Ứng dụng sơ đồ dòng giá trị để cải tiến năng suất tại chuyền lắp ráp bodyshop dòng xe GLC công ty TNHH mercedes benz vietnam

ĐẠI HỌC QUỐC GIA TP HCM TRƯỜNG ĐẠI HỌC BÁCH KHOA PHAN MINH HIẾU ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DỊNG XE GLC CƠNG TY TNHH MERCEDES-BENZ VIETNAM CHUN NGÀNH: QUẢN TRỊ KINH DOANH MÃ SỐ : 60 34 01 02 KHÓA LUẬN THẠC SĨ TP.HCM 8/2017 VIETNAM NATIONAL UNIVERSITY, HCM CITY BACH KHOA UNIVERSITY PHAN MINH HIEU APPLY VALUE STREAM MAPPING TO IMPROVE CAPACITY AT GLC BODYSHOP MERCEDES-BENZ VIETNAM LIMITED COMPANY MAJOR : BUSINESS ADMINISTRATION ID : 60 34 01 02 MASTER REPORT TP.HCM 8/2017 -i- CƠNG TRÌNH ĐƯỢC HOÀN THÀNH TẠI TRƯỜNG ĐẠI HỌC BÁCH KHOA ĐẠI HỌC QUỐC GIA TP HỒ CHÍ MINH Cán hướng dẫn khoa học: Tiến Sĩ Nguyễn Thị Đức Nguyên Cán chấm nhận xét 1: Cán chấm nhận xét 2: Khóa luận thạc sĩ bảo vệ Trường Đai học Bách Khoa, ĐHQG TP.HCM ngày 27 tháng 07 năm 2017 Thành phần Hội đồng đánh giá khóa luận thạc sĩ gồm: TS Nguyễn Thúy Quỳnh Loan TS Nguyễn Thị Thu Hằng TS Đường Võ Hùng Xác nhận Chủ tịch Hội đồng đánh giá khóa luận Trưởng khoa Quản lý Chuyên Ngành CHỦ TỊCH HỘI ĐỒNG TRƯỞNG KHOA - ii ĐẠI HỌC QUỐC GIA TP HỒ CHÍ MINH CỘNG HÒA XÃ HỘI CHỦ NGHĨA VIỆT NAM TRƯỜNG ĐẠI HỌC BÁCH KHOA Độc lập – Tự – Hạnh phúc - NHIỆM VỤ KHÓA LUẬN THẠC SĨ Họ tên học viên: PHAN MINH HIẾU MSHV: 13170660 Ngày, tháng, năm sinh: 20/06/1983 Nơi sinh: Bình Định Chuyên ngành: I MS: 60 34 01 02 QUẢN TRỊ KINH DOANH TÊN ĐỀ TÀI: ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DỊNG XE GLC, CƠNG TY TNHH MERCEDES-BENZ VIỆT NAM II NHIỆM VỤ VÀ NỘI DUNG: - Xác định xây dựng dòng giá trị dòng xe GLC chuyền lắp ráp BodyShop - Nhận diện lãng phí phân tích nguyên nhân - Đề xuất giải pháp để nâng cao suất xây dựng dòng giá trị tương lai III NGÀY GIAO NHIỆM VỤ: 15/03/2017 IV NGÀY HOÀN THÀNH NHIỆM VỤ: 05/07/2017 V CÁN BỘ HƯỚNG DẪN: TS NGUYỄN THỊ ĐỨC NGUYÊN Tp HCM, ngày 07 tháng 08 năm 2017 CÁN BỘ HƯỚNG DẪN CHỦ NHIỆM BỘ MÔN TRƯỞNG KHOA - iii - LỜI CẢM ƠN Đầu tiên xin gửi lời cảm ơn sâu sắc đến mẹ, vợ gái không ngừng giúp đỡ động viên suốt thời gian học cao học làm khóa luận Tơi xin chân thành cảm ơn sâu sắc Thầy, Cô khoa Quản Lý Công Nghiệp, trường Đại học Bách Khoa Thành phố Hồ Chí Minh, truyền đạt kiến thức tận tình hướng dẫn suốt thời gian học tập làm khóa luận Tơi xin chân thành cảm ơn TS Nguyễn Thị Đức Nguyên tận tình hướng dẫn giúp tơi hồn thành tốt khóa luận Tơi xin chân thành cảm ơn bạn đồng nghiệp công ty TNHH MercedesBenz Việt Nam giúp đỡ suốt q trình làm khóa luận TP.HCM, Ngày 07 tháng 08 năm 2017 Phan Minh Hiếu - iv - TÓM TẮT KHÓA LUẬN Sản lượng xưởng lắp ráp BodyShop dịng xe GLC Cơng ty TNHH Mercedes-Benz Việt Nam (MBV) đạt xe/ngày, đạt 80% so với sản lượng thiết kế (10 xe/ngày), sản phẩm ngày ưa chuộng thị trường Việt Nam sau mắt vào ngày 21 tháng năm 2016 (thời gian khách hàng nhận xe sau đặt hàng lên đến 13 tháng) Ứng dụng sơ đồ dòng giá trị (CVSM) để thể thực trạng tổng thể suất BodyShop GLC, giúp nhận diện điểm thắc cổ chai (bottleneck) loại lãng phí cách có hệ thống, có 05 trạm trạm: Z2.3, Z2.2, Sub Eng Comp, Sub Sidewall Finish nút thắc cổ chai Phân tích cụ thể cơng việc trạm nút thắc cổ chai, ứng dụng cơng cụ phân tích thống kê pareto xác định loại lãng phí chủ yếu biểu đồ xương cá để phân tích nguyên nhân, xác định loại lãng phí chờ đợi lãng phí tìm trả lại cơng cụ hai loại lãng phí lớn chuyền BodyShop dịng xe GLC Các giải pháp đề xuất để loại bỏ loại lãng phí phát giảm tải cho điểm thắc cổ chai, từ nâng cao suất nhằm đạt mục tiêu suất 10 xe ngày, đáp ứng mục tiêu đề khóa luận -v- ABSTRACT At Mercedes-Benz Vietnam, produced vehicles at Body workshop (Bodyshop) of GLC model is just vehicles per day, achived 80% design capacity (10 veh/day), whereas this is more and more interesting model at Vietnam market from the time it’s lauched, the customer ‘s waiting time to get the vehicle from order increase to 13 months Applied current state value stream mapping (CVSM) to show the current status of capacity at GLC BodyShop help us systematically recognize where is the bottleneck and what kind of wastes, stations Z2.3, Z2.2, Sub Eng Comp, Sub Sidewall and Finish are the bottlenecks Investigate the works at bottleneck stations, using Pareto tool to define main wastes and fishbone tool to find the root cause, waste of waiting and put up/ put down manually tools is the most at BodyShop GLC Proposed methods were raised to eliminate defined wastes and improve define bottlenect and the capacity will be increase The future-state value stream mapping showed that capacity increase to 10 vehicles/ day from vehicles/ day, and match with the purpose of this thesis - vi - LỜI CAM ĐOAN Tơi xin cam đoan: Đây cơng trình thực riêng dự hướng dẫn cô Tiến sĩ Nguyễn Thị Đức Nguyên, số liệu trích dẫn có nguồn gốc đầy đủ Các kết trình bày khóa luận trung thực chưa công bố công trình khác Tác giả khóa luận Phan Minh Hiếu - vii - MỤC LỤC CHƯƠNG GIỚI THIỆU ĐỀ TÀI 1.1 Lý hình thành đề tài .1 1.2 Mục tiêu thực 1.3 Phạm vi thực .3 1.4 Phương pháp thực .3 1.4.1 Quy trình thực 1.4.2 Nhu cầu thông tin phương pháp thu thập 1.4.2.1 Thông tin thứ cấp 1.4.2.2 Thông tin sơ cấp CHƯƠNG CƠ SỞ LÝ THUYẾT 2.1 Khái niệm sản xuất tin gọn – Lean Manufacturing 2.2 Lãng phí sản xuất phân loại 2.2.1 Khái niệm 2.2.2 Các loại lãng phí 2.2.2.1 Sản xuất dư thừa (Overproduction) .9 2.2.2.2 Chờ đợi (Waiting) .9 2.2.2.3 Di chuyển (Transportation) 2.2.2.4 Gia công thừa (Overprocessing) 10 2.2.2.5 Thao tác (Motion) 10 2.2.2.6 Tồn kho (Inventory) 10 2.2.2.7 Tạo sản phẩm lỗi (Making defective parts) .10 2.3 Lý thuyết sơ đồ dòng giá trị .11 2.3.1 Dòng giá trị (Value Stream) .11 2.3.2 Chọn họ sản phẩm: 12 2.3.3 Xác định thơng số q trình .12 2.3.4 Xây dựng sơ đồ dòng giá trị (CVSM) 14 2.3.5 Lập sơ đồ dòng giá trị tương lai (FVSM) 15 2.4 Biểu đồ xương cá 16 2.4.1 Giới thiệu 16 2.4.2 Cách tạo biểu đồ xương cá 16 - viii - CHƯƠNG XÂY DỰNG DÒNG GIÁ TRỊ HIỆN TẠI CHUYỀN BODYSHOP DÒNG XE GLC 18 3.1 Giới thiệu Công ty TNHH Mercedes-Benz Việt Nam .18 3.2 Giới thiệu xưởng lắp ráp Body GLC 20 3.3 Các thông số đầu vào 22 3.4 Sơ đồ dòng giá trị dòng xe GLC BS .25 3.4.1 Các loại ký hiệu 25 3.4.2 Sơ đồ CVSM: 26 3.5 Nhận xét CVSM: 28 CHƯƠNG NHẬN DIỆN LÃNG PHÍ VÀ PHÂN TÍCH NGUYÊN NHÂN 30 4.1 Nhận diện lãng phí 30 4.2 Phân tích nguyên nhân 34 4.2.1 Brain Storming 34 4.2.1.1 Thời gian chờ đợi 35 4.2.1.2 Thời gian tìm trả lại cơng cụ làm việc .36 4.2.2 Xác định nguyên nhân gốc rễ 37 CHƯƠNG ĐỀ XUẤT GIẢI PHÁP VÀ XÂY DỰNG DÒNG GIÁ TRỊ TƯƠNG LAI38 5.1 Giải pháp đề xuất 38 5.1.1 Trang bị thêm súng hàn bố trí lại súng hàn 38 5.1.2 Trang bị thêm súng bơm keo máy nung keo .38 5.1.3 Bố trí lại cơng việc cho hợp lý trạm: 39 5.2 Sơ đồ dòng giá trị tương lai (FVSM) 41 5.3 Nhận xét FVSM: 43 CHƯƠNG KẾT LUẬN VÀ ĐỀ NGHỊ 44 6.1 Kết luận 44 6.2 Đề nghị 44 Station: 6015 Sub ENG ZB Underbody Respot 6/16/2017 OP1 OP2 OP1 Process Step Content OP3 OP4 OP5 OP2 2988 3026 Duration Class waiting Start End Class 0 160 0 160 NVA 160 0 160 288 128 NVA 128 120 NVA 120 0 NVA 80 OP1 2.1 close locking clamps Close or open clamps manually 120 200 80 OP2 2.1 close locking clamps Close or open clamps manually 0 OP1 OP1 OP1 OP1 OP1 **6010 and 6015 share Guns X21, X14 and UE, Operators have to get guns from 6010** 17.1 walk to get gun UE Walk Operator (1 m) 17.2 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.4 