01-01-13 Operation Control 2

Operation Control
Preface
Curriculum Outline
AM
DAY 1
Introduction to Operation Control
DAY 2
Time Analysis According to Purpose
PM
Approach to Better Operating Procedure
Presentation of Cases & Practice

NML Practical Situation Identification
Presentation of Cases & Practices
Practical Operation Control
Practice
Option Allocation
DAY 3
Investigation & Improvement of Oppama Line
Investigation at the actual line&Draw up improvement plan
Agenda
Practice Operational Control by Nissan Production

Way
Approach to a Better Operating Procedure

Time Analysis according to Purpose
Practical Operational Control
How to Pursue Practical Operation Control

Problems in Operation Control NML in 1999
1. Standard Operation
2. Target Time
---There is a difference b/t standard operation sheet & actual operation

Operation is not implemented based on the standard. Also
operation makes quality variation
The way to decide implementation items for equipment check &
quality assurance is vague
---Operation accuracy for each operator is low, so the time can not be
measures as a standard.
Since actually measured target time is not inspected, there is not
much credibility, and the time can not be used as a standard for
allocation
3. Technique Management---Insufficient technique training
Training plan is not drawn up monthly
Training plan is not practical, thus improvement in technique

can not
progressed
Not being able to acquire vacations as planned

4. Practice PDCA Cycle ---Improvement is not progressed as planned
Not being able to identify items to be improved or problems

during
operation observation
As a
Due to lack
of cooperation
among co-workers, supervisors
result,
QTC
worsens
&
Flow of Practical Operation Control

<Step1.2>
Identify
Necessary Knowledge & Skills
Set
Operation Standard
Procedure
Key Points/Reasons
for Key Points
Target Time
# of In-process Objects
<Step 5>
Technique
training
plan
<Step 3>
Job
Allocation
Operation
Instruction
training
Improvement
to step up
UP
Production
Basic
Technique
Training
Re-instruction
Check
Items to
Operation
be
Observation
Managed
Operation
Improvement
Instruction
Operation
Observation
Confirm by Practicing
Revise
Standard Operation
Operation
<Step4>
Operation
Improvement
Steps for Activity

Realize Autonomous Operation Control
Step 7 Identify Roles in Each Dept.

Step 6 Establishment of Req. Staff
Activities to Step Up
Step 5 Technique Improvement

Step 4 Practice PDCA Cycle
Step 3 Operation arrangement
Establish Foundation
Step 2 Set a Target Time
Step1 Confirmation of Standard Operation
How To Pursue Practical Operation Control

Job Allocation
Using a target time, decide work procedure, work

amount, stock, key point for work, quality control
items, layout, route for each operator, according to
the production tact. Then present them clearly to the
operator.
Tools for a supervisor to teach a job
Job Allocation
1) Basic Principles for Job Allocation

Principle 1 Waiting shall be concentrated at the beginning or end of
process
Waiting shall be worked by an operator at the beginning
or end of process
100%
50%
OK
70%
90%
80%
100%
50%
60%
90%
NG
NG
NG
It appears 100% due to sluggishness
Job Allocation

Principle 2 FR to RR
Except for entering engine room and car room,
operation procedure for one operator is from
front to back.
-This principle is prioritized to principle 3 centralization of one
persons operation part/position
-This also promotes the idea that operation for engine room and/or
car room is operated from outside.
Job Allocation

Principle 3 :Centralization of 1 Persons Operation Positions
- It is also called block allocation which

helps reduce walking distance by centralizing
one persons operation parts/positions
- It is especially effective to the operation in
which a person enters an engine room/car room
ENG
ROOM
Car
Trunk
Room
Rear
Front
Body Side (R)
Body Side (L)
In a case of trim process
Job Allocation

Principle 4 One Part for One Operator
One person should be assigned to complete
one part. For example, one who sets a
headlamp should operate wire connection too
Pick-up
Completion by
One Person
Installation
Wire Connection
Job Allocation

Principle 5 1 person for one part for any vehicle
design
A person assigned for one part for one vehicle

design, should do the same part for the different
vehicle designs.
NG
Car A Headlamp Installation

Car A Battery Installation
Car B Headlamp Installation
Car A Headlamp Installation

