2/28/15

How Work Truck Fleets Could Benefit from Lean Six Sigma practices:






Often fleets assume that work trucks are outfitted with equipment that meet the standards of the Chassis Manufacturer.  In the case of the truck mounted equipment this may not be totally correct. Although there are some federal standards for lights, brakes, crash worthiness, etc. that the vehicle alterer or final body manufacturer must comply with, often there are little or no standards for equipment that is mounted to the chassis at the final manufacturer. Aftermarket manufacturers and installers vary in sophistication and the depth of their attention to the design, the production, and variation control.

Vehicle specifications should reflect the needs of the user department, fitness for use, conformance to laws, and maintainability. Often vehicles develop breakdowns caused by defects or variations in the manufacturing process effecting reliability of the unit over time. 


If fleets are interested in buying products with high reliability, best quality and are as safe as possible to operate, they should review their purchasing process and the specifications for the mounted equipment. 

Here are two suggestions - using Six Sigma Methodology: 

1) Add DFSS and Lean Six Sigma to the bid specifications:

Choose vendors that use DFSS (Design for Six Sigma) in their product development.  Add DFSS into the equipment specs, the vendor will acknowledge that they either have or have not complied with the process in their design stage.

In other words, give preference to vendors that practice DFSS. It shows that the vendor / equipment manufacturer has approached the design of their product using DFSS methodology.


DFSS enables the manufacturer to prevent defects from occurring. The manufacturer can then produce superior products and offer services that are more stable and should not allow occurrences of “special cause” variation. It’s been described as a “vaccination against variation”.
 

Design for Six Sigma, DFSS, is a business procedure utilizing Six Sigma methodology. There are several tools and methods to utilize within Six Sigma to assure the process will be running in the correct direction. These DFSS techniques include tools and processes to predict, model and simulate the product delivery system (the processes, the personnel and organization, the training, the facilities, and logistics used to produce the product/service). Many of the tools used by DFSS are often used in the classic DMAIC Six Sigma process to analyze new products and processes.

Remember, all business processes present an opportunity for a variation to occur. These deviations are often associated with human controlled process operations. Each deviation can potentially become a defect; some of these defects may not show up immediately and could potentially cause safety related accidents. It is because of this that the Design for Six Sigma, DFSS is important for every manufacturing business.

2) Use of DMAIC for the manufacturing process:

It would follow that the manufacturing process be designed and controlled by Lean Six Sigma methodology. Lean Six Sigma is a methodology that relies on team effort to improve performance by systematically removing waste and reducing defects. The process is a collaborative effort using a team made up of a Champion, process owners and others chosen within and often consultants from outside the  organization as well. The LSS methodology follows steps within DMAIC – Define, Measure, Analyze, Improve and Control and relies heavily on data to assure that a correct path is followed and the goals are met.

If six sigma methodologies are followed, the end result will be a higher quality, more reliable product. Defects will be reduced to 3.4 per one million opportunities or less. Therefore, there should be a maximum of 3.4 defects for each one million products produced or service opportunities. Most manufacturers and service providers do not come close to this. 

But as an example, one industry has a mixed record, one to brag about, and yet another that does not come close to meeting Six Sigma. It’s the airline industry, far fewer than 3.4 passengers per million end up not making their destinations because of crashes. However 6200 pieces of luggage do not make it to their destination for every 1 million pieces carried!

Although the manufacturer is not required to have a Lean Six Sigma Black or Green Belt on staff, they should be able to demonstrate that they routinely practice continuous improvement initiatives. These initiatives may also be facilitated by an outside consultant. Lean Six Sigma consultants should have obtained their certification from a credible organization such as the ASQ or Public or Private Universities.

PHOTO SOURCE: 
Source:  http://www.transecoenergy.com


By Steve Taylor: Steve is a certified lean six sigma consultant specializing in process improvement. He may be reached at steve@truckarchitect.com His LinkedIn profile is https://www.linkedin.com/in/stevectaylor  Steve has vast experience in the work truck manufacturing field and is an expert author specializing in writing and blogging about work trucks.

