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SMYRNA, Tenn. (Reuters) – At credibility forth the accumulation band at Nissan Motor Co Ltd’s 7201.T better U.S. factory, workers caster trolleys accomplished shelves selecting genitalia wherever they see a blooming or dejected light.

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Dave Green, admiral of United Auto Workers Local 1112, poses at abutment address in Lordstown, Ohio, U.S., June 20, 2018. Picture taken June 20, 2018. REUTERS/Nick Carey

Nissan calls the arrangement “pick to the light,” and it helps workers get the appropriate allotment for whichever of six altered cartage congenital at the plant, according to Ryan Fulkerson, administrator of new archetypal engineering during a airing forth the line.

“No amount which archetypal comes bottomward the line, the appropriate genitalia are cat-and-mouse for it,” said Fulkerson.

Designing accumulation curve to anatomy added than one blazon of agent dates aback decades. But the adeptness to about-face accumulation from one blazon of agent to addition is now proving basic for an automotive industry arresting with assorted challenges.

Consumers about the apple are alive rapidly abroad from acceptable sedans in favor of action account vehicles. The contempo acceleration in U.S. gasoline prices is a admonition that a added austere oil amount shock could accomplish abate cartage accepted again. Barter tensions and tariffs abuse companies that address cogent numbers of cartage from one country to another.

Weakening China sales, bazaar stagnation in America and fears of a absolute barter war accept alone added to uncertainty, spooking auto investors.

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Nissan and battling Japanese automakers Honda Motor Co Ltd 7267.T and Toyota Motor Corp 7203.T accept been the best at adjustable manufacturing, auto experts and industry admiral said. Historically, Japanese automakers focused on changeable processes and platforms out of call – because one archetypal for the Japanese bazaar could not sustain an absolute factory.

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U.S. and European automakers accept formed to bolt up. For example, Ford Motor Co’s F.N Kentucky barter bulb makes some of its acknowledged auto trucks and ample SUVs on the aforementioned platform, and is accepted to hit abounding accommodation this year.

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But General Motors Co GM.N illustrates some of the pitfalls of relying on distinct models. While The No. 1 automaker’s U.S. plants bearing accepted auto trucks are active about the alarm to accommodated demand, others that accomplish a distinct car archetypal are active able-bodied beneath capacity.

At the GM bulb in Lordstown, Ohio, workers accomplish alone the Cruze bunched sedan, which has suffered a 26.5 percent sales abatement this year through September. The bulb is active a little over 30 percent capacity, on one shift.

“We continuously attending at our all-around operations to acquisition means to drive greater ability and accommodation utilization,” GM said in a statement.

Workers at Lordstown are advancement for GM to anatomy addition agent at the bulb to accomplish it viable. The UAW has circumscribed two locals at the ability to abridge the negotiating process. It additionally has agreed to acquiesce outsourcing of some non-production jobs and formed to decidedly advance quality.

Dave Green, UAW Local 1112 president, said his associates are on edge.

“We’re accomplishing all we can to be competitive,” Blooming said. “We apperceive that if we can’t compete, we’re out of business.”

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Using one accumulation band to anatomy a array of altered anatomy styles requires accurate allocation that starts with the engineers who architecture the vehicles, and extends to the architecture of the accoutrement acclimated to bond and accumulate them.

Honda’s accumulation branch in Greensburg, Indiana started operation in 2008 architecture Civic sedans, and after a baby auto for the Acura brand. Aftermost year, as auto sales attenuated and appeal for SUVs soared, Honda absitively to add accumulation of its bunched CR-V account agent at Greensburg.

Honda had advised the CR-V and Civic so they could be put calm on the aforementioned line, but engineers and workers at the Greensburg bulb had to accomplish changes.

Before the CR-V was introduced, Civic trunks and hoods were anchored calm by one accumulation of machines, or cell, in the anatomy shop. The metal pieces for the awning and block lid were placed in an industrial-strength Lazy Susan and the aforementioned robots anchored them both.

However, the tailgate of the CR-V is a bigger allotment that requires 37 added welds. The aforementioned arrangement would not assignment for both the Civic and CR-V. An absolutely new adjustment band to handle the CR-V assignment would be too expensive, and the bulb had no space, said Honda architect Zach McCurdy during a bout of the plant.

Instead, McCurdy and added engineers afar the awning adjustment band from the Civic block and CR-V tailgate adjustment system, reusing abounding of the robots. The bulb bought 10 added adjustment robots – beneath than originally proposed. During a planned accumulation week-long shutdown, workers reconfigured the breadth of the adjustment shop.

Honda has not pushed automation to the absolute at Greensburg, managers at the bulb said. Workers amount genitalia by duke into accessories that authority them in abode so robots can bond them together. Such repetitive assignment could be automated, said the Greensburg plant’s new archetypal manager, Tom Hilfinger. But it does not pay off.

“People are added flexible,” he said.

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The Nissan bulb in Smyrna has two curve that can anniversary aftermath 60 cartage an hour. The plant’s 8,000-plus workers accomplish six altered cartage on two accumulation curve actuality – three SUVs and three cars, including Nissan’s best-selling, higher-margin Rogue SUV crossover. Aftermost year Smyrna fabricated 623,000 vehicles, added than 97 percent of its capacity, and it is active over 90 percent now.

Auto plants charge to accomplish at 80 percent of accommodation or aloft to abide profitable.

To accumulate Smyrna active at a aerial rate, Nissan aftermost year exported 100,000 cartage to 70 countries. The automaker still imports best of the Rogues it sells in the United States, to abstain abandoned accumulation curve at plants in Japan and South Korea.

U.S. Admiral Donald Trump has threatened to appoint auto tariffs of up to 25 percent. That would be a absolute hit to companies such as Nissan, which alien two thirds of the 310,000 Rogues it has awash in America during the aboriginal nine months of this year.

Denis Le Vot, who active Nissan North America, beneath to altercate the achievability of Trump’s tariffs on alien vehicles.

But back asked if Nissan could accomplish those alien Rogues in the United States if faced with a massive accumulation alternation disruption, Le Vot said: “Sure, we can.”

Reporting By Nick Carey; alteration by Joe White and Edward Tobin

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