01-01-13 operation control 2

8/19/2019 01-01-13 Operation Control 2

1/39

Operation Control


2/39

Preface

Curriculum Outline

Introduction to Operation Control Approach to Better Operating Procedure

Presentation of Cases & Practice NML Practical Situation Identification

Presentation of Cases & Practices

Investigation & Improvement of Oppama Line

Time Analsis According to Purpose

Investigation at the actual line&!ra" up improvement plan

Practical Operation Control

Practice

Option Allocation

AM PM

DAY

1

DAY2

DAY3


3/39

Agenda

■ ■ Practice Operational Control by “Nissan ProductionPractice Operational Control by “Nissan Production

Way” Way”

■ ■ Approach to a etter Operatin! Procedure Approach to a etter Operatin! Procedure

■ ■ "i#e Analysis accordin! to Purpose"i#e Analysis accordin! to Purpose

■ ■ Practical Operational Control Practical Operational Control


4/39

#o" to Pursue Practical Operation Control

Pro$lems in Operation Control NML in %

1$ %tandard Operation &&&"here is a di''erence b(t standard operation sheet ) actual operation

Operation is not i#ple#ented based on the standard$ Alsooperation #a*es +uality ,ariation

"he -ay to decide i#ple#entation ite#s 'or e+uip#ent chec* )

+uality assurance is ,a!ue

2$ "ar!et "i#e &&&Operation accuracy 'or each operator is lo-. so the ti#e can not be

#easures as a standard$

%ince actually #easured tar!et ti#e is not inspected. there is not#uch credibility. and the ti#e can not be used as a standard 'or

allocation

3$ "echni+ue Mana!e#ent&&&/nsu''icient techni+ue trainin!

"rainin! plan is not dra-n up #onthly

"rainin! plan is not practical. thus i#pro,e#ent in techni+ue

can not

pro!ressed

Not bein! able to ac+uire ,acations as planned

0$ Practice PDCA Cycle &&&/#pro,e#ent is not pro!ressed as planned

Not bein! able to identi'y ite#s to be i#pro,ed or proble#s

durin!

operation obser,ation

Due to lac* o' cooperation a#on! co&-or*ers. super,isors) 果として、ＱＣＴ悪化

As a result' (TC "orsens


5/39


)lo" of Practical Operation Control

Procedure

ey Points(easons

'or ey Points

"ar!et "i#e o' /n&process Ob4ects

標準作業の改訂

必要な知識・技能の洗いし

技能!"#$

作業%&

作業'(

!"

)*技能!"

+'(作業改

,

作業-

.

/012

3456

作業-

.

作業'(

作業改,

78

8

*Step%+,-*Step%+,-

*Step .-*Step .-*Step/-*Step/-

*Step 0-*Step 0-

標準作業の9:

;? @A のBの改,

CDEFG

Operation

/nstruction

Operation

/#pro,e#ent

Operation

Obser,ationProduction

Operation

Observation

Chec* /te#s to

be

Mana!ed

Operation

/#pro,e#ent e&instruction

asic "echni+ue

"rainin!

Operation

/nstruction

trainin!

"echni+ue trainin!

plan

5ob Allocation

1evise Standard Operation

Set Operation Standard Identify Necessary Knowledge & Skills

/#pro,e#ent to step up

Con'ir# by Practicin!


6/39


Steps for Activit

%tep1%tep1H

Con'ir#ation o' %tandard OperationCon'ir#ation o' %tandard Operation

%tep 2 %tep 2 H %et a "ar!et "i#e%et a "ar!et "i#e

%tep 3%tep 3：

Operation arran!e#ent Operation arran!e#ent

%tep 0%tep 0 H Practice PDCA CyclePractice PDCA Cycle

%tep 6 %tep 6 H "echni+ue /#pro,e#ent "echni+ue /#pro,e#ent

%tep 7 %tep 7 H 8stablish#ent o' e+$ %ta'' 8stablish#ent o' e+$ %ta''

%tep 9 %tep 9 H /denti'y oles in 8ach Dept$/denti'y oles in 8ach Dept$

1eali2e Autonomous Operation Control 1eali2e Autonomous Operation Control

3sta$lish )oundatio3sta$lish )oundatio

Activities to Step 4p Activities to Step 4p


7/39

#o" To Pursue Practical Operation Control

＜ 5o$ Allocation＞

:sin! a tar!et ti#e. decide -or* procedure. -or*

a#ount. stoc*. *ey point 'or -or*. +uality control

ite#s. layout. route 'or each operator. accordin! tothe production tact$ "hen present the# clearly to the

operator$

＜ Tools for a supervisor to teach a 6o$

＞


8/39



1; asic Principles 'or 5ob Allocation

Principle % Waitin! shall be concentrated at the be!innin! or end o' process

Waitin! shall be -or*ed by an operator at the be!innin!

