Case study
Nissan
Enhancing production scheduling even further to make the Qashqai
In this short video case study we hear from Nissan how PA supported the introduction of its new Qashqai by further enhancing its production scheduling system to allow even greater flexibility, so that up to four different models can be produced simultaneously across either of the production lines.
This is believed to be the automotive industry's most flexible scheduling system and remains at the forefront of scheduling technology. It also marks one of the most positive stories for UK auto manufacturing in recent years, securing around 3,000 jobs in Nissan and in associated suppliers around the region.
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Nissan's view of PA's work – quotes from the video
"The decision was made to build three models down two lines, without putting in a new production line … we needed to come up with a new scheduling system that could predict … and use that information to drive all our supply chain ordering."
"We knew this was a very difficult system to solve and PA had experience of solving very very difficult problems."
"In the last five years we have won most efficient plant. I honestly believe it's significantly down to being able to give smooth schedules to production." |
Summary
Nissan’s Sunderland plant has long been recognised as the most efficient in Europe. In 2000, Nissan launched its Almera model, which required it to simultaneously produce three models on its two production lines. Nissan wished to produce the new model as cost-effectively as possible and to reduce the capital investment associated with building a new production line. This was made possible by the development and use of a leading-edge production scheduling system, believed to be the first of its type in the world. This was designed and developed by PA and has been successfully scheduling all production in the plant for six years.
In September 2006 Nissan announced the launch of a new model, the Qashqai, with the first vehicle rolling off the production line in December 2006. This required the plant to be even more flexible than before. PA supported the introduction of the Qashqai by further enhancing this system to allow even greater flexibility, so that up to four different models can be produced simultaneously across either of the production lines. This is believed to the automotive industry's most flexible scheduling system and remains at the forefront of scheduling technology. It also marks one of the most positive stories for UK auto manufacturing of recent years, securing around 3000 jobs within Nissan and in associated suppliers around the region.
It was unheard of for Nissan to ask for outside help. However a number of suppliers viewed the problem as too complex and beyond their capability. Nissan feared right from the start that there may not be a solution. They knew this was an extremely difficult challenge to solve and PA had experience of solving difficult problems.
There are benefits all round in this type of system. Over the years Nissan has saved millions of pounds in paint alone. Production is dependent on being given an efficient schedule so that they can drive their manpower costs down. There have been savings in the supply chain in terms of taking away inventory that had to be kept to cope with fluctuations of the schedule.
Nissan could not have scheduled the plant in the first place without the new system. PA has put in place possibly the most important system in the plant; certainly without it Nissan couldn't have run the plant, and it works.
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