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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
20
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
13
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.
17
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)
19
TiCon – Ergobalancing
20
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
21 21
Production Plan
Compose the line and assign operat.
Evaluate workplace balancing
Time elements
RTM
EAWS-Ergo-UAS Project Plan
Thank You