 You may find interesting posts on work truck news and truck safety, including NHTSA Recall Notices at http://truckarchitect.blogspot.com/



Pothole Patcher - How it Works!



Kenworth Crew Cab with a Bergkamp Pothole Patcher
 
By Steve Taylor

I spotted a crew working a new Bergkamp FP5 Pothole Patcher while driving through my neighborhood in Tampa, Florida. I understand Hillsborough County bought 6 of these babies to take care of the potholes in County Roads.

I thought I'd stop and take a few pictures of this truck and then provide an explanation of the operation of the process.Many years ago I had the opportunity to operate a similar work truck.

 
Bergkamp Patcher-Filled with Hot Asphalt and Ready to Work

How it works:

Usually every working day the truck is loaded with hot asphalt at a local asphalt plant. It then goes out and patches potholes that day. It can be kept heated overnight if all the material is not used up.

This truck has many features not found on all others, first of all is the Kenworth Crew Cab. This cab will accommodate the whole crew for big jobs without bringing another vehicle to transport them. If my research is correct, this cab is a custom addition to the standard Kenworth cab.

The patcher body is a Bergkamp model FP5, it will carry 5.1 cubic yards of asphalt.The FP5 has a hydraulic-driven AC generator, providing onboard electric hydraulic power at all engine or travel speeds. 

The hopper heaters are using 220 VAC 4 kW electric heaters. It has a full hopper length auger which is hydraulically driven and reversible. There is an apron at the end of the auger.. The multi-spool control valves operate the hopper auger, agitator, doors and auxiliary tools,and have a built-in adjustable relief valve.

It has an insulated 80 gallon ASME asphalt emulsion system tank, spray hose for spraying  the tack coat, a spoils bin to carry the debris from clean up, and a vibrating single drum roller compactor.with a 4 hp gas engine for compacting the asphalt. It has a hand torch for drying out the wet holes. As well, it has an arrow board and brackets for carrying the wheelbarrow and hand tools.

Cutting a Square out of the pavement with Circular Saw


Hole is Cleaned out

The asphalt is shveled offf the apron, the hole is sprayed with Tack Material
and Hot Asphalt is shoveled into the hole

Hole is Filled

Vibrating Tamper compacts the Asphalt -it's Done!

Left Side View of Emulsion Tank

Another option on this truck is the InPave tracking system. Using the latest technology, it reports the patch location, the amount of material used and the temperature of the material being placed etc.The InPave System also maps the location of each reporting data point and allows you to click on it to review the status and full details. All this is reported back to management over the cellular system real time.

Bergkamp provides one year of free cellular data transmission service that allows for quick, reliable downloading of information. Moving forward, you can continue with this service or easily transition to a radio receiver system. You pick the method that works best for your needs and budget.

Find out more at http://www.bergkampinc.com/pothole_patching.html

Post by Steve Taylor.: Steve is a certified lean six sigma consultant in the the work truck equipment business  specializing in fleets and process improvement. Find his Linked in Profile at:  https://www.linkedin.com/in/stevectaylor He may be contacted at steve@truckarchitect.com or steve@upstreamsource.com



2/23/15

NHTSA Recall Notice 2.23.15

Please click on the following NHTSA Campaign ID links to view the recall information.



NHTSA Campaign ID Number : 15V066
Manufacturer : Piaggio Group Americas. Inc.
Make / Model Years : PIAGGIO / 2008-2011
Subject : Defective Fuel Pump may Result in Stall


NHTSA Campaign ID Number : 15V067
Manufacturer : Newmar Corporation
Make / Model Years : NEWMAR / 2013-2014
Subject : Loose Steering Linkage Castlenuts


NHTSA Campaign ID Number : 15V069
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : LAND ROVER / 2015
Subject : Engine may Seize due to Loose Connecting Rod Bolts


NHTSA Campaign ID Number : 15V071
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2009-2010
Subject : Rear Axle Half Shaft may Fail


