MTM, Ergo-Uas applications in Tofaş Turkey.

20 Novembre, 2010

MTM & Ergo-UAS Applications in TOFAŞ

16/05/2014

Samet Türker – M. Onur Topçu

Production Resources Analysis & Audit Administration

MTM-UAS in TOFAŞ

TiCon

EAWS / Ergo-UAS

Production Resources Analysis & Audit

Pres 1 Body 2 Paint 1 Montaj 4

Suspansion 1 Main Office 2

P.R.A. & A. Activities

Production & Logistic Units Labor Losses Man.

Labor Planning & Management

VAA/NVAA Analysis

Line Balancing

Time Changing Management

Capacity Analysis

Simulation Studies

Prokon Studies

Tİcon MTM-UAS / Analysis /

Production Resources Analysis & Audit Administration

MTM-UAS in TOFAŞ

TiCon

EAWS / Ergo-UAS

MTM-UAS History in TOFAŞ

2007 2010 2011 2012 2013 2014

Implementation of MTM-UAS

MTM-UAS Audit by Fiat

Implementation of MTM-UAS

with Ticon

EAWS Training & Ergo-UAS Training

Saturation in Ticon

Pilot Area Ergo-UAS Analysis

Prokon Studies for New Model

& Ergo-UAS Implementation

Why We Use MTM-UAS

Determine operation times without tempo

Analysis standardization

Determine VAA/NVAA activities according to detaily analysis

Quick calculation of kaizen activities

Quick update of analysis

Database for ergo analysis

Determine forecast analysis for new models nearly real analysis

2011 Re-Analysis

Time Reduction with MTM-UAS

Production Resources Analysis & Audit Administration

MTM-UAS in TOFAŞ

TiCon

EAWS / Ergo-UAS

TiCon

TiCon has been selected as main tool to address following

TOFAŞ Manufacturing needs:

• Support potential ergonomics issues detection

• Detail manpower needs

• Balance the line for multiple Volume/Mix product

• Improve Value Added Activities

• Support Workplace integrated design

• Continuos improvement activities accountability

WS

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Variants

PLANT

FINAL ASSEMBLY

OPERATION F443954

OPERATION F443954

Consumed ITEMS

TOOLS

Process

SHEETS

OPERATION F443222

GAS 100,

LHD

Teamcenter

LHD, OPT3

GAS 4000

UTE 6

CONTROL

PLAN

Teamcenter and TiCon

Work Station 20 #Oper. Variants F443222 LHD, OPT3

F234178 Don’t care

F443954 GAS 100, LHD

TiCon

TCM

TCM/TiCon – analysis workflow

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Time analysis + value added composition

Methods from TCM

Analysis Execution

Analysis Validation

Methods

TiCon–Time Analysis & NVA Evaluation

14 14

• Each activity, both from Manufacturing Engineering and from plant

analysis, is analyzed in terms of time basic elements or standard

data block.

• Each work element of an Analysis is characterized with a specific type

of Added Value.

Production Resources Analysis & Audit Administration

MTM-UAS in TOFAŞ

TiCon

EAWS / Ergo-UAS

Ergo-UAS system overview

Ergo-UAS

MTM-EAWS

MTM-UAS

WORK ASSIGNM

ENT

• MTM-UAS (Universal Analyzing

System)

it’s is a standard and universal procedure to

assign a basic predetermined time to

execute each manual operation of an

activity described on process sheets where

production cycles are collected

• MTM-EAWS (European Assembly

Work Sheets)

it’s an ergonomic method to calculate, for

each work-station, the proper

biomechanical load and to set standard

time

• WORK ASSIGNMENT

Ergo-UAS application requires line

balancing to calculate ergonomic scores

and trouble identification. Line balancing

means correct and efficient location of

different tasks to workers that perform

production steps.

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Ergo-UAS System Overview

EAWS-Ergo-UAS

19

• Ergobalancing functionalities allow to check the workplace compliance with

standards and ergonomics regulations

• Ergobalancing compute the overall ergonomics index, starting from basic

posture and movements and applying the number of times that such tasks

have to be repeated (product mix)

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TiCon – Ergobalancing

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TiCon – Ergobalancing

To evaluate the compatibility of the overall working load, rest factor could

be added based on ergonomics index and the resulting working time is

compared with the time available

Rest factor

computed according

to ergo-UAS rules

TiCon – Workload balancing

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Production Plan

Compose the line and assign operat.

Evaluate workplace balancing

Time elements

RTM

EAWS-Ergo-UAS Project Plan

Thank You