Beruflich Dokumente
Kultur Dokumente
Yoshio NAKA
Tatsuo YAMAZAKI
Hiroshi NAKAMURA
Keigo MORIGUCHI
Kazuki MAESOBA
Masaomi DOBASHI
Recently, the business environment of auto parts makers has been drastically changing as car makers are expanding
their overseas production. Under this globalization and borderless movement, auto parts makers have to establish
production engineering methods that achieve cost reduction. We have established a production engineering method
for designing production lines in low labor rate countries, through the design of the SE08 alternator production line at
DNTH. In this paper, we will discuss our method, mainly focusing on the following two topics :
(1) Machine design method to maximize labor ability
(2) Quality assurance method in labor intensive operations
Key words : Designing production, Low labor rate countries, Machine design method, Quality assurance method
21
ASEAN
Fig. 1
1.0
1.0
0.9
0.9
0.8
DNJP
(Japan)
DNTH
(Thailand)
DNIN
(India)
TDS
(China)
0.5
DNTH
Fig. 2
DNTHSE
60
DNTHFig.
3DNTH
SE
200422
41
Vol.No.2004
3.1
Fig. 4DNTH
Table 1
Indirect material
20
Labor
23
Depreciation
57%
Fig. 5
Work set
Draw in base pallet
Bearing press
Press load check
Pull out base palette
Convey next process
DNJP
Operator
Robot
Operator
Cylinder
Cylinder
Load cell
Operator
Cylinder
Load cell
Cylinder
Operator
Conveyer
42
SE
Fig. 610
Assy
Fig. 7
Palette exist?
Palette convey
from previous process
OK
Bearing exist?
Bearing set
OK
OK
Process
Convey
Japan
OK
OK
Fin.
OK
Process
Production cost
Fin.
Targ et
OK
Fin.
OK
Current
in Thailand
Thailand
Ordinary approach
Our approach
Min. target
Automatic rate
OK
Load OK?
OK
Fin.
Fin.
Forward to
the next process
3.2
OK
SE
SE08
1cycle finished?
OK
1cycle finished
Fig. 8SE
Fig. 5 Control flow in DNJP machine
1
Equipment cost
Conveyer
Control
Process
equipment
Electrical
equipment
Qualty check
0.89
0.88
0.90
0.92
0.95
DNJP
DNTH
(Automatic machine) (Conventional machine)
DAS
Fig. 9
43
Vol.No.2004
Conventional machine
Upper limit
for male
Upper limit
for female
35
30
25
20
15
10
5
0
Developed machine
Stator, Rr flame
Rr bearing
bush, terminal sub- assy
Dr bearing
under cover
10
15
Load kgf /each time
20
electric tubeauto
Hydraulic pressauto
Press
Press position Omega SW auto
Load check
Unit
Unit
Function
Work check Photo
Load celljig
Load OK/NG
Control circuitauto
Work discharge
Photo
electric tubeauto
Operatormanual
Hand presstool
Point sw tool
Inside
springjig
Lump tool
Operatormanual
30
Fig. 11 Labor-intensive machine example
Fig. 10
Fig. 11
Fig. 12
Production cost
1.0
Indirect
material
0.9
0.9
0.7
Labor
1.1
0.9
0.6
Depreciation
0.9
0.7
DNTH
Conventional Machine
DNTH
Developed machine
Unconsciousness
of Rule or system
Forget
of Rule or system
Mistake
of Rule or system
44
4.1
SE
4.2 DNTH SE
Fig. 13
Defects
DNTHSE
2
DNJP level
13.1
Pokayoketimes
DNTH
QAFig. 14
11QA
Table 23
Mechanical assurance
high
Mechanical
checker
Labor-intensive
pokayoke
low
System reliability
operator
Table 2
DNTH
45
Vol.No.2004
15
1SQC:
1994p.43.
2:QA
N=2
2004
pp.1-8.
NDNTH
N=2
DNTH SE
46
47