Agent skill

Assemblyoperations

Assembly operations guidance for LVA (Low Volume Assembly) and FML (Full Manufacturing Line) departments. Covers kitting, torque operations, poka-yoke verification, line balancing, SMED changeovers, and serialized traceability. USE WHEN user says 'assembly', 'LVA', 'FML', 'kitting', 'torque operation', 'line balancing', 'takt time', 'poka-yoke', 'work instruction', 'build sequence', or needs assembly process guidance.

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SKILL.md

AssemblyOperations

Expert guidance for MNMUK assembly departments - Low Volume Assembly (LVA) and Full Manufacturing Line (FML).

Workflow Routing

Department Note: LVA = Low Volume Assembly. FML = Final Module Line (also referred to as Full Manufacturing Line) — a paced, takt-driven production line distinct from LVA's high-mix flexible configuration.

Workflow Trigger File
Kitting "kitting process", "kit preparation" Workflows/Kitting.md
TorqueOperations "torque process", "fastening" Workflows/TorqueOperations.md
LineSetup "line setup", "SMED", "changeover" Workflows/LineSetup.md
Traceability "serial number", "traceability", "build record" Workflows/Traceability.md

Department Overview

LVA (Low Volume Assembly)

Characteristics:

  • Manual and semi-automated assembly
  • High-mix, low-volume production
  • Skilled operator dependency
  • Flexible workstation configuration

Core Processes:

Process WI Reference Description
Kitting WI-LVA-001 Component staging and verification
Assembly Sequence WI-LVA-002 Step-by-step build instructions
Torque Operations WI-LVA-003 Fastener installation and verification
Electrical Assembly WI-LVA-004 Harness routing and connection
Functional Verification WI-LVA-005 In-process and final testing
Traceability WI-LVA-006 Serial number and build record management

FML (Full Manufacturing Line / Final Module Line)

Characteristics:

  • Paced production line
  • Takt time driven
  • Higher automation level
  • Standardized work critical

Core Processes:

Process WI Reference Description
Line Setup/Changeover WI-FML-001 SMED methodology
Takt Time Monitoring WI-FML-002 Cycle time tracking and alerts
Error-Proofing Verification WI-FML-003 Poka-yoke checks
End-of-Line Test WI-FML-004 Final inspection and release

Key Concepts

Torque Operations

Critical Requirements:

  • Torque tools calibrated per MSA skill requirements
  • Joint classification: Safety Critical / Critical / Standard
  • Torque sequence specified for multi-fastener patterns
  • Angle monitoring for yield-controlled fasteners

Torque Verification:

Joint Class Verification Method Frequency
Safety Critical 100% electronic monitoring + audit Every joint
Critical Electronic monitoring Every joint
Standard Operator verification Per WI

Poka-Yoke (Error-Proofing)

Categories:

Type Description Example
Prevention Physically prevents error Keyed connectors
Detection Detects error before next step Vision system
Warning Alerts operator to potential error Light/sound alarm

Verification Requirements:

  • Daily poka-yoke verification at shift start
  • Documented on verification log
  • Failed poka-yoke = line stop until resolved

Line Balancing

Takt Time Calculation:

Takt Time = Available Production Time / Customer Demand

Example:
- Available time: 450 min/shift (7.5 hrs minus breaks)
- Demand: 50 units/shift
- Takt time: 9 minutes/unit

Balancing Principles:

  1. No station cycle time exceeds takt
  2. Minimize operator waiting time
  3. Balance workload across stations
  4. Identify and address bottlenecks

SMED (Single Minute Exchange of Die)

Changeover Phases:

Phase Activities Target
External Setup Done while line running Maximize
Internal Setup Done while line stopped Minimize
Adjustment Fine-tuning after restart Eliminate

SMED Steps:

  1. Document current changeover
  2. Separate internal vs external activities
  3. Convert internal to external where possible
  4. Streamline remaining internal activities
  5. Standardize and practice