change to gun X21 Put up and put down manually tools 17.6 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) 17.9 restore the welding gun UE & X21 Put up and put down manually tools 200 216 264 288 728 216 264 288 728 752 16 48 24 440 24 W VA W VA W 16 16 24 24 24 440 0 0 288 322 322 634 634 658 658 1178 1178 1202 OP2 OP2 OP2 OP2 OP2 17.1 walk to get gun X14 Walk Operator (1 m) 17.2 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.4 change to gun X21 Put up and put down manually tools 17.6 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) 17.9 restore the welding gun X14 & X21 Put up and put down manually tools **6010 and 6015 share Guns X21, X14 and UE, Operators have to bring guns to 6010** OP1 OP1 OP1 OP1 3.1 walk to get driller 3.2 drill holes (4lhs/4rhs) 3.3 deburr the holes 3.4 pur down drilling gun Walk Operator (1 m) Drilling manually Deburr after drilling Put up and put down manually tools 752 756 966 1014 756 966 1014 1026 210 48 12 OP2 OP2 OP2 OP2 3.1 walk to get riveting gun 3.2 riveting 4lhs and 4rhs 3.3 put down riveting gun 3.4 wait for OP1 Walk Operator (1 m) Riveting manually Put up and put down manually tools Waiting 0 0 0 0 0 0 OP1 OP1 4.1 Walk to get templates (2 in hand/walk) 4.2 Add templates Walk Operator (1 m) Load small part manually (radius 1m) 1026 1030 1030 1300 270 OP2 OP2 4.1 Walk to get templates (2 in hand/walk) 4.2 Add templates Walk Operator (1 m) Load small part manually (radius 1m) 0 0 0 OP1 OP1 OP1 OP1 OP1 OP1 OP1 5.1 walk to get stud welding gun 5.2 stud welding with black gun 5.3 change stud welding gun 5.4 stud welding with light blue gun 5.5 change welding gun 5.6 stud welding with green gun 5.7 restore the welding gun 1300 Walk Operator (1 m) 1304 Stud welding manually (autom conveyance) 1958 Put up and put down manually tools 1982 hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) 1982 Put up and put down manually tools 2006 hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) 2006 Put up and put down manually tools 1304 1958 1982 1982 2006 2006 2018 W VA W OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 5.1 walk to get stud welding gun 5.2 stud welding with yellow gun 5.3 change stud welding gun 5.4 stud welding with red gun 5.5 change welding gun 5.6 stud welding with blue gun 5.7 change welding gun 5.8 stud welding orange gun 5.9 restore the welding gun OP1 Walk Operator (1 m) hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) Put up and put down manually tools hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) Put up and put down manually tools hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) Put up and put down manually tools hand check (je Schw-Pt, HLS, Clinch-Pt.,Rivet, Klebenaht…) Put up and put down manually tools 2018 Waiting for OP2 till welding oparation is finished waiting 0 0 0 0 0 2244 654 24 24 12 0 0 0 0 0 226 OP1 OP2 6.1 unload underbody 6.1 unload underbody 2244 3026 782 NVA W NVA W W 4 210 48 12 W NVA 48 12 270 4 654 24 W 24 24 W 12 12 W 3026 50.4 226 0 0 0 0 1202 1212 1704 1716 1212 1704 1716 1836 10 492 12 120 0 0 0 32 342 0 0 0 0 0 0 0 0 0 0 2210 2226 2226 2238 2238 2250 2250 2262 2262 2226 2226 2238 2238 2250 2250 2262 2262 2274 16 12 12 12 12 0 2274 2988 714 W VA W VA W W VA W W W NVA 34 34 312 24 24 24 24 520 10 10 492 12 120 12 120 32 32 W 16 16 W 12 12 W 12 12 W 12 12 W 12 12 NVA 2988 49.8 422 422 Waiting 342 226 782 1142 1462 19 24.4 34 312 24 520 24 0 0 1836 1868 1868 2210 24 Put up and put down manually tools 0 0 48 24 VA Walk NVA Waste Operator (1 m) Duration 120 Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) Deburr after drilling 0 1.1 Load underbody from Station 6010 1.1 Load underbody from Station 6010 NVA Waste Put up and put down manually tools End OP1 OP2 VA Walk Operator (1 m) Start 28 120 48 226 714 1324 1344 22.1 22.4 320 5.3 320 92 108 120 Station: SubSide 6020 Z2.1A wallGeo 6/16/2017 OP1 OP2 OP1 Process Step Content OP1 OP2 START STEP1 1.1 Load underbody from Station 6010 1.1 Load underbody from Station 6010 Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) OP1 OP1 2.1 walk to pneumatic control panel 2.2 close pneu clamps Walk Operator (1 m) Press one hand start OP2 OP2 2.1 walk to pneumatic control panel 2.2 close clamps 1, Walk Operator (1 m) Close or open clamps manually OP1 OP1 5.1 walk to insert jig (frame) 5.2 close pin and clamps 5, Walk Operator (1 m) OP2 OP2 5.1 walk to insert jig (frame) 5.2 close pin and clamps 6, Walk Operator (1 m) Close or open clamps manually OP1 OP1 OP1 wait for finished gluing operation of OP 6.2 load insert jig 6.3 close clamp OP2 OP2 OP2 wait for finished gluing operation of OP 6.2 load insert jig 6.3 close clamp OP1 OP2 OP1 8.1 close clamps Close or open clamps manually OP2 8.1 close clamp 10, 11 Close or open clamps manually OP1 9.1 walk to get welding gun C8 Walk Operator (1 m) OP2 wait for OP1 Waiting OP1 OP2 OP1 OP3 OP4 OP2 3018 Start End Duration Class 0 0 40 0 40 NVA 40 44 44 48 W NVA 0 0 48 58 0 58 70 0 10 W 12 NVA 0 Waiting Load big part by hoist, manually (radius 3m) Close or open clamps manually 70 226 266 226 266 270 156 W 40 NVA NVA Waiting Load big part by hoist, manually (radius 3m) Close or open clamps manually 0 0 0 7.1 move sliding unit forward and close locking clamp Close or open clamps manually 270 278 7.1 move sliding unit forward and close locking clamp Close or open clamps manually 0 278 282 VA NVA Waste 0 10 12 156 156 40 0 NVA NVA 0 282 294 0 9.2 welding of simple geo spots with C8 togehter Spot with welding OP2 manually, Geo (simple) 9.2 welding of simple geo spots with C8 togehter Spot with welding OP1 manually, Geo (simple) 294 350 56 VA 9.3 restore welding gun C8 Put up and put down manually tools 350 362 12 W OP2 10.1 open pin 3, and clamps 1,2 Close or open clamps manually OP1 wait for OP2 END OF STEP1 Waiting 12 W 12 12 0 362 376 14 W 56 12 12 OP1 OP2 START STEP2 lh 1.1 Get SW inner lh out from box in front of frame Load big part, Operator manually (radius 3m) 1.1 Get SW inner lh out from box in front of frame Load big part, Operator manually (radius 3m) 376 400 24 NVA OP1 OP1 OP1 2.1 walk to get hand jig and part or 2.2 load part or in hand jig 2.3 load hand jig in SW inner Walk Operator (1 m) Load small part manually (radius 1m) Load small part manually (radius 1m) 400 406 418 406 418 424 W 12 NVA NVA OP2 OP2 2.1 walk to get gun wait for OP1 Put up and put down manually tools Waiting 0 0 0 0 0 40 0 40 44 44 52 0 0 52 58 58 70 0 0 0 70 70 190 70 190 194 10 14 14 24 12 2980 Put up and put Walk Operator Waiting down manually Start End Duration Class (1 m) tools 40 OP5 VA 0 40 NVA NVA Waste Put up and put Walk Operator Waiting down manually (1 m) tools 40 0 W NVA 4 6 0 W 12 NVA 12 0 0 120 NVA NVA 0 194 202 0 202 210 0 210 257 47 W 257 313 56 VA 0 313 393 0 393 417 0 0 0 417 429 429 444 120 NVA 8 NVA 47 47 12 15 15 56 80 NVA 80 0 24 NVA 24 0 12 W 15 W 12 OP1 OP2 2.4 welding of simple spots (Geo & Respots) with SpotC8 welding togehter manually, with OP1 Geo (simple) 2.4 welding of simple spots (Geo & Respots) with SpotC8 welding togehter manually, with OP1 Geo (simple) OP2 2.5 restore welding gun C8 OP1 wait for OP2 Waiting 512 524 12 W OP1 OP2 3.1 Load SW inner lh in framer 3.1 Load SW inner lh in framer Load middle part up to approx 1000x750 (radius 3m) Load middle part up to approx 1000x750 (radius 3m) 524 534 10 NVA 10 OP1 4.1 close clamps to Close or open clamps manually 534 554 20 NVA 20 OP2 4.1 close clamps to 10 Close or open clamps manually 0 OP1 START STEP2 rh walk to right side Walk Operator (1 m) 554 564 Put up and put down manually tools 424 512 0 88 VA 88 12 12 10 W 10 10 444 532 88 VA 532 544 12 W 0 544 554 0 554 590 0 88 12 12 0 10 NVA 10 36 NVA 36 OP2 walk to right side Walk Operator (1 m) 0 590 600 10 W 10 OP2 wait for OP1 Waiting 0 600 606 W 6 OP1 OP2 1.1 Get SW inner lh out from box in front of frame Load big part, Operator manually (radius 3m) 1.1 Get SW inner lh out from box in front of frame Load big part, Operator manually (radius 3m) 564 588 24 NVA 0 606 630 24 NVA OP1 OP1 OP1 2.1 walk to get hand jig and part or 2.2 load part or in hand jig 2.3 load hand jig in SW inner Walk Operator (1 m) Load small part manually (radius 1m) Load small part manually (radius 1m) 588 594 600 594 600 606 W NVA NVA 0 0 0 OP2 OP2 2.1 walk to get gun wait for OP1 Put up and put down manually tools Waiting 0 0 630 642 642 655 12 W 13 W 12 13 13 OP1 OP2 2.4 welding of simple spots (Geo & Respots) with SpotC8 welding togehter manually, with OP1 Geo (simple) 2.4 welding of simple spots (Geo & Respots) with SpotC8 welding togehter manually, with OP1 Geo (simple) 606 694 0 655 743 88 VA OP2 2.5 restore welding gun C8 Put up and put down manually tools 0 743 755 12 W OP1 wait for OP2 Waiting 694 706 12 W 0 OP1 OP2 3.1 Load SW inner lh in framer 3.1 Load SW inner lh in framer Load middle part up to approx 1000x750 (radius 3m) Load middle part up to approx 1000x750 (radius 3m) 706 716 10 NVA 10 755 765 OP1 4.1 close clamps 16 to 20 Close or open clamps manually 716 736 20 NVA 20 0 OP2 4.1 close clamps 21 to 24 Close or open clamps manually 0 765 801 36 NVA OP1 OP1 OP2 OP1 walk outside of frame lh wait for OP2 walk outside of frame lh wait for OP2 END OF STEP2 Walk Operator (1 m) Waiting Walk Operator (1 m) Waiting 736 756 0 756 792 40 20 W 36 W 40 W 0 801 821 0 821 821 0 20 W 792 816 824 816 824 844 24 NVA NVA 20 W 0 0 0 821 845 845 869 0 0 869 889 OP1 OP1 OP1 START STEP3 (gluing finished already by OP3) 3.1 close frame lh Load big part, Operator manually (radius 3m) 3.2 close locking clamp 1x Close or open clamps manually 3.3 walk outside of frame rh Walk Operator (1 m) OP2 OP2 3.1 close frame lh 3.2 close locking clamp 2x Load big part, Operator manually (radius 3m) Close or open clamps manually 0 0 OP1 OP1 3.4 close frame rh 3.5 close locking clamp 1x Load big part, Operator manually (radius 3m) Close or open clamps manually 844 868 868 876 OP2 4.1 close clamps 13 to 17 of framer lh Close or open clamps manually 0 24 6 6 0 88 VA 88 12 12 20 36 36 40 40 24 20 0 24 NVA NVA 20 24 20 10 24 0 12 88 12 12 0 10 NVA 10 36 20 0 24 NVA 24 NVA 24 24 0 20 NVA 20 20 OP1 OP1 5.1 walk to insert jig (rear frame) 5.2 load insert jig (rear frame) Walk Operator (1 m) Load big part by hoist, manually (radius 3m) 876 886 886 926 OP2 OP2 OP2 wait for OP1 (loading of frame) 5.2 load insert jig (rear frame) 5.3 close locking clamps Waiting Load big part by hoist, manually (radius 3m) Close or open clamps manually 0 0 OP1 OP1 5.3 walk to insert jig (front frame) 5.4 load insert jig (front frame) Walk Operator (1 m) Load big part by hoist, manually (radius 3m) 926 936 936 976 10 W 40 NVA 10 10 40 0 10 W 40 NVA 10 10 40 0 0 889 937 977 937 977 981 0 0 0 48 W 40 NVA NVA OP2 wait for OP1 (loading of frame) Waiting 0 981 1011 30 W 5.4 load insert jig (front frame) 5.5 close locking clamps Load big part by hoist, manually (radius 3m) Close or open clamps manually 0 0 0 1011 1131 1131 1143 120 NVA 12 NVA OP1 6.1 step into body to support welding Walk Operator (1 m) 976 984 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 6.1 walk to get gun X15 lh 6.2 welding of simple geo spots with X15 6.3 change to gun C8 6.4 welding of difficult geo spots with C8 6.5 welding of simple geo spots with C8 6.6 change to gun C21 6.7 welding of simple geo spots with C21 6.8 change to gun UU 6.9 welding of difficult spots with UU 6.10 welding of simple geo spots with UU 6.11 restore welding gun UU Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Spot welding manually, Geo (difficult) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools 0 0 0 0 0 0 0 0 0 0 0 OP1 OP1 OP1 6.2 support OP1 and OP2 for difficult welding operations Spot welding manually, Geo (difficult) waiting till geo welding is finished Waiting 6.11 get out of the body Walk Operator (1 m) Waiting 984 1140 1140 1342 1342 1350 W 8 156 VA 202 W W 156 202 202 0 1143 1155 1179 1191 1207 1243 1255 1263 1275 1299 1323 1155 1179 1191 1207 1243 1255 1263 1275 1299 1323 1335 12 24 12 16 36 12 12 24 24 12 0 0 0 0 W VA W VA VA W VA W VA VA W 0 1335 1381 46 W 0 1381 1401 20 NVA 8.1 unload insert jig (front frame) 8.2 walk to rear frame 8.3 unload insert jig (rear frame) OP2 7.4 open all clamps to 10, 13 to 17, Close or open clamps manually 0 1401 1497 96 NVA OP2 wait till rear frame is unloaded by OP1 Waiting 0 1497 1512 15 W OP2 OP2 10.2 push SW frame (lh) out 10.3 walk to SW frame (rh) Load big part, Operator manually (radius 3m) Walk Operator (1 m) 0 0 0 1512 1704 1704 1712 192 NVA W 192 OP2 10.4 push SW frame (rh) out Load big part, Operator manually (radius 3m) 0 1712 1904 192 NVA 192 OP1 OP1 11.1 walk to insert jig (frame) 11.2 open clamps to 11 on insert jig Walk Operator (1 m) Close or open clamps manually 1462 1466 1466 1494 W 28 NVA 28 0 0 0 OP1 OP1 12.1 push insert jig in back position 12.2 unload insert jig (frame) Unload middle part up to 1000x750 (radius 3m) Unload big part by hoist manually (radius 3m) 1494 1512 1512 1546 18 NVA 34 NVA 18 34 0 0 0 OP1 OP1 OP1 **Current Situation - Respoting in Z2.1A Geo** Calculation is simplified (lh) Get guns / change guns / restore Guns Put up and put down manually tools (lh) Respoting of difficult spots Spot welding manually, Geo (difficult) (lh) Respoting of 140 simple spots Spot welding manually, Geo (simple) 0 0 0 0 1546 1654 1654 1774 1774 2910 108 W 120 VA 1136 VA 10 0 10 108 120 1136 108 0 12 12 12 12 12 12 12 12 24 24 OP1 OP1 OP1 68 12 wait for OP1 34 12 16 36 7.1 open lh 2x lockings clamps of rear/front frame Close or open clamps manually 68 NVA 10 W 34 NVA 30 24 OP2 1350 1418 1418 1428 1428 1462 30 120 12 OP2 Unload big part by hoist manually (radius 3m) Walk Operator (1 m) Unload big part by hoist manually (radius 3m) 48 0 OP2 OP2 0 0 0 0 0 48 40 46 46 15 15 20 0 96 8 OP2 OP2 OP2 (rh) Get guns / change guns / restore Guns (rh) Respoting of difficult spots (rh) Respoting of 140 simple spots Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) OP1 12.3 unload body Unload big part by hoist manually (radius 3m) 0 0 0 2910 2978 0 1904 1952 1952 2036 2036 2980 68 NVA 3018 1644 50.3 27.4 68 644 10.7 730 12.2 730 48 W 84 VA 944 VA 48 2980 1392 1164 49.7 23.2 19.4 138 472 120 48 84 944 424 7.1 424 48 220 156 Station: Z2.2 6020 Z2.1A Geo 6/16/2017 OP1 OP2 OP1 Process Step Content OP3 OP4 OP2 3132 Start End Duration Class OP1 OP2 START STEP1 1.1 Load underbody from Station 6010 1.1 Load underbody from Station 6010 Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) 0 40 0 40 NVA OP1 OP1 2.1 walk to pneumatic control panel 2.2 close pneumatic clamps