or end o' process

70%

100%

90%

50%

80%

60%

N<

O

N<

100% 50%

90%

IJKして、LMNOPQQR

N<

It appears 100% due to sluggishness


9/39


＜ 5o$ Allocation＞1; asic Principles 'or 5ob Allocation

Principle , )1 to 11 8=cept 'or enterin! en!ine roo# and car roo#.

operation procedure 'or one operator is “'ro#

'ront to bac*$”

&"his principle is prioriti>ed to principle 3 centrali>ation o' one

person?s operation part(position

&"his also pro#otes the idea that operation 'or en!ine roo# and(or

car roo# is operated 'ro# outside$


10/39



Principle . @Centrali2ation of % Person7s Operation Positions

& /t is also called “bloc* allocation” -hich

helps reduce -al*in! distance by centrali>in!

one person?s operation parts(positions

& /t is especially e''ecti,e to the operation in

-hich a person enters an en!ine roo#(car roo#

ST


11/39



Principle / One Part for One Operator One person should be assi!ned to co#plete

one part$ or e=a#ple. one -ho sets a

headla#p should operate -ire connection too

Pic89up

Installation

:ire Connection

Completion $ Completion $

One PersonOne Person


12/39



Principle 0 % person for one part for an vehicledesign

A person assi!ned 'or one part 'or one ,ehicle

desi!n. should do the sa#e part 'or the di''erent

,ehicle desi!ns$

Car A #eadlamp Installation Car B #eadlamp Installation

Car A Batter Installation Car B Batter Installation

Car A #eadlamp Installation

Car B #eadlamp Installation Car A Batter InstallationCar B Batter Installation

N<

O


13/39


Principle ;


14/39


Principle > Smmetric Operations at the Same Stage

"-o operators are allocated at the sa#e sta!e

'or operations that are sy##etric on ri!ht and

le't sides. such as a 'ront a=le and so on




15/39


Principle ? Standardi2ation of toolsCo#bine operations in a -ay that one person

uses #ini#u# nu#ber o' bit types 'or tools ) air

tools




16/39


Principle !iscontinuit of the same $loc8 operation

Do not allocate #ore than t-o operators in a

ro- -ho operate the sa#e bloc* operation

8n!

roo#

8n!

roo#

Mr$A Mr$




17/39


Principle %@ !iscontinuit of ad6ustment operatorsDo not allocate #ore than t-o oeprators in a ro- -ho

do the ad4ust#ent operation such as door ad4ust#ent

Principle %%

!iscontinuit of operators for difficult9tas8 Do not allocate #ore than t-o operators in a ro-

because di''icult operations ti#e has ,ariations 'or each

cycle

Principle %,

!ivision of muscular operation & delicateoperation

Do not assi!n 1 person -ith #uscular operation

Bhea,y load(operation re+uirin! a lot o' stren!th; and

delicate operation B#atchin! o' s#all parts or operation;




18/39


19/39

h Case Stud i

)or Com$ination mied Production)or Com$ination mied Production

5o$ Allocation5o$ Allocation

5 $ All ti f C $i ti i d P d ti5 $ All ti f C $i ti i d P d ti


20/39

5o$ Allocation for Com$ination mied Production5o$ Allocation for Com$ination mied Production

Proble#s in Co#bination B#i=ed; Production

1 Hehicle #odels re+uirin! di''erent #anpo-er 'lo- rando#ly

%edan ) hatch bac* )

Module ) Nonodule・・・・

・・・・

2 /ncrease in 're+uency in allocation chan!e

Chan!e in ,ehicle #odel co#position

j Chan!es based on only shi't in the past

5 $ All ti f C $i ti i d P d ti5 $ All ti f C $i ti i d P d ti


21/39

A -ay to consider operation allocation in order to handle

co#bination B#i=ed; operation

Ma8e option allocation regular ccle allocation as a $asic

In a process of a regular ccle' maintain a regular ccle time

"hether

it7s among the same vehicle model or different vehicle models

To deal "ith difference in reDuired manpo"er' concentrate it on aspecific process