IATF 16949 Alignment

IATF Clause Requirement Assembly Coverage
7.1.3.1 Plant, facility, and equipment planning Line layout, workstation design
7.1.4 Environment for operation Assembly area conditions
8.5.1.1 Control plan Assembly control plan elements
8.5.1.2 Standardized work Work instructions, operator instructions
8.5.1.3 Verification of job setups Setup verification procedures
8.5.1.5 Total productive maintenance Equipment maintenance
8.5.1.6 Management of production tooling Tool/fixture control
8.5.2 Identification and traceability Serial numbers, build records
8.5.6.1 Control of changes Change implementation
8.6.2 Layout inspection First article inspection

Reference: ~/projects/work/docs/compliance/IATF16949_Compliance_Plan.md

Integration with Other Skills

Skill Integration Point
AutomotiveManufacturing Process documentation standards
Pfmea Assembly PFMEA development
Controlplan Assembly control plan elements
Msa Torque tool calibration studies
Spc In-process monitoring charts
Tribalknowledge Operator expertise capture
Skillsmatrix Operator competency tracking

Work Instruction Structure

Standard format for assembly work instructions:

markdown
# WI-[DEPT]-[SEQ]: [Title]

**Revision:** [Rev]
**Effective Date:** [Date]
**Applies To:** [Part numbers / product families]

## Purpose
[Brief description of operation]

## Safety Requirements
- [ ] PPE required: [list — e.g., safety glasses, gloves, steel-toe boots, hearing protection]
- [ ] Torque tool handling: ensure tool is within calibration, never exceed rated capacity
- [ ] Hazards: [list — e.g., pinch points, sharp edges, heavy components]
- [ ] Emergency procedures: [reference]

> **PPE is mandatory** before beginning any assembly operation. Operator must verify and don all specified PPE prior to first step.

## Materials and Tools
| Item | Specification | Qty |
|------|---------------|-----|
| [Component] | [P/N] | [#] |
| [Tool] | [Description] | [#] |

## Procedure
1. [Step with photo/diagram reference]
   - Visual Aid: ![Step 1 Diagram](images/WI-[DEPT]-[SEQ]-step1.png) *(photo or diagram required for each key step)*
   - Torque: [value] Nm
   - Quality check: [description]

2. [Next step with photo/diagram reference]
   - Visual Aid: ![Step 2 Diagram](images/WI-[DEPT]-[SEQ]-step2.png)

## Quality Checkpoints
| Step | Check | Method | Acceptance |
|------|-------|--------|------------|
| [#] | [What] | [How] | [Criteria] |

## Traceability
- Serial number location: [where]
- Data to record: [list]
- System entry: [how]

Common Assembly Issues

Issue Likely Cause Resolution
Torque not achieved Worn fastener, cross-thread Inspect, replace fastener
Component interference Tolerance stack-up Check dimensions, escalate to engineering
Missing component Kit error Return to kitting, add poka-yoke
Connector not seated Alignment issue Verify orientation, check for damage
Test failure Assembly error or component Follow troubleshooting tree

Examples

Example 1: New product assembly setup

User: "We're starting production of a new damper variant next week"
-> Review BOM and assembly sequence
-> Verify kitting process (Workflows/Kitting.md)
-> Confirm torque specifications
-> Set up traceability in system
-> Create/update work instructions
-> Train operators (link to Skillsmatrix)

Example 2: Line balancing issue

User: "Station 3 is bottlenecking the line"
-> Calculate current takt time
-> Document cycle times at each station
-> Identify tasks that can be redistributed
-> Update line balance chart
-> Revise work instructions
-> Re-train affected operators

Example 3: Changeover improvement

User: "Changeover is taking too long on Line 2"
-> Document current changeover (Workflows/LineSetup.md)
-> Video the changeover
-> Separate internal vs external activities
-> Convert internal to external where possible
-> Create standardized changeover procedure
-> Practice and time improvements

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