Walk Operator (1 m) Press one hand start 40 44 44 46 W NVA OP2 OP2 2.1 walk to clamps 1, 2.2 close clamps 1, Walk Operator (1 m) Close or open clamps manually 0 0 OP3 OP3 OP3 3.1 walk to rack to get SW (lh) 3.2 load SW in frame (lh) 3.3 close red clamps 1, on frame (lh) Walk Operator (1 m) Load big part, Operator manually (radius 3m) Close or open clamps manually 0 OP4 OP4 OP4 3.1 walk to rack to get SW (lh) 3.2 load SW in frame (lh) 3.3 close red clamps 3, on frame (lh) Walk Operator (1 m) Load big part, Operator manually (radius 3m) Close or open clamps manually OP3 OP3 OP3 3.4 walk to rack to get SW (rh) 3.5 load SW in frame (rh) 3.6 close red clamps 1, on frame (rh) OP4 OP4 OP4 VA OP5 2608 OP3 Put up and Walk put down NVA Waste Operator (1 Start End Duration Class manually m) tools 0 40 VA Walk NVA Waste Operator (1 Waiting m) 0 0 40 40 0 0 0 0 40 44 44 52 0 0 0 0 0 0 0 0 0 0 0 0 Walk Operator (1 m) Load big part, Operator manually (radius 3m) Close or open clamps manually 0 0 0 0 3.4 walk to rack to get SW (rh) 3.5 load SW in frame (rh) 3.6 close red clamps 1, on frame (rh) Walk Operator (1 m) Load big part, Operator manually (radius 3m) Close or open clamps manually 0 0 0 0 OP1 OP1 OP1 OP1 OP1 OP1 5.1 walk to frame (lh) 5.2 push sliding unit in frame (lh) down 5.3 close locking clamps 5.4 walk to frame (rh) 5.5 push sliding unit in frame (rh) down 5.6 close locking clamps Walk Operator (1 m) Close or open clamps manually Close or open clamps manually Walk Operator (1 m) Close or open clamps manually Close or open clamps manually 46 56 68 76 92 104 56 68 76 92 104 112 10 12 16 12 OP2 OP2 OP2 6.1 walk to get part 6.2 load part into insert jig no 6.3 close pins 1, and clamps 3, Walk Operator (1 m) Load middle part up to approx 1000x750 (radius 3m) Close or open clamps manually 0 0 0 OP2 OP2 OP2 7.1 / 9.1walk to get part / 7.2 / 9.2 load part / into insert jig no / 7.3 / 9.3 close pins 1, and clamps 3, Walk Operator (1 m) Load middle part up to approx 1000x750 (radius 3m) Close or open clamps manually 0 OP3 OP3 OP3 8.1 walk to get part 8.2 load part into insert jig no 8.3 close pins 1, and clamps 3, END STEP1 Walk Operator (1 m) Load middle part up to approx 1000x750 (radius 3m) Close or open clamps manually 2486 OP4 Put up and put down Start End Duration Class manually tools 0 VA Walk NVA Waste Operator (1 Waiting m) 2490 Put up and put down Start End Duration Class manually tools 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 26 26 34 24 0 0 0 0 0 0 0 0 0 0 0 0 30 30 38 24 0 0 0 0 34 38 62 38 62 70 24 0 0 0 0 0 0 0 0 0 0 0 0 0 38 48 72 48 72 80 10 24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 52 58 78 58 78 94 20 16 W NVA NVA 20 16 0 0 0 94 100 110 100 110 126 10 16 W NVA NVA 10 16 0 0 0 0 0 0 0 0 0 0 0 4 W NVA NVA W NVA NVA 10 10 16 16 12 12 0 6 0 0 0 0 0 0 0 0 0 0 70 72 92 72 92 108 20 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 80 116 671 691 697 717 741 116 671 691 697 717 741 761 36 555 20 20 24 20 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1.3 get the gluing gun (Terostat) 1.4 apply sealer on left side Put up and put down manually tools Sealer application manually, simple (100mm) 112 220 220 380 108 160 W VA 160 OP1 OP1 2.1 walk to right side 2.2 apply sealer on right side Walk Operator (1 m) Sealer application manually, simple (100mm) 380 386 386 501 115 W VA 115 OP1 OP1 OP1 OP1 2.3 change cartridge (Terostat to Betamate) 2.4 walk to left side 2.5 apply sealer on left side 2.6 restore gluing gun Put up and put down manually tools Walk Operator (1 m) Sealer application manually, simple (100mm) Put up and put down manually tools 501 585 585 599 599 1029 1029 1173 84 14 430 144 W W VA W OP3 3.1 walk outside of frame (lh) Walk Operator (1 m) OP2 OP3 OP4 wait for OP1 and OP4 wait for OP1 and OP4 wait for OP1 Waiting Waiting Waiting OP1 3.1 walk outside of frame (rh) Walk Operator (1 m) OP2 3.1 walk outside of frame (rh) Walk Operator (1 m) OP1 OP1 OP2 OP2 3.2 close frame (rh) 3.3 close locking clamp 3.2 close frame (rh) 3.3 close locking clamp Load big part, Operator manually (radius 3m) Close or open clamps manually Load big part, Operator manually (radius 3m) Close or open clamps manually OP3 OP3 OP4 OP4 3.2 close frame (rh) 3.3 close locking clamp 3.2 close frame (rh) 3.3 close locking clamp Load big part, Operator manually (radius 3m) Close or open clamps manually Load big part, Operator manually (radius 3m) Close or open clamps manually OP1 4.1 close clamps 35 to 47 Close or open clamps manually 0 OP2 4.1 close clamps 48 to 60 Close or open clamps manually 0 868 920 52 OP3 4.1 close clamps to 17 Close or open clamps manually 0 0 0 0 144 0 0 0 0 0 126 830 704 0 0 830 840 10 0 840 864 0 864 868 0 24 0 0 0 0 0 0 1217 1241 1241 1245 0 0 0 0 144 1173 1217 14 0 0 1245 1297 44 W 44 24 0 NVA NVA 24 0 0 52 NVA 52 44 0 OP1 OP1 430 24 0 0 0 0 0 84 0 0 0 0 0 W NVA NVA 24 0 0 0 0 0 W NVA NVA 0 Put up and put down manually tools Sealer application manually, simple (100mm) Sealer application manually, simple (100mm) Walk Operator (1 m) Sealer application manually, simple (100mm) Put up and put down manually tools Walk Operator (1 m) 84 14 START STEP2 1.1 get the gluing gun (Betamate) 1.2 apply sealer on right side 10.1 apply sealer on rear roof frame (rh) 10.2 walk to left side 10.1 apply sealer on rear roof frame (rh) 1.3 restore gluing gun 3.1 walk outside of frame (lh) 108 OP4 OP4 OP4 OP4 OP4 OP4 OP4 108 W NVA 40 W 704 W NVA NVA NVA 10 24 52 704 10 W NVA NVA 2 20 16 108 110 W 110 0 840 0 730 W 730 0 0 0 840 864 0 0 0 761 0 1289 0 528 0 0 0 0 0 0 0 0 0 0 0 0 0 0 864 868 0 24 0 NVA NVA 24 730 0 0 1289 1313 1313 1321 0 24 0 0 0 0 0 0 868 920 52 0 NVA 52 Walk NVA Waste Operator (1 m) Put up and put down Deburr after Waiting manually drilling tools 0 NVA VA W NVA NVA 24 W NVA NVA 24 W VA VA W VA W W 10 10 36 36 555 20 6 24 20 20 20 W NVA NVA 528 24 24 528 OP4 4.1 close clamps 18 to 30 Close or open clamps manually OP1 OP1 5.1 / 6.1 walk to insert jig / 5.2 / 6.2 load insert jig / Walk Operator (1 m) Load big part by hoist, manually (radius 3m) OP2 OP2 5.1 / 6.1 step in to body 5.2 / 6.2 support loading insert jig / Walk Operator (1 m) Load big part by hoist, manually (radius 3m) 0 0 OP3 OP3 7.1 walk to insert jig 7.2 load insert jig Walk Operator (1 m) Load big part by hoist, manually (radius 3m) 0 OP4 OP4 7.1 step in to body 7.2 support loading insert jig Walk Operator (1 m) Load big part by hoist, manually (radius 3m) 0 OP1 8.1 get gun X21 Put up and put down manually tools OP2 wait for OP1 Waiting OP1 OP1 8.2 welding of difficult geo spots with X21 8.3 welding of simple geo spots with X21 Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) OP2 OP2 8.2 support OP1 welding of difficult geo spots with Spot X21 welding manually, Geo (difficult) 8.3 support OP1 welding of simple geo spots with Spot X21 welding manually, Geo (simple) 0 0 0 0 0 0 OP3 8.1 get gun X21 Put up and put down manually tools 0 0 0 964 976 12 OP4 wait for OP3 Waiting 0 0 0 0 OP3 OP3 8.2 welding of difficult geo spots with X21 8.3 welding of simple geo spots with X21 Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) 0 0 0 0 0 0 OP4 OP4 8.2 support OP3 welding of difficult geo spots with Spot X21 welding manually, Geo (difficult) 8.3 support OP3 welding of simple