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Production in Oppama expected to grow off modest base

22nd September 2017

By: Tracy Hancock

Creamer Media Contributing Editor

     

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Vehicle manufacturer Nissan intended to initially produce about 140 Leaf 2 electric vehicles (EVs) a day at its Oppama mixed-model vehicle manufacturing plant in Yokohama, Japan, the company said earlier this month.

Leaf production has just started at the plant, so it is currently “fairly small”, but the company hopes to grow this number going forward. Sales of the new zero-emissions EVs are scheduled to start on October 2 in Japan.

Speaking at a media tour of the plant earlier this month, following the Leaf 2 world premiere, company representatives noted that vehicles were manufactured in the sequence in which purchase orders were received from customers.

The plant simultaneously produces 900 EVs and non-EVs a day, manufacturing five Nissan models – the Cube, the Note, the Juke, the Leaf and the Bluebird Selphy – equating to 240 000 vehicles a year.

Oppama is where Nissan has pioneered technological advances such as its auto guided vehicles (AGVs), developed to streamline its vehicle assembly line, speeding up production and increasing competitiveness. This technology is currently being rolled out at the company's manufacturing plants around the world.

There are 500 AGVs used at the plant in various processes, with Nissan seeking to advance the use of AGVs.

The technology was rolled out at Oppama in 2005, replacing the use of people to transfer parts using equipment such as forklifts. The AGVs facilitate faster production by transferring parts kits to where they are needed and moving them along the assembly line within minimum walking distance, ensuring employees are supplied with the correct components as they are needed.

Other advances include the introduction of ergonomic solutions, which, for instance, adjust the height of the vehicle, depending on where parts are being installed on the vehicle, to improve employee comfort while working.

The production of the Leaf starts with the pressing of large body panels from steel sheets between 0.55 mm and 2 mm thick. One roll of steel yields body panels for 300 vehicles. The largest press at Oppama weighs 500 t.

The next step involves body assembly, during which the vehicle shape is formed.

The highly automated Oppama plant comprises 500 welding machines, with 3 000 spot welds needed on the new Leaf.

Thereafter, the body is sent to the paint shop, coating the body in paint 0.1 mm thick.

The assembly of the Leaf 2 involves the installation of 3 000 parts, with this part of the production process less than 10% automated.

Nissan admits that the biggest challenge regarding the incorporation of EV production is the timing of parts and components per unit process differing from model to model. The company has been trying to streamline the processes of its flexible production line, some of which are still segregated.

The final stage is inspection, during which Nissan conducts 700 tests, including the inspection of the chasis, engine components, the electric function and the exterior and interior.

Oppama, which employs a two-shift system, has 1 200 employees, of whom 3.7%, or 54, are women.

The 55-year-old plant has four EV charging stations, consisting of 110 charging points, for employees commuting to work using their own EV. There are 1 000 vehicles used by employees, of which 46 are EVs. Oppama's guest hall parking area also has quick charging stations.

Nissan would like to double the number of charging stations at Oppama to accommodate the use of EVs by more employees.

Edited by Martin Zhuwakinyu
Creamer Media Senior Deputy Editor

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