Professional Documents
Culture Documents
Wassim Katbey, Nicholas Figueras, Kayla Hutchison, Kayla Schalte, Chris Johnson
Table of Contents
Executive Summary 3
Research Methods 14
Primary Research 14
Secondary Research 15
Conclusion 16
References 17
Executive Summary
Hope Global, a manufacturing firm based in Rhode Island, received an order from Ford Motor
Company to produce 1.2 million Ford F150 gap covers annually. An alternative method of
production is pursued by Hope Global staff, as current cutting equipment is lacking in
production speed.
This report addresses the difficulties encountered at Hope Globals Auburn Hills facility. Our
team consists of Wayne State University engineering and computer science students. The purpose
of this project is to secure Hope Globals reputation with Ford Motor Company, and to complete
technical documentation for an engineering industry.
Ray Bohlinger, Vice President of Advance Engineering, and project manager at Hope Global,
has provided statistical data on the Ford F150 gap cover through an informative spreadsheet.
This information is displayed in Appendix A. Additionally, Alliance Industries provided a price
quote on an embosser machine. The full price quote is displayed in Appendix B. Primary
research was gathered from data within these documents.
Secondary research was gathered through a field study, to determine the human resources needed
to operate several cutting machines. No substantial research was gathered to back up an
alternative prototyping lab.
Our team recommends the use of Accurate Tool and Dies die cutter for production of the Ford
F150 gap cover. This decision was made over the following companies:
Lectra
Gerber Technology
Alliance Industries
Introduction
Hope Global, a firm based in Rhode Island, engineers manufacturing products for the
automotive, apparel, and commercial industries. Our team requested an inquiry into possible
complications at the facility, for an opportunity to find a solution through technical writing.
Mr. Figueras is an intern at Hope Globals Auburn Hills, MI facility, and serves as our teams
representative. Mr. Figueras informed our team of two issues the facility is facing.
Ford Motor Company requested the production of 1.2 million Ford F150 gap covers annually at
Hope Globals Auburn Hills facility. Hope Global produces gap covers using a Lectra cutter.
However, a recent gap cover test indicated that the Lectra cutter has an inefficient cutting speed.
Project managers are looking for an alternative cutting machine.
Our team has contacted the following companies to inquire on their cutting machines:
Alliance Industries
Gerber Technologies
Lectra
Accurate Tool and Die
Additional information on the Ford F150 gap cover has been provided through Ray Bohlinger,
Vice President of Advance Engineering. Mr. Figueras interviewed Mr. Bohlinger. The interview
is displayed in Appendix C, and constitutes the majority of the information provided to us by
Hope Global.
Hope Globals Auburn Hills facility outsources prototyping work to an RCO Engineering facility
in Roseville, MI. Prototyping, or the repurposing of plastics into substrates, is essential to Hope
Globals presence in the automotive industry. However, outsourcing to RCO Engineering has
given rise to delayed delivery times and technical mistakes at Hope Globals facility.
The problems listed in this section are addressed in detail in Organizational and Gap Hider
Difficulties.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 5
Hope Global is looking for a profitable means of manufacturing the gap cover. Materials such as
cutting tools are sought out after. The Auburn Hills facility tested the performance of a Lectra
cutter, followed by underwhelming results. Due to the Lectra cutters underperformance in mass
production, Hope Global is looking for alternative cutting tools.
Additionally, the facility has been experiencing delayed deliveries and logistical problems.
Company representatives claim that these issues precipitate from an RCO Engineering facility,
where Hope Global outsources its repurposing of plastics, or prototyping.
This section will consider the issues at Hope Globals Auburn Hills Facility, and the weight of
each problem.
Ray Bohlinger, Vice President of Advance Engineering, and project manager at Hope Global,
informed our team of an order from Ford Motor Company, to produce 1.2 million Ford F150 gap
covers. Gap covers constitute a leather or vinyl cover that conceals wires above or below the
steering column.
Hope Global manufactures gap covers for other automotive companies, however the recent order
serves as the first project from Ford Motor Company. The companys reputation may advance
with the successful execution of the order. Ford Motor Company contractors may refer other
suppliers to Hope Global for manufacturing solutions.
Hope Global normally produces gap covers using vinyl or leather sheets. Figure 1 (pg. 6)
displays a sketch of the Ford F150 gap cover that was presented at Hope Globals August 2016
Summit. A cutting machine is used to create a line across the material and eventually shape the
product. The following cutting machines are typically used by manufacturers:
Lectra cutter
Die press
Embosser
Laser cutter
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 6
Mr. Bohlinger has provided data collected from a gap cover test performed at Hope Globals
Auburn Hills facility. The test was performed on a Lectra cutter. Table 1 (page 15), in Research
Methods, displays the results of the test. Mr. Bohlinger estimates that 2500 covers will be
produced per shift. Shifts will typically last 8 hours. Meeting this quota requires the use of an
effective cutting tool.
