light bulb at a time! Stop buying from overseas companies!

(We should have awakened a decade ago....)

Let's get with the program and help our fellow Americans keep their jobs and create more jobs here in the USA .

I passed this on . .. . Will you???

Greediest Generation

Although her letter is addressed to an American politician, but it pretty much refers to most of the politicians all over the world..........

Alan Simpson, former Republican Senator from Wyoming, Co-Chair of Obama's deficit commission, calls senior citizens the Greediest Generation as he compared "Social Security" to a Milk Cow with 310 million teats.

Here's a response in a letter from a citizen in Montana ... I think she is a little ticked off! She also tells it like it is!

Hey Alan, let's get a few things straight..

1. As a career politician, you have been on the public dole for FIFTY YEARS.

2. I have been paying Social Security taxes for 48 YEARS (since I was 15 years old. I am now 63).

3 My Social Security payments, and those of millions of other Americans, were safely tucked away in an interest bearing account for decades until you political pukes decided to raid the account and give OUR money to a bunch of zero ambition losers in return for votes, thus bankrupting the system and turning Social Security into a Ponzi scheme that would have made Bernie Madoff proud..


4. Recently, just like Lucy & Charlie Brown, you and your ilk pulled the proverbial football away from millions of American seniors nearing retirement and moved the goalposts for full retirement from age 65 to age 67. NOW, you and your shill commission is proposing to move the goalposts YET AGAIN.

5. I, and millions of other Americans, have been paying into Medicare from Day One, and now you morons propose to change the rules of the game. Why? Because you idiots mismanaged other parts of the economy to such an extent that you need to steal money from Medicare to pay the bills.

6. I, and millions of other Americans, have been paying income taxes our entire lives, and now you propose to increase our taxes yet again. Why? Because you incompetent bastards spent our money so profligately that you just kept on spending even after you ran out of money. Now, you come to the American taxpayers and say you need more to pay off YOUR debt.


To add insult to injury, you label us "greedy" for calling "bullshit" on your incompetence. Well, Captain Bullshit, I have a few questions for YOU.

1. How much money have you earned from the American taxpayers during your pathetic 50-year political career?

2. At what age did you retire from your pathetic political career, and how much are you receiving in annual retirement benefits from the American taxpayers?

3. How much do you pay for YOUR government provided health insurance?

4. What cuts in YOUR retirement and healthcare benefits are you proposing in your disgusting deficit reduction proposal, or, as usual, have you exempted yourself and your political cronies?

It is you, Captain Bullshit, and your political co-conspirators called Congress who are the "greedy" ones. It is you and your fellow nutcases who have bankrupted America and stolen the American dream from millions of loyal, patriotic taxpayers. And for what? Votes. That's right, sir. You and yours have bankrupted America for the sole purpose of advancing your pathetic political careers. You know it, we know it, and you know that we know it.

And you can take that to the bank, you miserable son of a bitch.

If you like the way things are in America delete this.