geo spots with Spot X21 welding manually, Geo (simple) 0 0 0 0 0 0 0 0 0 OP1 8.4 restore welding gun X21 Put up and put down manually tools 1503 1599 96 W 96 OP1 9.1 walk to insert jig no.1 Walk Operator (1 m) 1599 1605 W OP2 wait for OP1 Waiting OP1 OP2 9.2 load insert jig no 9.2 load insert jig no Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) 9.3 close pins 7, Close or open clamps manually OP2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 920 934 934 974 14 40 0 0 0 0 0 0 0 0 0 0 0 920 924 924 964 40 0 0 0 0 0 0 0 0 0 0 1297 1311 1311 1351 1351 1399 0 1399 1447 1447 1503 0 1605 1645 0 14 40 48 W NVA 14 14 40 W 48 48 48 56 VA VA 48 56 0 0 986 12 0 0 0 986 1034 1034 1090 96 40 0 974 NVA 40 48 56 W NVA 14 W VA VA 14 40 12 12 48 56 1321 1373 W NVA 4 40 1373 1387 1387 1427 52 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 976 1144 1144 1256 168 112 12 12 1427 1447 VA VA 168 112 0 0 1447 1615 1615 1727 40 14 14 W 20 20 0 168 112 0 0 0 0 0 0 0 0 0 0 0 15 W NVA 20 15 52 0 14 40 W NVA 1090 1105 15 W 0 1105 1145 40 NVA 40 0 0 0 0 0 0 1145 1153 NVA 0 0 0 0 0 VA VA 168 112 **Process step 10 (apply glue on rear roof frame) is done in process step by OP4** OP3 8.4 restore welding gun X21 Put up and put down manually tools 0 0 0 1256 1268 12 W 12 OP3 11.1 walk to insert jig no Walk Operator (1 m) 0 0 0 1268 1270 W OP4 11.2 walk to get part Walk Operator (1 m) 0 0 0 0 1727 1737 10 W OP4 OP4 wait for OP3 Waiting 11.3 load part in body while OP3 is loading insert Load jig no big 5part by hoist by hoist, manually (radius 3m) 0 0 0 0 0 0 0 0 0 1737 1757 1757 1797 20 40 W NVA OP3 11.3 load insert jig no Load big part by hoist, manually (radius 3m) 0 0 0 OP4 OP4 12.1 walk to get foam parts 12.2 clip foam part for ASD 2x Walk Operator (1 m) clip or seal Foarm Parts 0 0 0 0 0 0 0 0 0 OP3 OP3 OP3 OP3 14.1 walk to get welding gun X21 Put up and put down manually tools 14.2 welding of simple geo spots with X21 at rear Spot roofwelding frame (rh) manually, Geo (simple) 14.3 walk to front roof frame Walk Operator (1 m) wait fo OP2 Waiting 0 0 0 0 0 0 0 0 0 0 0 0 1310 1322 1354 1356 1322 1354 1356 1358 12 32 2 W VA W W OP3 OP2 14.4 welding of simple geo spots with X21 at front Spot roof welding frame (rh) manually, Geo (simple) 14.4 support OP welding of simple geo spots with SpotX21 welding at front manually, roof frame Geo(rh) (simple) 0 0 0 1358 1390 0 32 VA OP1 OP1 OP1 14.1 walk to get welding gun X21 Put up and put down manually tools 14.2 welding of simple geo spots with X21 at rear Spot roofwelding frame (rh) manually, Geo (simple) 14.3 walk to front roof frame Walk Operator (1 m) Waiting 1645 1741 1741 1757 1757 1765 0 96 16 0 1153 1169 W VA W 16 16 OP2 wait for OP1 OP1 OP2 14.4 welding of simple geo spots with X21 at front Spot roof welding frame (rh) manually, Geo (simple) 14.4 support OP welding of simple geo spots with SpotX21 welding at front manually, roof frame Geo(rh) (simple) 1765 1781 0 16 VA OP1 OP1 OP1 OP1 OP1 OP1 OP1 14.5 change to gun C16 (lh) 14.6 welding of simple geo spots with C16 14.7 change to gun C5 (lh) 14.8 welding of 20 simple geo spots with C5 14.9 change to gun X13 (lh) 14.8 welding of simple geo spots with X13 14.9 restore welding gun X13 Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 1781 1877 1949 2045 2213 2297 2353 1877 1949 2045 2213 2297 2353 2461 96 72 96 168 84 56 108 W VA W VA W VA W OP3 OP3 OP3 OP3 OP3 OP3 OP3 14.5 change to gun C16 (lh) 14.6 welding of simple geo spots with C16 14.7 change to gun C5 (lh) 14.8 welding of 19 simple geo spots with C5 14.9 change to gun X13 (lh) 14.8 welding of simple geo spots with X13 14.9 restore welding gun X13 Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 0 0 0 0 0 0 0 OP4 OP4 OP4 OP4 13.1 walk to get drilling machine 13.2 dill holes at fender area (lh) 13.3 deburr holes at fender area (lh) 13.4 walk to fender area right side Walk Operator (1 m) Drilling manually Deburr after drilling Walk Operator (1 m) 0 0 0 0 96 96 96 96 96 96 0 0 0 16 1270 1310 VA 16 0 1169 1181 12 W 0 1181 1197 16 VA 12 16 12 40 32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1867 1877 1919 1967 1877 1919 1967 1973 10 42 48 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1390 1402 1522 1534 1790 1802 1938 1402 1522 1534 1790 1802 1938 1950 12 120 12 256 12 136 12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 84 12 0 0 0 0 108 2 0 0 0 0 84 12 32 W VA W VA W VA W 12 12 12 12 12 12 12 12 120 256 136 10 10 20 20 40 10 60 0 0 0 0 108 0 0 0 0 0 56 1797 1807 1807 1867 0 0 0 0 0 168 40 0 0 0 0 0 72 NVA 12 W VA W NVA W W 10 10 10 10 48 6 60 42 48 OP4 OP4 OP4 13.5 dill holes at fender area (lh) 13.6 deburr holes at fender area (lh) 13.7 restore drilling machine Drilling manually Deburr after drilling Put up and put down manually tools 0 0 0 0 0 0 0 0 0 OP2 OP2 OP2 OP2 OP2 OP2 OP2 13.7 walk to get blind rivet gun Walk Operator (1 m) wait for OP4 till drilling + debirr left side is finishedWaiting 13.8 apply blind rivets at fender area (lh) Riveting manually Walk Operator (1 m) 13.9 walk to fender area right side wait for OP4 till drilling + debirr right side is finished Waiting 13.10 apply blind rivets at fender area (rh) Riveting manually 13.11 restore blind rivet gun Put up and put down manually tools 0 0 0 0 0 0 0 0 0 0 1197 1207 1256 1556 1562 1577 1817 1207 1256 1556 1562 1577 1817 1829 10 49 300 15 240 12 W W VA W W VA W OP2 OP3 OP4 wait for OP1 till geo welding is finished wait for OP1 till geo welding is finished wait for OP1 till geo welding is finished END STEP2 0 0 0 0 1829 1900 0 0 71 0 W Waiting Waiting Waiting 0 0 2461 2505 OP1 START STEP3 1.1 open clamps + locking clamps on insert jigs Close and or 3/2 open (lh) clamps manually OP2 1.1 open clamps + locking clamps on insert jigs Close and or 3/2 open (rh) clamps manually OP1 OP2 OP2 2.1 unload insert jigs 2.1 support unload insert jigs wait for OP1 Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) Waiting 2505 2573 0 0 OP1 OP1 OP2 2.2 walk insert jigs 2/3 2.3 unload insert jigs 2/3 2.3 support unload insert jigs 2/3 Walk Operator (1 m) Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 2573 2577 2577 2645 2645 2645 0 0 44 NVA 44 68 0 NVA 68 68 W NVA 0 0 4 68 0 10 49 10 15 49 300 15 240 12 12 71 71 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1950 2010 0 0 NVA 0 0 60 1973 2015 2015 2051 2051 2063 0 0 0 W 0 0 0 0 0 0 48 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 1900 1948 48 0 1948 2016 2016 2022 68 NVA W 68 2022 2022 2022 2022 2022 2090 0 68 NVA 68 6 1.1 open 11 clamps + locking clamps on insert jigs Close and or open (lh)clamps manually 0 0 0 1.1 open 11 clamps + locking clamps on insert jigs Close and or open (rh)clamps manually 0 0 0 OP3 OP4 OP4 2.1 unload insert jigs 2.1 support unload insert jigs wait for OP3 Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) Waiting 0 0 0 0 0 0 0 0 0 2062 2130 0 0 68 0 NVA OP3 OP3 OP4 2.2 walk insert jigs 5/8 2.3 unload insert jigs 5/8 2.3 support unload insert jigs 5/8 Walk Operator (1 m) Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 0 0 0 0 0 0 0 0 2130 2132 2132 2200 0 68 W NVA OP1 OP1 OP1 3.1 walk to sliding unit in frame (lh) 3.2 open clamps on sliding unit 3.3 pull up sliding unit (lh) Walk Operator (1 m) Close or open clamps manually Close or open clamps