The Lectra cutter was used to cut 10 different parts. Hope Global staff voiced concern over the
Lectra cutters max speed. Cutting through the interior portions put the cutter at a disadvantage,
as it averaged 28 seconds for interior cuts. In the case of the production of 1.2 million Ford F150
gap covers annually, the Lectra cutting tool is not efficient.
Mr. Bohlinger has accepted our initiative to find the best possible method of manufacturing the
Ford F150 gap covers. This encompasses finding the most efficient and lowest risk method.
We are responsible with searching for various sources of tools to complete the order. These tools
consist of:
Cutting tables
Embosser tooling
Die tools
Laser cutters
We are accountable for finding the manufacturers of these items, and the quotes their
representatives would provide. This information will be used to find the most cost-effective
method of production. We are flexible with costs so long as the cutting method is advantageous
for mass production.
Prototyping is the repurposing of plastics into substrates. This is primarily used to create interior
covers within vehicles. Hope Globals Auburn Hills facility outsources its prototyping to an
RCO Engineering facility in Roseville, MI.
Cheryl Merchant, CEO and President of Hope Global and Mr. Bohlinger have voiced concern
over this. Hope Global contractors often invest more into RCO Engineerings prototypes.
Outsourcing to RCO Engineering has resulted in numerous delayed deliveries and extended
processing times for projects.
The following section illustrates situations where complications arose between Hope Global and
RCO Engineering staff.
Communication errors often arise between Hope Global and RCO Engineering staff. Confusion
arises as to what substrates to use for certain projects. Several cases occurred where the incorrect
substrate was used.
An RCO Engineering employee appeared at Hope Globals Auburn Hills facility to wrap
substrates with vinyl material. The best method to wrap the material wasnt strictly adhered to,
and Hope Global assigned another RCO Engineering employee the same task the next day. The
delivery of the products was delayed by six days.
Prototyping could be outsourced to other facilities, however compared to other institutions, RCO
Engineering provides the most convenient and least expensive services.
This section expands upon our purpose in finding an alternative cutting tool for gap cover
production, and an alternative prototyping lab.
Reputation
As this is Hope Globals first job with Ford Motor Company, this project is key as well as
opportune for Hope Global to elevate their position within the automotive industry.
Recommending an alternative facility for prototyping ensures that the Auburn Hills facility is
running efficiently. Dissipating logistical issues at the facility will heighten Hope Globals
reputation in Michigan.
Industry Experience
The recommendations provided arose from the comparisons of cutting tools, in a manner of cross
examination on the efficiency of each machine offered. These machines consist of the Lectra
cutter, die cutter, embosser, and various table cutters. We will be comparing and contrasting
these processes in several manners, including in the costs, cutting speed, and the time in which
the item can be delivered to Hope Globals Auburn Hills facility.
Technical Documentation
Writing for Hope Global increases our teams knowledge of mechanical engineering. This
additional information, and the text accompanying it, can be used for applications within each
students respective field. Technical documentation showcases our abilities and gives our team a
competitive edge in the engineering and software development industries.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 9
The cost-effectiveness of a cutting machine was measured under the following criteria:
Delivery time is observed as Hope Global is under time constraints to begin manufacturing the
gap covers. In this case, our team recommends the use of Accurate Tool and Dies die cutter.
Hope Globals Auburn Hills facility requires the establishment of an in-house prototyping
facility. The costs of establishing an in-house facility have been acknowledged by Mr. Bohlinger,
who believes this will dissipate the facilitys logistical difficulties. This section will elaborate
upon our proposed solutions to current Hope Global complications.
Hope Globals Auburn Hills facility uses a Lectra cutter to produce gap covers. However, Ford
Motor Companys new order of 1.2 million Ford F150 gap covers will see production annually,
and further efficiency is preferable.
Mr. Bohlinger informed our team of time constraints at the facility to begin production of the
Ford F150 gap cover. This section lists the companies that were contacted to find an alternative
solution to Hope Globals Ford F150 gap cover production.
Mr. Figueras contacted the following companies, with requests for price quotes on their cutting
technology:
Alliance Industries
Gerber Technology
Lectra
Accurate Tool and Die
The following sections examine the information received from each firm.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 10
Alliance Industries
Mr. Figueras contacted Tom Fournier at Alliance Industries, for information on their embosser
cutters. A response was met with a price quote totaling $44,500.00 (Displayed in Appendix B).
This includes the cost of building the machine according to the Ford F150s gap cover design.