NHTSA Campaign ID Number : 15V072
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2006
Subject : Rear Brake System Air Line may Detach


NHTSA Campaign ID Number : 15V073
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2007
Subject : Exhaust Pipe Leak may Result in Fire


NHTSA Campaign ID Number : 15V074
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2007
Subject : Wires In Connector For ABS System May Be Reversed


NHTSA Campaign ID Number : 15V075
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2006-2007
Subject : Rear Exit Door Controls may not Function Properly


NHTSA Campaign ID Number : 15V076
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2008
Subject : Emergency Exit Windows Difficult to Open/FMVSS 217


NHTSA Campaign ID Number : 15V077
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2007-2009
Subject : Incorrectly Routed Power Feed Cable


NHTSA Campaign ID Number : 15V078
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2009
Subject : Power Relay Incorrectly Wired


NHTSA Campaign ID Number : 15V079
Manufacturer : Nova Bus
Make / Model Years : NOVA BUS / 2009
Subject : Damaged Crimping Rings on Air Brake Hoses


NHTSA Campaign ID Number : 15V088
Manufacturer : Mercedes-Benz USA, LLC.
Make / Model Years : MERCEDES BENZ / 2013-2015
Subject : Rubber Seal may Dislodge and Contact Exhaust


NHTSA Campaign ID Number : 15V093
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : LAND ROVER / 2013-2015
Subject : Passenger Air Bag May Be Disabled




2/16/15

NHTSA Recall Notice 2.16.15

Please click on the following NHTSA Campaign ID links to view the recall information.



NHTSA Campaign ID Number : 15V037
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : JAGUAR / 2015
Subject : Incorrect Airbag Description in Handbook/FMVSS 208


NHTSA Campaign ID Number : 15V040
Manufacturer : Ford Motor Company
Make / Model Years : FORD / 2010-2013
LINCOLN / 2011-2013
Subject : Interior Door Handle Return Spring may Unseat


NHTSA Campaign ID Number : 15V047
Manufacturer : Toyota Motor Engineering & Manufacturing
Make / Model Years : TOYOTA / 2011-2012
Subject : Sub-Woofer Electrical Short


NHTSA Campaign ID Number : 15V049
Manufacturer : Heartland Recreational Vehicles, LLC
Make / Model Years : HEARTLAND / 2015
Subject : Incorrect Axle Placement


NHTSA Campaign ID Number : 15V050
Manufacturer : Ford Motor Company
Make / Model Years : FORD / 2014
Subject : Improper Torque of Seat Belt Bolts


NHTSA Campaign ID Number : 15V051
Manufacturer : PACCAR Incorporated
Make / Model Years : KENWORTH / 2015
PETERBILT / 2015
Subject : Improperly Torqued Brake Caliper Bolts


NHTSA Campaign ID Number : 15V052
Manufacturer : All Wheel Drive Equipment Mfg., Inc.
Make / Model Years : FORD / 2011
Subject : PTO Pressure Switch Oil Leak may Result in Fire


NHTSA Campaign ID Number : 15V053
Manufacturer : Brammo, Inc.
Make / Model Years : BRAMMO / 2013-2014
Subject : Oil may Leak from Breather onto Rear Tire


NHTSA Campaign ID Number : 15V054
Manufacturer : Nissan North America, Inc.
Make / Model Years : INFINITI / 2008-2009
NISSAN / 2009
Subject : Steering Column Tube may be Out of Round


NHTSA Campaign ID Number : 15V055
Manufacturer : KTM North America, Inc.
Make / Model Years : HUSQVARNA / 2015
Subject : Fork Piston Rod may Detach from Fork Cap


NHTSA Campaign ID Number : 15V056
Manufacturer : Mack Trucks, Inc.
Make / Model Years : MACK / 2015
Subject : Inability to Open Door from Inside


NHTSA Campaign ID Number : 15V057
Manufacturer : Mack Trucks, Inc.
Make / Model Years : MACK / 2014-2015
Subject : Air Brake Reservoir too Small/FMVSS 121