manually 0 0 0 0 OP2 3.4 open clamps on frame (lh) Close or open clamps manually OP1 3.4 open clamps on frame (lh) Close or open clamps manually OP3 OP3 OP3 3.1 walk to sliding unit in frame (rh) 3.2 open clamps on sliding unit 3.3 pull up sliding unit (rh) Walk Operator (1 m) Close or open clamps manually Close or open clamps manually 0 0 0 OP4 3.4 open clamps on frame (rh) Close or open clamps manually OP3 3.4 open clamps on frame (rh) Close or open clamps manually OP1 3.5 open locking clamp of SW frame (lh) Close or open clamps manually OP2 3.5 open locking clamp of SW frame (lh) Close or open clamps manually OP1 OP2 3.6 push SW frame (lh) out 3.6 push SW frame (lh) out Unload big part, Operator manually (radius 3m) Unload big part, Operator manually (radius 3m) OP3 3.5 open locking clamp of SW frame (lh) Close or open clamps manually 0 0 0 OP4 3.5 open locking clamp of SW frame (lh) Close or open clamps manually 0 0 0 OP3 OP4 3.6 push SW frame (lh) out 3.6 push SW frame (lh) out END STEP3 Unload big part, Operator manually (radius 3m) Unload big part, Operator manually (radius 3m) 0 0 0 0 0 0 0 0 0 0 0 2677 2705 20 NVA 28 20 0 0 0 0 0 0 0 0 0 0 0 0 0 2709 2739 0 0 0 2739 2763 NVA 30 0 24 NVA 30 12 0 2146 2161 15 Walk Operator (1 m) OP2 1.1 walk to body right side Walk Operator (1 m) OP1 OP2 1.2 welding of difficult respots with gun C11 together Spot welding with OP2 manually, Respot (difficult) 1.2 support welding of difficult welding spots with Spot gunwelding C11 manually, Respot (difficult) 2763 2812 0 49 VA OP1 OP1 1.3 change to gun C5 (lh) 1.4 welding of 24 simple respots with gun C5 Put up and put down manually tools Spot welding manually, Respot (difficult) 2812 2896 2896 3064 84 168 W VA OP2 OP2 1.3 walk to get gun C5 (rh) 1.4 welding of 24 simple respots with gun C5 Put up and put down manually tools Spot welding manually, Respot (difficult) 0 0 0 OP3 OP3 OP3 OP3 OP3 3.1 walk to get punch rivet gun 3.2 apply punch rivet (lh) 3.3 walk to right side 3.4 apply punch rivet (rh) 3.5 restore punch rivet gun Put up and put down manually tools punch rivet first point Walk Operator (1 m) punch rivet first point Put up and put down manually tools 0 0 0 0 0 0 0 0 0 0 0 0 OP4 OP4 OP4 OP4 OP4 OP4 OP4 2.1 walk to get drilling machine 2.2 dill holes at fender area (lh) 2.3 deburr holes at fender area (lh) 2.4 walk to fender area right side 2.5 dill holes at fender area (lh) 2.6 deburr holes at fender area (lh) 2.7 restore drilling machine Walk Operator (1 m) Drilling manually Deburr after drilling Walk Operator (1 m) Drilling manually Deburr after drilling Put up and put down manually tools 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 W 24 24 49 84 168 84 44 52 68 2 68 NVA 52 34 32 NVA W 34 0 0 2241 2275 0 34 NVA 34 NVA 44 0 0 0 0 0 0 0 0 0 0 0 0 0 NVA 24 24 2275 2319 44 0 0 0 0 12 0 0 0 15 0 0 0 0 0 0 0 2238 2250 0 2250 2340 0 12 NVA 12 90 NVA 90 2319 2323 NVA 0 2323 2338 15 NVA 15 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2340 2352 2412 2414 2474 2352 2412 2414 2474 2486 12 60 60 12 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2338 2340 2354 2384 2390 2404 2434 2340 2354 2384 2390 2404 2434 2470 14 30 14 30 36 49 W VA 10 10 49 0 12 308 W VA 12 308 12 0 W VA W VA W 12 12 60 2 60 12 12 W 0 2175 2209 2209 2241 0 0 36 12 60 60 32 32 0 0 W NVA NVA 36 12 52 0 42 2123 2175 0 2214 2238 NVA NVA 0 0 2200 2202 2202 2210 2210 2214 NVA 52 0 10 2220 2232 2232 2540 NVA 0 0 0 2171 2220 0 0 0 2161 2171 0 2010 2062 2134 2146 START STEP4 1.1 walk to get welding gun C11 OP1 44 0 28 2090 2134 2705 2709 W NVA NVA 0 60 0 OP3 20 0 0 2063 2123 60 NVA W W 0 0 0 0 0 OP4 2645 2665 2665 2673 2673 2677 60 0 0 0 42 36 12 0 W NVA W W NVA W W 2 30 6 14 30 14 30 36 30 36 OP4 OP4 OP4 OP4 4.1 walk to pneumatic control panel 4.2 open pneumatic clamps 4.3 walk to clamps 1, 4.4 open clamps 1, Walk Operator (1 m) Press one hand start Walk Operator (1 m) Close or open clamps manually OP1 OP2 5.1 unload body 5.1 unload body Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 0 0 0 3064 3132 0 0 0 68 0 0 NVA 68 3132 1354 564 52.2 22.6 9.4 0 0 0 2540 2608 1214 20.2 1214 0 0 68 NVA 68 2608 1033 601 43.5 17.2 10 170 1044 974 16.2 974 0 0 0 0 0 0 2470 2472 2476 2478 2472 2476 2478 2490 12 0 0 0 0 0 0 2486 976 586 41.4 16.3 9.8 66 884 24 924 15.4 924 W NVA W NVA 792 108 2 12 2490 935 539 41.5 15.6 24 1016 16.9 1016 104 108 660 144 Station: Z2.3 6010 ZB Underbody 6/16/2017 OP1 OP2 OP1 Process Step Content OP3 OP4 OP2 3466 Start End Duration Class 0 12 12 42 0 42 64 0 71 87 353 369 381 87 353 369 381 413 16 266 16 12 32 0 0 OP1 OP1 1.1 Get the foam parts from rack (16m) 1.2 Clip foam parts in the long member lh/rh Walk Operator (1 m) clip or seal Foarm Parts OP2 2.1 retract locater pins 2x(1, 2) and Close or open clamps manually OP1 3.1 Load long members lh + rh Load big part, Operator manually (radius 3m) OP2 4.1 load engine compartment (part3) Load big part by hoist, manually (radius 3m) OP1 OP1 OP1 OP1 OP1 5.1 Close clamps 6, and ascend retractable pin Close 8, or open clamps manually Waiting wait for engine compartment OP2 6.1 close clamps 11 - 13 Close or open clamps manually 7.1 walk to get gun Walk Operator (1 m) 7.2 welding of simple geo spots with X21 Spot welding manually, Geo (simple) OP2 OP2 OP2 OP2 7.1 walk to get gun 7.2 welding of simple geo spots with X21 7.3 walk to get gun waiting for support of OP for diffcult weld spots Walk Operator (1 m) Spot welding manually, Geo (simple) Walk Operator (1 m) Waiting 0 0 0 0 OP2 OP1 7.3 welding of simple geo spots with UZ togehter Spot welding manually, Geo (simple) 7.3 welding of simple geo spots with UZ togehter Spot welding manually, Geo (simple) 413 477 64 VA OP1 OP1 OP1 8.1 get the glueing gun 8.2 apply sealer on long member lh + rh 8.3 Change Position for next glueing operation Put up and put down manually tools Sealer application manually, simple (100mm) Change position (gun,studwelding gun or sealer gun) 477 513 673 513 673 693 36 W 160 VA 20 W OP1 OP1 9.1 apply sealer on engine compartment 9.2 put down glueing gun Sealer application manually, simple (100mm) Put up and put down manually tools 693 738 738 774 45 VA 36 W OP2 7.4 Put down the welding gun Put up and put down manually tools 0 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 10.1 Walk to main floor rack Walk Operator (1 m) 10.2 Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) Put up and put down manually tools 10.3 Put up the punching gun 10.4 punch rivet first point punch rivet first point 10.5 punch rivet 2nd point punch rivet additional point 10.6 Put down the punching gun Put up and put down manually tools Waiting for finished gluing operation of OP1 Waiting 10.7 Load main floor by hoist, manually Load big part by hoist, manually (radius 3m) 10.8 Close clamps 22, 23 and retract pin 4,5 Close or open clamps manually 0 0 0 0 0 0 0 0 0 0 0 0 OP1 waiting till main floor is loaded by OP2 OP1 OP1 11.1 apply sealer on main floor (CGIS in Step 10)Sealer application manually, simple (100mm) 11.2 put down glueing gun (CGIS in Step 10) Put up and put down manually tools 1207 1237 1237 1261 30 VA 24 W OP2 OP2 OP2 12.1 walk to insert jig (big frame) 12.2 load insert jig (big frame) 12.3 close clamps 2x25, 27 OP1 12.2 Support loading of insert jig 0 0 0 0 1261 1304 0 0 