(Figure 1 displays the design) The quote estimates a delivery time of 12-14 weeks.
Embosser machines carve specified shapes into a sheet of material. The embosser, according to
Alliance Industries quote, will meet a maximum cycle time of 9 seconds. Furthermore, the
embosser will include controlled heat rods. The heat rods will raise the temperature of the
machine, following an appropriate activation of the machine.
Gerber Technology
Gerber Technology did not respond to Mr. Figueras request for a price quote. Due to the lack of
contact, no estimates on delivery time are available.
Our team initially looked into the firm to inquire on the GERBERcutter Paragon HX Cutting
System, a machine specialized for vehicle interiors. Gerber Technologys website affirms that the
product cuts efficiently: that is, with speed and precision. However, no test results are available
to confirm cycle-time.
Lectra
An attempt was made to contact Lectra to inquire on a cutter designed for the mass production of
Ford F150 gap covers. A price quote was not provided, however Mr. Figueras received an
estimate of $190,000. No further information on delivery time was provided.
Furthermore, Mr. Bohlinger informed Mr. Figueras of Ford Motor Companys possible purchase
of a die cutter to aid Hope Global in production. The die cutter can generate 96 parts in about 2
minutes and 2 seconds, per Mr. Figueras.
Among the firms that responded to our requests, Alliance Industries embosser had the highest
cycle speed. However, the price quote was the largest, and thus isnt feasible. Accurate Tool and
Dies die cutter is the least expensive among the other items and has the highest cycle-speed. The
die cutter is a favorable option among Mr. Bohlinger and Ford Motor Company.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 11
Additionally, Hope Globals Len, Mexico facility has a die cutter. To avoid purchasing a new
die cutter, production of the Ford F150 gap cover can be carried out at Hope Globals Len
facility.
Our team strongly recommends that Accurate Tool and Dies die cutter is considered for Ford
F150 gap cover production.
Hope Global currently outsources its prototyping work to an RCO Engineering facility.
Prototyping can be performed at any prototyping lab.
The closest, and therefore most convenient prototyping lab is RCO Engineerings Roseville
facility, currently in use by Hope Global. However, the logistical issues faced by Hope Globals
Auburn Hills facility have a negative impact on delivery times. This can damage the companys
reputation with manufacturers.
Our team has requested that Hope Global staff consider the establishment of an in-house
prototyping facility. Hope Globals Auburn Hills facility recently constructed a new space, of
approximately 8000 square feet, with no current purpose. The new space is large enough to
house a prototyping lab.
The costs for establishing an in-house prototyping lab are considered in Costs to Proposed
Solutions.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 12
The cutting tool will constitute the bulk of the costs. This section will demonstrate why Accurate
Tool and Dies die cutters purchasing price is preferable over the costs of the Lectra cutter.
Purchasing Costs
The Lectra cutter tends to have a higher cost compared to similar devices. The Lectra cutter is
estimated to cost $180,000 with a $10,000 set up.
Accurate Tool and Dies die cutter is estimated to cost approximately $20,000. (An
approximation is considered as this estimate was not a price quote) However, set up costs may be
avoided if production is carried out at the Len facility.
If Hope Global executes production of the Ford F150 gap covers at the Len facility, the
purchasing costs will not be considered. What follows the purchasing costs are the tooling costs.
Tooling costs for the die cutter are illustrated in Figure 2.
The next section will evaluate the human resources involved in maintaining a Lectra cutter and
Accurate Tool and Dies die cutter. The costs for maintaining the tool are evaluated before
utilizing the tool. Manufacturers pay an additional price for training and maintenance. This
includes the costs of hiring new employees.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 13
Human Resources
The Lectra cutter is a new piece of equipment at the Auburn Hills facility, therefore employees
will need to be trained to use it. This training will cost anywhere between $6,000 to $10,000 and
will last about two to four days, per Mr. Bohlinger.
The Lectra cutter will also require yearly maintenance and IT support through the Lectra
company. The cost for maintenance and support is $10,000 a year. With this new equipment,
more people will need to be hired and trained.
According to J. Bruce Traceys Industry Practices and Strategic Insights, the cost to hire and
train new people is estimated to be up to $4,000. Twelve new hires will be required, thus the
total estimation for additional employees will be up to $48,000. (Tracey, 2014)
Accurate Tool and Dies die cutter will require significantly less training and less new hires since
it is a much more simple piece of equipment. It will only require hiring four more people leading
to a total cost of $16,000.
With the information provided in this section, we have determined that due to the die cutters
simplicity and availability, it is less expensive to purchase and maintain, than the Lectra cutter.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 14
Research Methods
Research was conducted to provide an informed recommendation of a cutting tool for the
production of Ford F150 gap covers. No research was conducted to back our recommendation to
establish an in-house prototyping facility. Rather, this recommendation was made to Mr.
