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July 1st,

2014

DENSO ROBOTICS, our history of


implementation

DENSO ROBOTICS
PETER CAVALLO
310-991-7343
peter_cavallo@densodrive.c
om
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
History of Denso Robots and their capabilities 1

Year ‘70 ‘75 ‘80 ‘85 ‘90 ‘95 ‘00 ‘05


Assembly
Die Cast Material Handling Assembly With Visual Aid Assembly Cell
Multiple Variations
Application Serv
o

Powered Safety
Digital by Network
Controller Control Micro Capable
Regul
ations
Feature Controller

x100
Memory 2 programs 10 100 255
programs programs programs
Accuracy ±1.0mm ± 0.5mm ± 0.03mm ± 0.02mm x5

(VS. Human) x10


Speed x0.5 x0.7 x2.3 x4.8
(MTBF* ) x200
Reliability 500 Hours 10,000 28,000 120,000
Hours
*(not counted Hours UIO×Operation
incidents during installation, Hours
Hour/Units Repaired)

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
Denso Robotics Utilization History 2

20 Factory
15 Workers
10
5 Robot
0 UIO
Multi Pass Production Line
Basic Robot Development
(was no robot previously) In Process Vision Inspection
Tech.
Assy non-rigid part High Precision
Development Insertion
6 axis assy Flexible Robotics cells
Die Cast 4 axis assy Gripper゙ Mobile
Cartesia Clean
n room robot
Production Engineering Volume/Variation Scalable
Drove Robot Development Automate Complex Tasks  
Robots’ Redeployable Production Systems
Role Exceed speed of Human Being
Automate repeating process
Rescue Humans from Dangelous + Dirty + Difficult work
Line Small Large Valuations Redeployable Volume
Capabilit Valuations Large Volume Over product gens Fluctuation
y Yea Large Volume
70 75 80 85 90 95 00
r This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
Concurrent Engineering 3

Planning
Kick Off Developme Start
Developme nt Production
nt
Product
Design

Production
Engineering

Production System
Design/Build Output
Product design
Tim optimized for automation
e
What DENSO Got after years of concurrent engineering
=> Functions needed to automate each process
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
Denso’s expansion in application fields 4

DENSO
Japan Auto
Co’s.
Consumer
Other Auto SuppliersElectronics

Food Pharmaceutical Medical


Devices

Service Medical

DENSO is continuously expanding its application fields


This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
What Denso Learned from non-Auto applications 5

Product Life Volume Variations Size of Work

Auto Parts 4-5 Years Large Large 3 feet – 1 inch


Consumer 6 Month Large Small / Various 1 feet – 6 inch
Electronics
Medical Devices 5-10 Years Small Small 2 inch – ½ inch

Food 5-10 Years Large Large Liquid/Powder/Grain


6inch – 2 inch
Denso May find the similar application some where in the current or past application.

Large

Robot FMS Fully automated line


Volume ⅡⅠ
ⅢⅣ
Smal
l
Plural, small line
Manual work cell
Large Small
Variations
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
The history of production system in DENSO 6
The level of production

Net
work
3
Business rationalization
dimension
Squar Factory rationalization
e ・Global production
Lin Products  network
rationalization ・Production information
e
Point system
Line rationalization  Production control
・Integrated line 環境調和型システム
(Raw material, Quality control
Single process ・ Small Tr line Assembling, FMS for a flexible quantity
rationalization Inspection)
FMS for a multi-generation
・Automatic special FMS(Flexile manufacturing system) for a large quantity
purpose machine
Low types in large quantity production
‘50        ‘60        ‘70         ‘80        ‘90       ‘00 Yea
r
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
Latest A/B-ECU Assembly 7

Conventional Robotics Robot


Automation
Get Work
Process
Put Work

Conveyor
Accumulated Knowledge of process Transfer to
Next Process
Dedicated Machine for each Process Rapid Installation
Burn In Inspect 
Redeploy able
Solderin Sea Pack Impact Functio Pac
g l Inspec n k
Cosmeti
Screw t
Cut Assembl Tighte Inspect c
PCB e n Inspect

5m
Robot only for transfer
20m
This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.
DENSO’s Strength 8

• Experience Variety of Automation in its own


production.
• Accumulated knowledge regarding process,
transportation and inspection.
• Strong internal Automation and Robotics
organization
• Global footprint for Robot support already
supporting the 86 Denso plants worldwide

This information is the exclusive property of DENSO CORPORATION. Without their consent, it may not be reproduced or given to third parties.