Car B Headlamp Installation
Car A Battery Installation

Car B Battery Installation
Car B Battery Installation
OK
Job Allocation

Principle 6: Completion of front/back operation by 1 person
What is front/back operation?
For example:
Front Install Side Mirror
side mirror vehicles
Back Install Side Mirror Cover
fender mirror vehicle
The above is assigned to 1 person
Job Allocation

Principle 7 Symmetric Operations at the Same Stage
Two operators are allocated at the same stage

for operations that are symmetric on right and
left sides, such as a front axle and so on
Job Allocation
Principle 8 Standardization of tools

Combine operations in a way that one person
uses minimum number of bit types for tools & air
tools
Job Allocation

Principle 9 Discontinuity of the same block operation
Do not allocate more than two operators in a

row who operate the same block operation
Eng
room
Mr.A
Eng
room
Mr.B

Job Allocation
Principle 10 Discontinuity of adjustment operators
Do not allocate more than two oeprators in a row who
do the adjustment operation such as door adjustment
Principle 11 Discontinuity of operators for difficult-task
Do not allocate more than two operators in a row
because difficult operations time has variations for each
cycle
Principle 12 Division of muscular operation & delicate
operation
Do not assign 1 person with muscular operation
(heavy load/operation requiring a lot of strength) and
delicate operation (matching of small parts or operation)
Job Allocation

Principle 0 Options Option allocation
Principle 1 Concentrate inefficiency of waiting at the
beginning
or end of process
Principle 2 FR to RR
Principle 3 Centralization of one persons operation positions
Principle 4 One part for one person
Principle 5 One person for one part for any vehicle design
Principle 6 Completion of front/back operation by one person
Principle 7 Symmetric operations at the same stage
Principle 8 Standardization of tools
Principle 9 Discontinuity of the same block operation
Principle10 Discontinuity of adjustment operators
Principle11 Discontinuity of difficult-task operation
Principle12 Division of muscular operation & delicate operation
Case Study
For Combination (mixed) Production
Job Allocation
Job Allocation for Combination (mixed) Production
Problems in Combination (mixed) Production
1 Vehicle models requiring different manpower flow randomly

Sedan & hatch back
FF & FR
Module & Non-module
2 Increase in frequency in allocation change

Change in vehicle model composition
Changes based on only shift in the past
Job Allocation for Combination (mixed) Production
A way to consider operation allocation in order to handle

combination (mixed) operation
Make option allocation (regular cycle allocation) as a basic
In a process of a regular cycle, maintain a regular cycle time

whether
its among the same vehicle model or different vehicle models
To deal with difference in required manpower, concentrate it on a

specific process
Mi
n
Mi
n
Job Allocation for Combination (mixed ) Operation

A way to consider operation allocation to handle combination (mixed) operation
Why Option Allocation?

Option Allocation
Allocation in which operation time varies
(
min
(
min
Cycle time
Tact time
Mr.A
E
Mr.E
Mr.F
Car model
Car model
Tact time
Cycle time
Mr.A
Tact time
Tact time
Mr.F
Job Allocation for Combination (mixed) Operation

Option
allocation
Allocation change only in
Allocation change required
Disturbance of
Difficult for everyone to get

parts- setting
Easy for everyone to get
Equal
operation
time
Easy to allocate operation
Complicated job allocation
Readiness for
changes
Model composition
change
option process
affected
Partssupplying
shuttle
Allocation in which
operation
time varies
Parts-supply
for everyone
affected
Difficult to supply to the best
Easy to supply to the best position

position
Shuttle
Easy to use because starting
position is always the same
Difficult to use because starting
position changes every time

Option allocation
Operation
control
Allocation in which
operation
time varies
Control of
Easy to control
Difficult to control
Inefficiency of
Inefficiency is clear
Inefficiency is unclear
operation loading
rate
waiting
(concentrated)
(dispersed)
of
Inefficiency
Operation
waiting
interference
Operation interference occurs only

Operation interference can
to a person in option process

easily occur to everyone
Process
Option process area
plan
area
required
Option process area
not required
How to Proceed
Basic Knowledge
1)Make an allocation centering around a main model
2)Make an allocation for other models in harmony
with operation procedure for main model
3)Gather difference in manpower among different
models and difference in VS manpower among the
same model to option process (option allocation)
How to Proceed
Step1: Examine the balance of overall operation amount by each process
1) Inspect amount of operation & production for each model
Select a model that becomes a center in making an allocation (mostproduced model)
Calculate # of worker required based on operation time for each model