Bohlinger, to assess his opinion on the matter.
Primary Research, gathered from Hope Global documentation and documentation from
other companies.
Secondary Research, gathered from a scholarly paper, on the human capital involved in
operating the cutting tool.
The information provided led to the recommendations of the die cutter which appears to be the
most effective cutting tool within the scope of price, cutting speed, and availability.
Primary Research
The Primary Research that was conducted was provided through several first hand sources
including:
Hope Global
Lectra
Alliance Industries
The most significant research material constitutes a gap cover test, performed at Hope Globals
Auburn Hills facility. This test utilized a Lectra cutter already at the facility, and measured its
overall cycle time. The data is displayed in Table 1 (pg. 15). Mr. Bohlinger provided the excel
spreadsheet with the data, displayed in Appendix A. The test determined that an alternative
cutting tool was required for production of the gap cover.
According to Mr. Figueras, the gap covers should be created in ten seconds, which is faster than
the Lectra cutters average of 37.9 seconds. (This time was measured for cutting individual parts
of the cover, not the entire item)
Moreover, Ernest Washington of Lectra ran efficiency tests at a Lectra facility, informing our
team that the Lectras convenience stems from its lack of waste. However, no information is
available to display. If more information on Mr. Washingtons efficiency tests is required, our
teams contact information is available in Conclusion.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 15
Accurate Tool and Dies die cutter was estimated as the fastest and cheapest tool. However, the
only research gathered to back up this claim was a reply from a representative at Accurate Tool
and Die. If more information is desired, our contact information is provided in Conclusion.
Attempts to gain primary research about the other products were not as successful as the
information gathered about the Lectra cutter and Alliance Industries embosser.
Secondary Research
To find secondary research we have looked in scholarly avenues and given research conducted
by Hope Global themselves to conduct and discover various information when it comes to cost
points about machines, as well as the hiring of new employees.
The secondary research we have gathered when it pertains to this project have been costs that
were provided through several outside sources. This pertains to the various costs and upkeep and
maintenance that it will take to keep the Lectra cutter operational, as well as in good condition.
Secondary research also followed the costs and upkeep for training new employees, including the
amount of hires, and what it will take to train and ensure they are prepared to take on such a
project, as turnover rates in the industry can be higher than average turnover rate within other
industries.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 16
Conclusion
Hope Globals Auburn Hills facility is looking for alternatives to the Lectra cutter for mass
production of Ford F150 gap covers. Additionally, the facility is looking for an alternative
prototyping lab, as outsourcing to RCO Engineering has brought about several logistical
problems.
Our team recommends the use of a die cutter. Hope Globals Len, Mexico facility has a die
cutter, and production of the F150 gap covers may be executed there. Furthermore, Ford Motor
Company may purchase a die cutter for Hope Global. We recommend that all these options are
considered.
Our team assessed the situation between Hope Global and RCO Engineering, and we
recommend that the Auburn Hills facility establish an in-house prototyping lab. A new building
has been constructed on site, and serves no current purpose. The prototyping lab may be
established within the empty space.
If you have any questions regarding our proposed solutions, you may contact us at
fv6124@wayne.edu.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 17
References
Tracey, J. Bruce. "A Field Study of New Employee Training Programs." A Field Study of New
Employee Training Programs Cornell Hospitality Quarterly - J. Bruce Tracey, Timothy
R. Hinkin, Thao Li Bui Tran, Teresa Emigh, Michael Kingra, Jonathan Taylor, David
Thorek, 2015. N.p., 5 Nov. 2014. Web. 19 July 2017.
HOPE GLOBAL: GAP HIDER CUTTING MECHANISMS 18
June 14 2017
1. I was wondering if my group and I could do a project on Hope Global.
Response: Yes you can. What would you were you thinking about
2. My group and I were thinking about doing a project on the making this facility a prototype lab
Response: That is a good idea and all however how about looking into multiple ways to
manufacture this Gap Hider for us and which is the best
3. We could also do that I will just have to ask my group if they are willing to do that.
Response: Okay get back to me
June 20 2017
1. Hey Ray was wondering if we could if we could work on a solution for Gaps Hiders for you.
Response: Sure thing Let me email all the information I have to you.
Yeah I can also send you a few contacts that I have for possible die cutting which I think is the
better than the lectra find the costs out for that. We have a die press in Mexico so you dont
have to include that in your report you can probably fit 12 of those gap hiders ion one tool
another thing when we buy a tool like that normally Ford will buy that tool and it will be theirs.