5o$ Allocation for Com$ination mied Production5o$ Allocation for Com$ination mied Production

kl

m

kl

m

5 $ All ti f C $i ti i d O ti5o$ Allocation for Com$ination mi ed Operation


22/39

A -ay to consider operation allocation to handle co#bination B#i=ed; operation

:h Option AllocationE

nop

qop

rnop

qop

str

uvw xvw yvwz

VW6d{Wf

{6^{Wf

|}~

{6^{Wf

uvw yvwzz

VW6d{Wf

|}~

•

€‚

•

€‚

{6^{Wf {6^{Wf

nop

qop

str nop

qop

str

Option Allocation Allocation in "hich operation time varies

5o$ Allocation for Com$ination mied Operation5o$ Allocation for Com$ination mied Operation

Mr$A Mr$8 Mr$ Mr$A Mr$

#in #in

C y c l e t i #

e

C y c l e t i #

e

"act ti#e "act ti#e "act ti#e "act ti#e

C ar # o d el

C ar # o d el

5 $ All ti f C $i ti i d O ti5o$ Allocation for Com$ination mied Operation


23/39



ƒ„…†]%& •€‚%&

op‡&

ˆ化

○

‰>?Š‹ŒŽの%&‘

×

NO’%&‘

“”準化–

○

NO—˜™し—šい

×

NO—˜™し›い

‚œž ○

作業%&’Ÿ

×

作業%&’¡

¢£¤¥

¦§¨

¢£¤¥ ○

©ª«¬の¤¥’®›

×

©ª«¬の¤¥’¯°

¦§¨ ○

±²«¬’³´µ¶·¸¹いº»い

×

±²«¬’³´ˆ¼½·¸¹い—šい


eadiness 'or

chan!es

Parts&

supplyin!

shuttle

Model co#position

chan!e

Option allocation

Allocation chan!e only in

option process Allocation chan!e re+uired

'or e,eryone

8asy to allocate operation Co#plicated 4ob allocation

Parts&supply

%huttle

8asy to supply to the best position

8asy to use because startin!

position is al-ays the sa#e

Di''icult to supply to the best

position

Di''icult to use because startin!

position chan!es e,ery ti#e

Disturbance o'

parts& settin! Di''icult 'or e,eryone to !et

a''ected 8asy 'or e,eryone to !et

a''ected

Allocation in -hich

operation ti#e ,aries

8+ual operation

ti#e



24/39



ƒ„…†]%& •€‚%&

作業/0 ¾C¿ÀÁ ○

/0しº»い

×

/0し—šい

%&\Â ○

\Â’ÃFÄ\ÂÅÆ~

×

\Â’ÇÃFÄ\Â}È~

%&\Â 作業ÉÊ ○

作業ÉÊË、‰>?Š‹ŒŽの

ÌÍÎ

×

作業ÉÊ’NO—Ï7し

º»いÐ

Ž9# 4_` ×

‰>?Š‹ŒŽ4_`FÑ必要

○

‰>?Š‹ŒŽ4_`Ç要


Operation

control

Process

planarea

Control o'

operation loadin!

rate

Operation

inter'erence

Option allocation

8asy to control

Operation inter'erence occurs only

to a person in option process

Option process area

re+uired

Di''icult to control

Operation inter'erence can

easily occur to e,eryone

Option process area

not re+uired

Allocation in -hich

operation ti#e ,aries

/ne''iciency o'

-aitin!

/ne''iciency o'

-aitin! /ne''iciency is clear

Bconcentrated;

/ne''iciency is unclear

Bdispersed;



25/39

Io- to Proceed

Basic Fno"ledge


%Ma8e an allocation centering around a main model

,Ma8e an allocation for other models in harmon

"ith operation procedure for main model .Gather difference in manpo"er among different

models and difference in HS manpo"er among the

same model to option process option allocation



26/39

Io- to Proceed

Step%< 3amine the $alance of overall operation amount $ each process


% Inspect amount of operation & production for each model % Inspect amount of operation & production for each model

ÒopÓとの作業Ô 78Ô

A o B o C o

©Ô8oのÕÖ×ØI

•€‚ØI

Select a model that $ecomes a center in ma8ing an allocation most9

produced model

Calculate of "or8er reDuired $ased on operation time for each model

No‚Car A Car Car C A,era!e o'

all cars

Amount of operation & production for each model

"i#e o' allocation in -hich

Operation ti#e ,aries

O,erall ti#e ta*en to produce

One #ost&produced #odel



27/39

Io- to Proceed

Step %< 3amine the $alance of overall operation amount $ each process


, !ivide operation for each model into $loc8s, !ivide operation for each model into $loc8s