43 Waiting Walk Operator (1 m) Load big part by hoist, manually (radius 3m) Close or open clamps manually 774 1207 VA 12 W 30 VA 2999 Change Put up position Walk and put (gun,stud welding Start End Duration Class NVA Waste Operator Waiting down manually gun or (1 m) tools sealer gun) 0 12 12 30 22 NVA NVA W NVA W VA OP5 22 16 266 266 16 12 12 32 64 36 36 160 20 20 45 36 36 0 0 20 0 20 100 0 0 0 0 0 0 0 100 106 138 146 106 138 146 228 32 82 228 292 64 VA 0 0 0 0 0 0 0 0 292 304 304 312 312 392 392 404 404 444 444 464 464 476 476 1010 1010 1090 1090 1106 433 W 433 433 30 24 24 0 20 NVA 80 NVA 80 12 40 20 12 534 80 16 0 0 0 0 W VA W W 80 W NVA W VA VA W W NVA NVA 4W 40 NVA 12 NVA 6 82 32 82 64 12 W 0 20 0 1106 1110 1110 1150 1150 1162 VA Put up Walk and put NVA Waste Operator Waiting down (1 m) manually tools 12 12 80 12 12 40 20 12 534 12 534 80 16 40 12 OP1 12.3 close clamps 2x24, 28 Close or open clamps manually 1304 1316 12 NVA 12 OP2 OP1 13.1 Load rear floor 13.1 Load rear floor Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) 0 1316 1436 120 NVA 1162 1282 0 120 NVA 120 120 OP2 OP1 14.1 retract pins 15, 17 14.1 retract pins 14, 16 Close or open clamps manually Close or open clamps manually 0 1436 1444 NVA 1282 1294 0 12 NVA 12 OP2 OP1 15.1 close clamps 19, 21 15.1 close clamps 18, 20 Close or open clamps manually Close or open clamps manually 0 1444 1452 NVA 1294 1306 0 12 NVA 12 OP2 OP1 16.1 close clamps 27, 29 16.1 close clamps 26, 28 Close or open clamps manually Close or open clamps manually 0 1452 1460 NVA 1306 1318 0 12 NVA 12 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 OP2 17.1 walk to get gun X14 Walk Operator (1 m) 17.2 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.3 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) 17.4 change to gun UL Put up and put down manually tools 17.5 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.6 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) 17.7 change to gun X21 Put up and put down manually tools 17.8 welding of 57 simple spots (Geo & Respots)Spot welding manually, Geo (simple) 17.9 restore the welding gun X21 Put up and put down manually tools 0 0 0 0 0 0 0 0 0 0 0 0 0 OP1 OP1 OP1 OP1 OP1 OP1 OP1 OP1 OP1 17.1 walk to get gun UE Walk Operator (1 m) 17.2 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.3 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) 17.4 change to gun UL Put up and put down manually tools 17.5 welding of difficult spots (Geo & Respots) Spot welding manually, Geo (difficult) 17.6 welding of simple spots (Geo & Respots) Spot welding manually, Geo (simple) Put up and put down manually tools 17.7 change to gun X21 17.8 welding of 58 simple spots (Geo & Respots)Spot welding manually, Geo (simple) 17.9 restore the weling gun X21 Put up and put down manually tools 1460 1474 1522 1554 1578 1674 1794 1830 2182 1474 1522 1554 1578 1674 1794 1830 2182 2218 14 48 32 24 96 120 36 352 36 OP1 waiting till welding operation of OP2 is finished Waiting 2218 2371 OP2 OP2 18.1 open clamps 26, 28 19.1 open clamps of frame Close or open clamps manually Close or open clamps manually OP1 OP1 18.1 open clamps 26, 28 19.1 open clamps of frame Close or open clamps manually Close or open clamps manually 2371 2379 2379 2387 NVA NVA 8 OP2 OP1 19.2 unload frame 19.2 unload frame Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 2387 2523 136 NVA 136 OP2 OP2 OP2 20.1 walk to get gun X21 20.2 welding of 17 simple respots 20.3 restore welding gun X21 Walk Operator (1 m) Spot welding manually, Respot (simple) Put up and put down manually tools OP1 OP1 OP1 20.1 walk to get gun X21 20.2 welding of 16 simple respots 20.3 restore welding gun X21 Walk Operator (1 m) Spot welding manually, Respot (simple) Put up and put down manually tools OP2 OP2 OP2 21.1 get the gluing gun Put up and put down manually tools 21.2 apply sealer on connection member lh + rh Sealer application manually, simple (100mm) Put up and put down manually tools 21.3 put down the gluing gun OP1 wait till gluing of connection members is finished OP2 OP1 22.2 load connection member in insert jig 22.2 load connection member in insert jig Load big part, Operator manually (radius 3m) Load big part, Operator manually (radius 3m) OP2 23.1 Load insert jig (frame) Load big part by hoist, manually (radius 3m) 0 0 0 0 0 2523 2537 2537 2692 2692 2728 0 24 24 36 36 36 36 96 120 352 153 153 14 W 155 VA 36 W 133 96 NVA 0 1324 1408 1512 1524 1620 1748 1760 2080 2104 84 104 12 96 128 12 320 24 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 2128 2196 0 2196 2202 2202 2317 2317 2329 14 14 155 36 36 0 0 0 2329 2353 2353 2433 2433 2469 96 1318 1324 1408 1512 1524 1620 1748 1760 2080 0 0 2104 2116 2116 2128 0 2728 2861 14 0 0 0 14 48 32 153 W 0 0 2861 2957 W VA VA W VA VA W VA W 0 W VA VA W VA VA W VA W 6 84 104 12 12 12 12 24 24 96 128 320 0 12 NVA 12 NVA 12 12 0 68 NVA 6W 115 VA 12 W 68 6 115 12 12 24 24 36 36 0 24 W 80 VA 36 W 80 2469 2541 0 72 NVA 72 2541 2621 80 NVA 80 OP2 23.2 close clamp 30 Close or open clamps manually 0 OP1 OP1 23.1 Load insert jig (frame) 23.2 close clamp 31 Load big part by hoist, manually (radius 3m) Close or open clamps manually OP2 OP2 OP2 OP2 OP2 OP2 24.1 walk to get gun X21 24.2 welding of difficult spots (Geo) 24.3 welding of simple spots (Geo & Respots) 24.4 change to gun ZU 24.5 welding of simple respots 24.5 restore welding gun ZU Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 0 0 0 0 0 0 0 0 0 OP1 OP1 OP1 OP1 OP1 OP1 24.1 walk to get gun X21 24.2 welding of difficult spots (Geo) 24.3 welding of simple spots (Geo & Respots) 24.4 change to gun ZU 24.5 welding of simple respots 24.5 restore welding gun ZU Put up and put down manually tools Spot welding manually, Geo (difficult) Spot welding manually, Geo (simple) Put up and put down manually tools Spot welding manually, Geo (simple) Put up and put down manually tools 3001 3025 3085 3133 3157 3189 3025 3085 3133 3157 3189 3213 24 60 48 24 32 24 OP2 25.1 open clamps Close or open clamps manually 0 OP1 25.1 open clamps Close or open clamps manually 3213 3221 NVA OP2 OP1 25.2 unload insert jig 25.2 unload insert jig Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 3221 3323 102 NVA 102 OP2 26.1 open all clamps Close or open clamps manually OP1 26.1 open all clamps Close or open clamps manually 3323 3371 48 NVA 48 OP2 OP1 27.1 unload underbody 27.1 unload underbody Unload big part by hoist manually (radius 3m) Unload big part by hoist manually (radius 3m) 0 3371 3473 102 NVA 102 2957 2997 2997 3001 0 2621 2629 40 NVA NVA W VA VA W VA W 40 24 24 24 24 24 24 60 48 32 0 0 0 2629 2653 2713 2777 2789 2829 2653 2713 2777 2789 2829 2841 24 60 64 12 40 12 0 0 0 0 0 0 0 0 0 2841 2849 0 3290 1304 54.8 21.7 762 12.7 NVA 852 300 20 12 12 12 12 2883 2931 48 NVA 48 68 NVA 2999 1247 50 20.8 52 24 40 34 24 60 64 34 NVA 2931 2999 0 1224 W VA VA W VA W 2849 2883 0 1224 20.4 NVA 68 894 14.9 858 14.3 858 38 616 204 Station: Finish OP1 OP2 1.1 1.2 OP1 OP1 OP2 2.1 2.2 2.2 Process Step Step Transport part from previous station Transport part from previous station 6/16/2017 Content Load big part by hoist, manually (radius 3m) Load big part by hoist, manually (radius 3m) OP1 OP2 OP1 3017 Start End Duration Class 0 0 40 40 NVA 0 go to Close pneumatic clamps Close pneumatic