Amount
of operation & production for each model
Overall time taken to produce
One most-produced model
Time
of allocation in which
Operation time varies
Car
A
A
Car
B
B
Car
C
C
Average of
all cars
How to Proceed
Step 1: Examine the balance of overall operation amount by each process
2) Divide operation for each model into blocks
- Estimate process/parts for option operation setting
7
5
6
Overall
time taken to complete one part
RR end
Car room
Eng room
Car
A
A
Car
B
B
Car
C
C
1 FR END
2 ENG ROOM
3 DASH
4 ROOM
5 RR END
6 BODY SIDE RH
7 BODY SIDE LH
8 SUB practiced as sub
9 OP set as an OP operation
Option allocation needs to be allocated,
focusing on car Cs RR end and Eng.
Room that require a lot of manpower
How to Proceed
Step 1: Examine the balance of overall operation amount by each process
3) Examine amount of sub-operation for each model
- Utilize as combination for a process with low operation loading rate
Loading time for sub-operation
ABS
ABS
sub
Car
A
Radio
sub
Hose
sub
Car B
Radio
sub
ABS
ABS
sub
Sub-operation for
most-produced model
Radio
sub
Car
C
Its relatively easy for sub-operation to make re-allocation of operation

procedure and/or combination, compared to main procedure
Job Allocation for Combination(mixed) Operation
How to Proceed
Step1:Examine the balance of overall operation amount by each process
4) Examine amount of option operation for each model
Estimate option allocation setting

Loading time for option operation
Overall OP
operation time for
upright model of
most-produced
vehicle in Car C
*Only installation rate below 80% applies OP

operation since installation rate over 80% is
considered as all vehicles
S/roof
Navigation
A
Car
S/roof
Navigation
Car
B
Spoiler
S/roof
Navigation
Spoiler
Average time
based on
production rate
for OP operation
for Car C
C
Car
Build VS operation with a lot of manpower into OP

allocation as much as possible since it would inhibit the
How to Proceed
Step2: Select a main model to make an allocation
1) How to Select a Main Model
- Select a model with the least manpower required among
models that have production rate of 30% or more
- If it has production rate of 80% or more, select a model as
the main model, regardless of size of manpower required
Main
model is Car A in the case
below
33
min
24
min
22
min
A
Car
80%
Component
ratio
10
10
35
min
35
min
Target time
Target time
Main
model is Car D in the case
below
30
min
25
min
20min
D
Car
40%
10
10
30%
Component
ratio
10
How to Proceed
Step3: Decide # of Target Allocation
1) Decide # of regular cycle allocation & # of option
allocation
-Understand the current operation loading rate for an allocation
(# of workers required for target time/# of workers required for allocation)
-Calculate # of workers required for target time, # of workers
required for weighted average
Estimate # of allocation
-Calculate # of workers required, considering current operation loading

rate for an allocation
Estimate # of allocation
-Understand difference in manpower among models
Estimate # of OP allocation
tact
Car
A
80%
Car
B
10% 3.00
Car
C 10%
Ave.
Production
rate
Target time
24.10
21.50
32.90
24.72
# of allocationOperation
rate
for allocation
M /
8.0
7.2
0.95
11.0
8.2
# of allocation
8.4
7.5
11.5
8.7
Difference in manpower
among most-produced
cars
-2.6
+8.8
Regular cycle
allocation for main
model : 8 operators
# of all allocation:
9 operators
# of OP allocation:
How to Proceed
Step4: Decide Operation Procedure & Job Allocation
1) Describe an image of the whole allocation
Describe a whole image before making a specific allocation
due to difference in manpower in each models target time, #
of workers required and most-produced vehicle
Regular cycle
allocation
Car A
tact
NO.1
OP
allocation
NO.2
NO.8
NO.9
Differences in manpower for