1 8ND

2 8N


28/39

Io- to Proceed

Step %< 3amine the $alance of overall operation amount $ each process


. 3amine amount of su$9operation for each model . 3amine amount of su$9operation for each model

9 4 tili2e as Jcom$inationK for a process "ith lo" operation loading rate

It7s relativel eas for su$9operation to ma8e re9allocation of operation

procedure and=or com$ination' compared to main procedure

%ub&operation 'or#ost&produced #odel

ÚÛÜ

Ý>T

ÞŠT‰

Ý>T

ÞŠT‰

Ý>T

ÞŠT‰

Ý>T

ÚÛÜ

Ý>T

Sß;Ý

>T

uo Ｃoào

Loading time for su$9operation

Car A Car Car C

A%

sub

adio

subIose

sub

adio

sub

A%

subadio

sub

5o$ Allocation for Com$inationmied Operation5o$ Allocation for Com$inationmied Operation


29/39

Io- to Proceed


/ 3amine amount of option operation for each model / 3amine amount of option operation for each model

3stimate option allocation setting

Build HS operation "ith a lot of manpo"er into OP

allocation as much as possi$le since it "ould inhi$it the

uo Ｃoào

áâ

T

ÝŒãß> ;S?äÞ

ß

ÝŒãß> áâ

T

ÝŒãß> áâ

T;S?äÞ

ß

JOnly installation rate belo- FEK applies OP

operation since installation rate o,er FEK is

considered as all ,ehicles

Loading time for option operation O,erall OPoperation ti#e 'or

upri!ht #odel o'

#ost&produced

,ehicle in Car C

A,era!e ti#e

based on

production rate

'or OP operation

'or Car C %(roo' Na,i!ation %(roo' Na,i!ation %poiler %(roo' Na,i!ation %poiler

Car A Car Car C

Step%


30/39

Io- to Proceed

Step,< S elect a main model to ma8e an allocation


%% #o" to Select a Main Model #o" to Select a Main Model

9 Select a model "ith the least manpo"er reDuired among

models that have production rate of .@ or more

9 If it has production rate of ?@ or more' select a model as

the main model' regardless of si2e of manpo"er reDuired

åæのçèのéW]opË êuoë åæのçèのéW]opË êìoë

2

標

Ø

I

í

ïðñ òð òð óðñ òð

ôõ}

ôQ}

öõ } öõ}

öQ}

uo

à

Ｃ

÷o ø

ù

2

標

Ø

I

‡ íî

úðñ òð òð

ôû}

öö}

ü

ôô}

" ar ! e t t i # e

" ar ! e t t i # e

20 #in 22 #in

33 #in

26 #in

ýðþlm

36 #in

3E #in

36 #in

Car A Car D

Co#ponent ratio Co#ponent ratio

Main #odel is “Car A” in the case belo- Main #odel is “Car D” in the case belo-



31/39

Io- to Proceed

Step.< !ecide of Target Allocation


%% !ecide of regular ccle allocation & of option!ecide of regular ccle allocation & of optionallocationallocation9 4nderstand the current operation loading rate for an allocation

of "or8ers reDuired for target time= of "or8ers reDuired for allocation

9Calculate of "or8ers reDuired for target time' of "or8ers

reDuired for "eighted average 3stimate of allocation

9 Calculate of "or8ers reDuired ' considering current operation loading

rate for an allocation 3stimate of allocation

94nderstand difference in manpo"er among models

3stimate of OP allocation

② ① ③ ④

78 tact "ar!et ti#e of allocation %& ②① ©Ô8o—

íî ¾C¿ of allocation ÿ»½数差

uo

?@ 20$1E ?+@ ?+/

ào 1EK 3$EE 21$6E >+, E$G6 >+0 &2$7

Ｃo 1EK 32$GE %%+@ %%+0 LF$F •€‚ 20$92 ?+, ?+>

/Ｔ k Ｔk

e!ular cycle

allocation 'or #ain

#odel @ F operators

o' all allocation@

G operators o' OP allocation@

Car A

Car

Car C A,e$

Production

rateOperation rate

'or allocation

Di''erence in #anpo-er

a#on! #ost&produced

cars



32/39

Io- to Proceed

Step/< !ecide Operation Procedure & 5o$ Allocation


%% !escri$e an image of the "hole allocation!escri$e an image of the "hole allocation

!escri$e a "hole image $efore ma8ing a specific allocation

due to difference in manpo"er in each model7s target time'

of "or8ers reDuired and most9produced vehicle

…・

・

Ａo Ｂo Ｃo

NO$1

:Ýä

ã%&

Ýä

ã%&

NO$2 NO$F NO$G

ﾀｸﾄ

Ｐ

%&

Ｐ

%&

%ince a#ount o' operation 'or

Car is e+ual to 9$6 #anpo-er.