clamps Close Clamp 1&2 **sequence changed** 11.1 Get the part (lh) 11.2 Load the part into clamping frame Walk Operator (1 m) Press two hand start Close or open clamps manually 40 44 44 48 4W NVA Walk Operator (1 m) Load middle part up to approx 1000x750 (radius 3m) 48 56 56 146 8W 90 NVA Close or open clamps manually OP2 OP2 OP2 12.1 Close the clamps to **sequence changed** 3.1 Get the foam part 3.2 walk to the Part 2&3 3.3 Install the foam part to part 2&3 146 170 24 NVA Walk Operator (1 m) Walk Operator (1 m) clip or seal Foarm Parts 0 0 0 OP2 3.4 Load the part to clamping frame Load middle part up to approx 1000x750 (radius 3m) 0 OP2 4/5 Ascend pin and close clamp 2,3 (lh) Close or open clamps manually OP1 OP1 OP1 3.1 3.2 3.3 walk to get part Load the part to clamping frame (rh) Ascend pin 15 and close clamp 16,17 (rh) Walk Operator (1 m) Load middle part up to approx 1000x750 (radius 3m) Close or open clamps manually 170 174 324 0 174 324 356 OP2 OP2 6.1 6.2 Close LH slide frame Close Clocking clamp Load small part manually (radius 1m) Close or open clamps manually 0 0 OP2 7.1 Close clamp 4-14 Close or open clamps manually OP1 OP1 6.1 6.2 Close RH slide frame Close Clocking clamp Load small part manually (radius 1m) Close or open clamps manually 0 356 362 OP1 7.1 Close clamp 18-28 Close or open clamps manually 366 OP2 OP1 8.1 8.1 Load insert jig (rear frame) with hoist Support loading clamping frame Load big part by hoist, manually (radius 3m) OP1 8.2 Close locking clamps (rh) OP2 OP2 8.2 8.3 OP1 9.1 OP1 OP1 OP1 VA OP3 OP4 OP5 OP2 2835 NVA Waste Start End Duration Class 0 40 0 0 40 40 NVA NVA Waste 40 0 40 0 48 90 0 0 0 24 0 0 0 48 166 174 166 174 234 234 304 70 NVA 70 304 24 NVA 0 0 24 0 328 0 0 0 328 334 334 338 NVA NVA 0 362 366 0 NVA NVA 382 0 44 NVA 0 44 338 0 44 NVA 0 73 44 0 410 410 0 483 382 0 542 0 160 NVA Close or open clamps manually 483 487 NVA 0 walk to clamp (lh) Close locking frame (lh) Walk Operator (1 m) Close or open clamps manually 0 Close or open clamps manually 487 0 NVA 542 552 Close clamp 1,2 of cross frame (lh) 0 495 552 556 0 0 4W 150 NVA 32 NVA VA 150 32 0 NVA 118 W 8W 60 VA 118 60 160 10 W NVA 0 10 OP2 9.1 OP1 OP1 OP1 wait till clamping is finished Waiting 10.1 Get the Gun AI Put up and put down manually tools 10.2 Weld GEO spot with AI acc to WI-161-ED-1824Spot welding manually, Geo (simple) OP2 OP2 10.1 Get the Gun AI Put up and put down manually tools 10.2 Weld GEO spot with AI acc to WI-161-ED-1824Spot welding manually, Geo (simple) OP1 OP1 10.3 Change the Gun X22 Put up and put down manually tools 10.4 Weld GEO spot with X22 acc to WI-161-ED-1824 Spot welding manually, Geo (simple) OP2 OP2 OP2 10.3 Change the Gun X22 Put up and put down manually tools 10.4 Weld GEO spot with X22 acc to WI-161-ED-1824 Spot welding manually, Geo (simple) 10.5 restore gun X22 Put up and put down manually tools OP1 OP1 OP1 10.5 Change the Gun C9 Put up and put down manually tools 10.6 Weld GEO spot with C9 acc to WI-161-ED-1824Spot welding manually, Geo (simple) 10.7 restore gun C9 Put up and put down manually tools OP2 Close clamp 3,4 of cross frame (rh) waiting for OP1 Close or open clamps manually Waiting 0 495 1116 1116 1152 1152 1216 0 0 1216 1240 1240 1264 0 0 1264 1300 1300 1308 1308 1356 0 621 W 36 W 64 VA 0 24 W 24 VA 621 36 64 24 24 36 13.1 Close clamping frame 6030 HMS to body 13.1 Close clamping frame 6030 HMS to body Load big part, Operator manually (radius 3m) Load big part, Operator manually (radius 3m) 1356 1380 0 24 NVA 24 OP1 OP2 13.2 Close locking clamps 13.2 Close locking clamps Close or open clamps manually Close or open clamps manually 1380 1384 0 NVA OP1 OP2 14.1 Close Clamp 7,8 14.1 Close Clamp 9,29 Close or open clamps manually Close or open clamps manually 1384 1392 0 NVA OP1 OP2 1.1 STEP Get the Gun C9 waiting for OP1 Put up and put down manually tools Waiting 1392 1428 0 36 W OP1 OP2 1.2 1.2 Weld GEO C9 support OP1 Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) 1428 1484 56 VA OP1 OP2 OP1 OP2 1.3 Change the Gun X7 waiting for OP1 Weld GEO X7 support OP1 Put up and put down manually tools Waiting Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) 1484 1508 0 1508 1564 0 24 W 56 VA Change the Gun AI waiting for OP1 Weld GEO AI Put up and put down manually tools Waiting Spot welding manually, Geo (simple) 1564 1588 0 1588 1644 24 W 56 VA OP1 OP2 OP1 1.5 1.6 0 0 NVA 0 0 600 680 0 36 W 80 VA 0 680 716 740 716 740 764 36 W 24 VA 24 W 0 0 764 900 900 924 24 NVA 24 924 928 NVA 928 936 NVA 36 80 36 24 24 0 48 OP1 OP2 1.4 1.4 564 564 600 0 36 W VA 48 W 556 36 56 24 56 24 56 0 936 1141 136 W 205 W 0 1141 1197 56 VA 0 1197 1282 0 1282 1338 85 W 56 VA 0 1338 1554 0 136 216 W 205 56 85 56 216 OP2 1.6 support OP1 **sequence changed** Weld 39 respot AI together with OP2 Weld 39 respot AI together with OP1 Spot welding manually, Geo (simple) OP1 OP2 6.1 6.1 OP1 6.2 OP1 Spot welding manually, Geo (simple) Spot welding manually, Geo (simple) 1644 1956 0 312 VA Put up and put down manually tools 1956 1968 12 W 2.1 restore welding gun AI **sequence changed** Open all Clamp and pins (lh) Close or open clamps manually 1968 2140 172 NVA OP2 2.1 Open all Clamp and pins (rh) Close or open clamps manually OP1 3.1 Unload insert jig (rear frame) with hoist Unload big part by hoist manually (radius 3m) OP2 OP2 OP2 4.1 4.2 4.3 Walking to frame push rear frame out (HMS) push frames out (lh/rh) Walk Operator (1 m) Unload big part, Operator manually (radius 3m) Unload big part, Operator manually (radius 3m) OP1 OP1 6.1 6.2 Get the gun AI (lh) Weld 29 spot Put up and put down manually tools Spot welding manually, Respot (simple) OP2 OP2 6.1 6.2 Get the gun AI (rh) Weld 34 spot Put up and put down manually tools Spot welding manually, Respot (simple) OP1 OP1 6.3 6.4 Change the Gun C9 (lh) Weld 23 C9 Put up and put down manually tools Spot welding manually, Respot (simple) OP2 OP2 6.3 6.4 Change the Gun C9 (rh) Weld 17 C9 Put up and put down manually tools Spot welding manually, Respot (simple) OP2 OP2 OP1 7.1 7.2 7.2 Open Pneumatic clamps Close or open clamps manually Move the body to next station Unload big part by hoist manually (radius 3m) Help the opther ÓP move the body to next station 0 2140 2616 0 0 0 2616 2640 2640 2810 0 0 2810 2834 2834 2959 0 0 0 0 2959 3017 312 0 1610 1922 312 VA 312 0 0 1922 2094 NVA 476 2094 2126 2126 2270 2270 2390 W VA 24 170 0 24 125 56 172 0 24 170 56 VA 12 476 1554 1610 0 0 2390 2414 2414 2614 W VA 24 125 0 0 172 NVA 172 W NVA NVA 144 120 32 144 120 0 24 200 W VA 200 125 2614 2638 2638 2763 24 125 W VA 0 58 2763 2767 2767 2835 0 68 NVA NVA 925 15.4 24 0 0 2886 871 1090 48.1 14.5 18.2 32 24 68 2835 969 912 47.3 16.2 15.2 954 15.9 ... -2- xuất xe GLC vấn đề cấp bách MBV thời điểm tại, chuyền BodyShop Đề tài Ứng dụng sơ đồ dòng giá trị để cải tiến suất chuyền lắp ráp BodyShop dịng xe GLC, Cơng ty TNHH Mercedes- Benz Vietnam giúp... ngành: I MS: 60 34 01 02 QUẢN TRỊ KINH DOANH TÊN ĐỀ TÀI: ỨNG DỤNG SƠ ĐỒ DÒNG GIÁ TRỊ ĐỂ CẢI TIẾN NĂNG SUẤT TẠI CHUYỀN LẮP RÁP BODYSHOP DÒNG XE GLC, CÔNG TY TNHH MERCEDES- BENZ VIỆT NAM II NHIỆM VỤ... CHƯƠNG XÂY DỰNG DÒNG GIÁ TRỊ HIỆN TẠI CHUYỀN BODYSHOP DÒNG XE GLC 3.1 Giới thiệu Công ty TNHH Mercedes- Benz Việt Nam Công ty TNHH Mercedes- Benz Việt Nam (MBV) công ty liên doan tập đồn Daimler AG