Major modernisation of assembly lines in Spanish factory

In order to create more flexibility, improved working ergonomics and increased production capacity Nissan Forklift España, S.A. just finalised a total modernisation of its forklift assembly line. This extensive process has been carried out in two phases while keeping in mind that during both phases the production work should continue without affecting quality and productivity levels. Phase I Major objective of the first phase was to change the philosophy from “fixed positions” mast mounting to a concept of mast assembly on a moving assembly line. A complete new mast assembly line was created, parallel to the future final assembly line, ending the mast construction nearby the point where the masts are mounted to the forklift. Features of the new mast assembly line. Great increase of the production capacity, which allows Nissan Forklift to absorb easily special customer order productions and the possibility to produce loose masts orders within existing working cycles. Continuous production chain, with new and more ergonomic tooling. Significantly reducing training periods for operators, enabling also a big improvement in quality. Capable to handle all models of masts, including possible special customer requests. Total flexibility of the mast assembly area, on-time delivery is essential for the main assembly line. New lifting system for materials plus the installation of two new material handlers to facilitate an ergonomic operation and preventing high and heavy loads handling. A total restructuring of the components supply to the assembly. This enables Nissan Forklift to quickly introduce new models in the production line. Following the ‘Nissan Production Way’ philosophy, all intermediate losses are eliminated, gaining space and making the access to components clearer, easier and increasing the quality level and improved waste management. Phase II During the second phase the new forklift assembly line was totally installed from beginning to end. At the same time a flexible component warehouse has been installed parallel to the new assembly line, enabling Nissan Forklift to stock and introduce each component at the exact point of consumption during the assembly process. This resulted in a great improvement of the material handling operations. By completion of Phase II Nissan Forklift achieved the goal of producing trucks with optimal Quality (Q), Cost (C) and Time (T), through a better use of “people, materials and machinery”. Features of the new main forklift assembly line Implementation of the BTO (Build To Order) process which allows Nissan Forklift to produce a truck in a single stage. Approximately 2000 parts are supplied to the line in sequence, thus making it very flexible and allowing Nissan Forklift to integrate almost all special customer requests. Total renewal of assembly line facilities; new and state-of-the-art underground conveyor system. Together with new assembly tooling, this has lead to improved ergonomics and safety. New lifting systems have been installed with 9 new handlers providing an ergonomic operation and in addition ensuring the quality in various assembly operations. Following the ‘Nissan Production Way’ philosophy, the new assembly line covers most of the sub-assemblies, eliminating spaces and achieving improved waste management. The better flexibility of the sequenced component supply greatly facilitates the integration of new products within the assembly line and can be easily adapted to the production of other, new, models. It fully complies with the current growing customer demand for optimum conditions of quality, cost and lead time. With the aim of modernizing its production facilities, Nissan Forklift invested over 1.0 million Euros for both phases, achieving a 10% increase in the productivity ratios and an even better quality of the already high quality products where Nissan Forklift is famous of. The assembly lines are now able to absorb and integrate both new models and special dedicated customer options, in a very short time thus improving the delivery times as well.

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