Plymouth Township's TDM plant shifts production to create hero-helping face shields


It is amazing what the company has accomplished in the year 2020 during the Covid-19 pandemic. The display of American spirit and call to action was thriving at TDM in reaction to an unprecedented crisis. The UAW/Salary collaboration was outstanding and as a result we protected 17.5 Million folks. Here is a summary:

• Reaction to North America Covid-19 in Manufacturing:

Leadership identified who was on travel status and stopped sending TDM employees out in the field.
The Visitor Questionnaire was implemented and sanitation stations were deployed per the CDC guidelines.
Manufacturing business operations were stopped with State of Michigan’s official Notice to shut down.
TDM gets the call to look at assembling prototype shields - “Art of Possibility”
Leadership team started calling the UAW/Salary volunteers back to work without revealing what they will be doing!
–Teams collaboratively worked together and the process replicating Henry Ford’s Assembly Line and then the rest is history…..

• Safety First:

Cycle line layout was designed to incorporate social distancing.
Protective personal equipment policy for the assembly workers were deployed (face shields and non-latex gloves)
Launched a contact-free Thermal temperature scan process for all employees to be screened before returning to the work area.
Kicked off a study using Samsung “fit bit” watches to detect social distancing.
Designed employee entrance/exit to accommodate social distancing due to the increased number of people in the building.
QA Team Launched safe measures to pass out 30,000 donated lunches from Ford Land and pizza donations from Little Caesars with the help zone leaders.


• All food overages donated to local 1st responders and charities, including: St. Mary’s Hospital, Ascension Providence Hospital, Beaumont Hospital, Plymouth Police & Fire, Northville Police & Fire, Redford Police & Fire, Canton Police & Fire, Wayne County Family Center and First Step Family Shelter

•Process Improvements:

We started with 165 work stations with production aids in 200K square foot.
Design team increased Mylar thickness from .007 to .012 to eliminate double patch & reduce time it was taking to assemble.
Changed presentation of foam deliveries to rolls vs single sheet.
TDM designed new process using Ford push pins & Cooper Standard window seal as head strap.
Changed strap from orange to FORD blue.
Shipping boxes will come in pre-labeled and incorporated the UAW/TDM Logo.
Introduced branding stickers into the boxes similar to “Apple”.
Kicked off patent and automated machine driven design process.

• Delivery:

Developed Material Storage Areas with specific rolls and responsibilities for just in time deliveries to the work stations.
We quickly reacted to a change of materials.
Developed error proofing with productions aids, established team leader meeting to communicate process changes and started tinsel tests design not that new materials were introduced.
TDM became the market place for all PPE (Face Shields, PPARs, Ventilators, Masks) which saved on transportation time.
Decanted for FCSD shields/masks for dealerships in smaller quantities.