there?s no operation in OPallocation

tact C a r A

e!ular cycle

allocation OP allocation

Di''erences in #anpo-er 'or

Car A that can not be included

in the F allocations Ba -hole;

BE$0 #anpo-er;

Di''erence in #anpo-er in

#a*in! Car C. co#pared to

#ost&produced ,ehicle BCar A;

loadin! ratio 1EK



33/39

Io- to Proceed



,, Ma8e an allocation for a main model Ma8e an allocation for a main model

!ecide allocation of "or8ers' considering process laout' operation

procedure for large parts and eDuipment conditions

OP operation area

Calculate Allocated Target Time

Assign Jobs

tact operation loadin! rate 'or allocation ・・・・・3#inE ．

G62 ．

F6#in rou!h standard j basic is 1EEK

・ /n,esti!ate based on “basic principles 'or 4ob allocation”

・ %tandard is that di''erence in #anpo-er a#on! #odels is -(in L(& 6K

'or re!ular cycle allocation



34/39

Io- to Proceed



.. Ma8e an allocation for other modelsMa8e an allocation for other models

9 Be in harmon "ith operation procedure for the main model

One person for one part for an vehicle modelK

9 Standard for difference in manpo"er among models "=in =909 Target time allocation is the same as main model

…・・

NO$1

:Ýäｸã%&

NO$2 NO$F NO$G

ﾀｸﾄ

Ｐ%&

Ｐ%&

Assi!ned

tar!et

ti#e

Within õR

éW]op Mass&produced #odels 'or each desi!n

"act

e!ular Cycle

AllocationOption

allocation

Main #odel



35/39

Io- to Proceed

Step/< !ecide operation procedure & 6o$ allocation


/ !ecide Option Allocation/ !ecide Option Allocation

9 :ithin the of option allocation decided in step .

9 Ma8e option process concentrated as much as possi$le

h

set it $eond the frame of processi

9 Allocate . times of tact or less

ø／ÞäﾆŒｸTNO$F

‰>?Š‹ŒŽNO$G

“Principles 'or option allocation”

{6^のö倍以内

I(linin Option process

Within 3 ti#es

o' tact



36/39

Io- to Proceed



00 Minimi2e inefficienc of "aiting $ operation procedure ad6ustment Minimi2e inefficienc of "aiting $ operation procedure ad6ustment

9 3amine to $uild fractional figures in a regular ccleallocation in option process or integrate them in the process

that comes $efore or after

9 )or option process' eamine the integration $ ad6ustmentamong processes



37/39

Io- to Proceed



; Investigate to )orm Option Allocation; Investigate to )orm Option Allocation9Is operation procedure formed

9Is large enough space secured' assuming the case "hen ma+

amount of operation for one car needs to $e doneE

9Is there interference "ith other operationsE

9Can "or8ers "al8 $ac8 to the original position aftercompleting a 6o$ simulation

e+uired sta!e Hö oadin! condition H Hehicle Ｃ inter,als #ore than 7 ,ehicles

/#a!e o' operators? #o,e#ent

OP allocation firstoadin!

order #odel ti#e

Model co#ponent ratio

#in

#in

No operation

"act 3$E #in

Car ABFEK;

Car B1EK;

Car CB1EK;

Car C

Car ACar A

Car A

Car

Car A

Car A

Car C

Car A

Car



38/39

Io- to Proceed

Step0< S ecure Operation Area

5o$ Allocation for Com$inationmied Operation p

P ~

~ Secure operation area to prevent interference "ith aSecure operation area to prevent interference "ith a

process $efore and after process $efore and after

91egular Ccle process

< In case of seDuence ofthe

same $loc8s %+0 pitch

9Option Process < . pitch standard

Step;< Create Line Side Laout

Suppl Stri8e one



39/39

ules 'or Monthly Allocation Chan!e

5o$ ocat o o Co $ at o ed Ope at o p

3ecute allocation changes in harmon "ith changes in3ecute allocation changes in harmon "ith changes in

contentscontents Allocation chan!es only

-ithin op$ operation全体の編成替え

1$

Main #odel chan!e

Main #odel doesn?t chan!e

ý. 変更

3$ chan!es in OP. H% ratio

%(

変更

なし

O,erall allocation

chan!es

No

chan!es

%hi't base chan!e

Chan!es in

#odel co#ponents

%(

01-01-13 operation control 2

Documents