NHTSA Campaign ID Number : 15V058
Manufacturer : Terex South Dakota, Inc.
Make / Model Years : TEREX / 2013
Subject : Platform Rotate Cylinder may Move Unintentionally


NHTSA Campaign ID Number : 15V059
Manufacturer : Blue Bird Body Company
Make / Model Years : BLUE BIRD / 2011-2016
Subject : Exhaust Hanger Failure


NHTSA Campaign ID Number : 15V060
Manufacturer : Blue Bird Body Company
Make / Model Years : BLUE BIRD / 2011-2016
Subject : Exhaust Hanger Failure


NHTSA Campaign ID Number : 15V061
Manufacturer : Newmar Corporation
Make / Model Years : NEWMAR / 2014-2015
Subject : Defective Quick Release Valve Seat


NHTSA Campaign ID Number : 15V062
Manufacturer : Newmar Corporation
Make / Model Years : NEWMAR / 2015
Subject : Steering Shaft may Disconnect or Slip


NHTSA Campaign ID Number : 15V063
Manufacturer : Utility Trailer Manufacturing Company
Make / Model Years : UTILITY / 2014-2015
Subject : Improperly Seated Brake Chamber Diaphragm


NHTSA Campaign ID Number : 15V064
Manufacturer : General Motors LLC
Make / Model Years : CHEVROLET / 2006-2007
PONTIAC / 2006-2007
Subject : Sudden Loss of Electric Power Steering


NHTSA Campaign ID Number : 15V065
Manufacturer : Morgan Olson Corporation
Make / Model Years : MORGAN OLSON / 2014
Subject : Rear Vehicle Illumination Incorrect/FMVSS 108


2/09/15

NHTSA Recall Notice 2.9.15

.
Please click on the following NHTSA Campaign ID links to view the recall information.
NHTSA Campaign ID Number : 15V030
Manufacturer : Highland Ridge RV
Make / Model Years : HIGHLAND RIDGE / 2015
Subject : Screws for Awning Lateral Arm Brackets may Fail
NHTSA Campaign ID Number : 15V034
Manufacturer : BMW of North America, LLC
Make / Model Years : MINI / 2014-2015
Subject : Incorrect Capacity Information on Label/FMVSS 110
NHTSA Campaign ID Number : 15V035
Manufacturer : DS Corp DBA Crossroads RV
Make / Model Years : CROSSROADS / 2015
Subject : Incorrect Ramp Capacity Label
NHTSA Campaign ID Number : 15V036
Manufacturer : PACCAR Incorporated
Make / Model Years : PETERBILT / 2015
Subject : Incorrect Horn Contact Plate may Disable ESC
NHTSA Campaign ID Number : 15V038
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : JAGUAR / 2012-2015
Subject : Parking Lamps may Turn Off/FMVSS 108
NHTSA Campaign ID Number : 15V039
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : LAND ROVER / 2006-2012
Subject : Front Brake Hose(s) may Rupture
NHTSA Campaign ID Number : 15V041
Manufacturer : Chrysler (FCA US LLC)
Make / Model Years : JEEP / 2014-2015
Subject : Unintended Side Curtain Air Bag Deployment
NHTSA Campaign ID Number : 15V042
Manufacturer : Jaguar Land Rover North America, LLC
Make / Model Years : LAND ROVER / 2013-2014
Subject : Incorrect Routing of Brake Vacuum Hose
NHTSA Campaign ID Number : 15V044
Manufacturer : General Motors LLC
Make / Model Years : BUICK / 2015
CHEVROLET / 2015
GMC / 2015
Subject : Tire Tread Cracking/FMVSS 110
NHTSA Campaign ID Number : 15V048
Manufacturer : Grech Motors, L.L.C
Make / Model Years : GRECH / 2014-2015
Subject : Batteries may be Incorrectly Positioned

2/02/15

NHTSA Recall Notice 2.1.15

Please click on the following NHTSA Campaign ID links to view the recall information.



