The scope of the project was to analyze an hourly work force of 13,000 UAW employees and identify manpower reductions. A team of 2 to 4 experienced industrial engineers was deployed to each of the 13 plants.

The direct labor studies consisted of time studies of the constraint of each line and the actual manning compared to the process intent, and provided recommendations for improvements. The time studies were broken down by value added, non-value added essential and non-value added work.

The indirect labor (both skilled and unskilled) studies consisted of work samplings that identified the opportunities for labor reductions. These studies led to the identification of significant cost savings across the 13 plants. The cost reductions are documented and validated.

Additionally, the team reviewed the work practices of each plant and documented actions that could further improve the profitability of each plant. These operational changes included manning levels, relief practices, shift patterns, contracted services, etc.

The next steps after the “identify and assess” phases have been completed is to develop and implement the “To/From’s” that enable the plants to accomplish the reductions identified.