Car A that can not be included
in the 8 allocations (a whole)
(0.4 manpower)
Since amount of operation for
Car B is equal to 7.5 manpower,
theres no operation in OP
allocation
Difference in manpower in
making Car C, compared to
most-produced vehicle (Car A)
loading ratio 10%
How to Proceed
2) Make an allocation for a main model
Decide allocation of workers, considering process layout, operation
procedure for large parts and equipment conditions
OP operation area
Calculate Allocated Target Time

tact operation loading rate for allocation 3min0 95=2 85min
rough standard basic is 100%
Assign Jobs
Investigate based on basic principles for job allocation
Standard is that difference in manpower among models is w/in +/- 5%
for regular cycle allocation
How to Proceed
3) Make an allocation for other models
- Be in harmony with operation procedure for the main model
One person for one part for any vehicle model
- Standard for difference in manpower among models w/in +/-5%
- Target time allocation is the same as main model
Regular Cycle
Allocation
Option
allocation
Tact
Assigned
target
time
NO.1
NO.2
Main
model
NO.8
Mass-produced models for each design
NO.9
Within
How to Proceed
Step4: Decide operation procedure & job allocation
4) Decide Option Allocation
- Within the # of option allocation decided in step 3
- Make option process concentrated as much as possible
set it beyond the frame of process
- Allocate 3 times of tact or less
Principles for option allocation
Within 3 times
of tact
NO.8
NO.9
Option process
H/lining
How to Proceed
5) Minimize inefficiency of waiting by operation procedure adjustment
-Examine to build fractional figures in a regular cycle
allocation in option process or integrate them in the process
that comes before or after
-For option process, examine the integration by adjustment
among processes
How to Proceed
6) Investigate to Form Option Allocation
-Is operation procedure formed
-Is large enough space secured, assuming the case when max.
amount of operation for one car needs to be done?
-Is there interference with other operations?
-Can workers walk back to the original position after
completing a job simulation
Image of operators movement
OP allocation
Model component ratio
Loading
order
first
model time
Car C
Car A
Car A
min
Car A
Car B(10%)
No operation
Car B
Car C(10%)
min
Car A
Car A(80%)
Car A
Car C
Tact 3.0 min
Car A
Car B
Required stage
Loading condition Vehicle intervals more than 6 vehicles
How to Proceed
Step5: Secure Operation Area
Secure operation area to prevent interference with a

process before and after
-Regular Cycle process : In case of sequence of
the
same blocks 1.5 pitch
-Option Process
: 3 pitch (standard)
Step6: Create Line Side Layout
Supply Strike Zone
Rules for Monthly Allocation Change

Execute allocation changes in harmony with changes in
contents
Overall allocation
changes
1.Shift base S/B change

Main model change
S/B 2. Changes in
model components
Main model doesnt change

No
changes
3. changes in OP, VS ratio
Allocation changes only

within op. operation

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01-01-13 Operation Control 2

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Operation Control

Introduction to Operation Control

Time Analysis According to Purpose

Presentation of Cases & Practice

Presentation of Cases & Practices

Practical Operation Control

Investigation & Improvement of Oppama Line

Investigation at the actual line&Draw up improvement plan

Practice Operational Control by Nissan Production

Approach to a Better Operating Procedure

How to Pursue Practical Operation Control

---There is a difference b/t standard operation sheet & actual operation

Training plan is not drawn up monthly

Training plan is not practical, thus improvement in technique

Not being able to acquire vacations as planned

Not being able to identify items to be improved or problems

How to Pursue Practical Operation Control

Flow of Practical Operation Control

How to Pursue Practical Operation Control

Steps for Activity

Step 7 Identify Roles in Each Dept.

Step 5 Technique Improvement

Step 2 Set a Target Time

Step1 Confirmation of Standard Operation

How To Pursue Practical Operation Control

Using a target time, decide work procedure, work

Tools for a supervisor to teach a job

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

It appears 100% due to sluggishness

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

- It is also called block allocation which

Body Side (R)

Body Side (L)

In a case of trim process

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

A person assigned for one part for one vehicle

Car A Headlamp Installation

Car B Headlamp Installation

Car A Headlamp Installation

Car A Battery Installation

Car B Battery Installation

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

Two operators are allocated at the same stage

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

Principle 8 Standardization of tools

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

Do not allocate more than two operators in a

How to Pursue Practical Operation Control

How to Pursue Practical Operation Control

1) Basic Principles for Job Allocation

For Combination (mixed) Production

Job Allocation for Combination (mixed) Production