home / skills / robdtaylor / personal-ai-infrastructure / assemblyoperations

Assemblyoperations skill

This skill provides comprehensive assembly guidance for LVA and FML, covering kitting, torque, poka-yoke, line setup, SMED, and traceability.

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---
name: Assemblyoperations
description: 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.
---

# AssemblyOperations

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

## Workflow Routing

| 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)

**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]
- [ ] Hazards: [list]
- [ ] Emergency procedures: [reference]

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

## Procedure
1. [Step with photo/diagram]
   - Torque: [value] Nm
   - Quality check: [description]

2. [Next step...]

## 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
```

Overview

This skill provides practical assembly operations guidance for LVA (Low Volume Assembly) and FML (Full Manufacturing Line) departments. It covers kitting, torque operations, poka-yoke verification, line balancing, SMED changeovers, and serialized traceability. Use it to standardize work, reduce errors, and align assembly processes with IATF 16949 requirements.

How this skill works

The skill routes user requests to focused workflows for Kitting, Torque Operations, Line Setup (SMED), and Traceability. It inspects assembly requirements like torque classes, verification frequency, poka-yoke checks, takt calculations, and work instruction structure. It outputs actionable steps: prepare kits, verify tools and calibration, balance line tasks to takt, and document traceability and control points.

When to use it

Starting production of a new product or variant
Investigating a bottleneck or takt-time imbalance
Addressing recurring fastener or torque failures
Implementing or auditing poka-yoke and verification logs
Planning and reducing changeover time (SMED)
Setting up serialized traceability and build records

Best practices

Define torque joint classification and verification method per joint class
Perform daily poka-yoke verification and log failures with immediate line stop if required
Calculate takt using available production time and customer demand, then ensure no station exceeds takt
Document and convert internal changeover tasks to external ones during SMED
Standardize work instructions with clear checkpoints, torque values, and traceability fields
Link operator training to a skills matrix and practice procedures after any WI change

Example use cases

New variant ramp-up: review BOM, verify kitting, confirm torque specs, establish traceability, update WIs, train operators
Line balance fix: measure cycle times, compute takt, redistribute tasks, update work instructions and retrain
Changeover reduction: video current changeover, separate internal/external tasks, convert where possible, standardize and practice
Torque issue investigation: confirm tool calibration, check fasteners and sequences, inspect joint class and record verification data
Poka-yoke failure: execute daily verification, stop line on failure, troubleshoot device or process and record corrective actions

FAQ

How often should torque tools be calibrated?

Follow MSA requirements and site calibration schedule; critical torque tools should be on a documented periodic calibration plan with records stored in the quality system.

What triggers a line stop for poka-yoke failure?

Any failed poka-yoke verification that risks a nonconforming build should trigger an immediate line stop until resolved and documented on the verification log.