NHTSA Campaign ID Number : 15V016
Manufacturer : Porsche Cars North America, Inc.
Make / Model Years : PORSCHE / 2011-2012
Subject : Fuel Injection System may Leak


NHTSA Campaign ID Number : 15V019
Manufacturer : Volkswagen Group of America, Inc.
Make / Model Years : AUDI / 2011-2013
VOLKSWAGEN / 2012
Subject : Fuel Injection System Fuel Leak


NHTSA Campaign ID Number : 15V020
Manufacturer : Polaris Industries, Inc.
Make / Model Years : POLARIS / 2015
Subject : Roll Hoops Not Meeting Specifications


NHTSA Campaign ID Number : 15V021
Manufacturer : Polar Tank Trailer, LLC.
Make / Model Years : POLAR TANK / 2015
Subject : Internal Rubber Diaphragm Incomplete Attachment


NHTSA Campaign ID Number : 15V022
Manufacturer : Polaris Industries, Inc.
Make / Model Years : POLARIS / 2015
Subject : Steering Rack Assembly may Disengage


NHTSA Campaign ID Number : 15V023
Manufacturer : Great Dane Trailers
Make / Model Years : GREAT DANE / 2015
Subject : Internal Rubber Diaphragm Incomplete Attachment


NHTSA Campaign ID Number : 15V024
Manufacturer : Life Line Emergency Vehicles
Make / Model Years : FORD / 2014-2015
Subject : Bracket for Suspension Fluid Tank may Fracture


NHTSA Campaign ID Number : 15V025
Manufacturer : Mack Trucks, Inc.
Make / Model Years : MACK / 2015
Subject : Internal Rubber Diaphragm Incomplete Attachment


NHTSA Campaign ID Number : 15V026
Manufacturer : Volvo Trucks North America
Make / Model Years : VOLVO / 2015
Subject : Internal Rubber Diaphragm Incomplete Attachment


NHTSA Campaign ID Number : 15V027
Manufacturer : Autocar, LLC
Make / Model Years : AUTOCAR / 2015
Subject : Fuel Filter Shell may Separate and Cause Stall


NHTSA Campaign ID Number : 15V028
Manufacturer : Volkswagen Group of America, Inc.
Make / Model Years : VOLKSWAGEN / 2014-2015
Subject : Fuel Leaking Into Engine Compartment


NHTSA Campaign ID Number : 15V029
Manufacturer : TOR Truck Company
Make / Model Years : TOR TRUCK / 2008
Subject : Accelerator Pedal Failure/FMVSS 124


NHTSA Campaign ID Number : 15V031
Manufacturer : General Motors LLC
Make / Model Years : CHEVROLET / 2015
Subject : Improperly Fastened Toe Link Outer Ball Joint


NHTSA Campaign ID Number : 15V032
Manufacturer : Nissan North America, Inc.
Make / Model Years : NISSAN / 2008-2014
Subject : Electrical Short Due to Water Seepage


NHTSA Campaign ID Number : 15V033
Manufacturer : Nissan North America, Inc.
Make / Model Years : INFINITI / 2013-2014
NISSAN / 2013-2014
Subject : Hood Release Cable Assembly


NHTSA Campaign ID Number : 15V043
Manufacturer : Toyota Motor Engineering & Manufacturing
Make / Model Years : PONTIAC / 2003-2004
TOYOTA / 2003-2004
Subject : Inadvertent Air Bag Deployment


NHTSA Campaign ID Number : 15V045
Manufacturer : Honda (American Honda Motor Co.)
Make / Model Years : ACURA / 2003
HONDA / 2003-2004
Subject : Inadvertent Air Bag Deployment


NHTSA Campaign ID Number : 15V046
Manufacturer : Chrysler (FCA US LLC)
Make / Model Years : DODGE / 2003-2004
JEEP / 2002-2004
Subject : Inadvertent Air Bag Deployment