Introduction of Cell production

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Manufacturing industryIntroduction of Cell production

Parts supply〜Assembly〜Shipping A high-efficient production with basic AGV

1.AGV and the cell production

Since our engines (ENG) and transaxles (T/A) are the products for mass market, we had been assembling them by the conveyer lines. However, the variation of the products increased as the history was piled up, and the losses due to combined production in a same line has been actualized.
Then, diverse models with large man-hour difference and low-volume production model were separated from the mass production model, and the mass production model was moved to a line with high productivity. At the same time, we pursued a profitable, non-mass production line no way inferior to the mass production line.

As a result, we were able to construct the cell-production line with simple Auto Guided Vehicle (AGV) based on below concepts. The non-mass production line must be

    ・no losses related to the structure of the line, even the production models are not consistent:
    ・flexible about volume changes:
    ・easy to handle for everyone and human friendly:
    ・low-priced and flexible

We hereto introduce it.


2.What is the assembly line by simple AGV?

Set up a cell production
(self contained)assembly line.

 Since the non-mass production line has models with big man-hour difference and volume change,it generally enjoys advantages of the cell production system. AGV can minimize disadvantages of the cell production system. Therefore, we adopted a circuit method that enhances pace management and self operation by using AGV.

(bench production)

(one process a person)
Cellular manufacturing
Division meth
(partial round)
round method
(so called “Rabbitchasing”in Japanese)

Organization efficiency

Part and tool handling

Model arrangements
Work skill
Easiness of automation
Installation cost (I・C)
Flexibility for volume change
Optimal production in each factor Production volume large   ←←←←←←←   small
Number of models few  →→→→→→→    many
net man-hour many   ←←←←←←←   few

Multifunctional AGV is not necessary, as long as the automatic machine has the stop position accuracy. Therefore a low-priced, simple typed AGV around 500,000 yen with the basic specification was adopted this time.

3.A case with non-mass production assembly line

1Launching of T/A non-mass production line ・・・ The AGV is used from Parts collection to finish test throughout the processes.

  When the line of a new unit was set up, even picking (part collection) process of the gear parts (13 parts) and test process that falls on the process before and after assembly were incorporated in the line. Then a one-person conclusion by AGV was advanced, and it was able to be a line saved labor, processed one by one.
(From the layout based on the function to the layout based on the products. )


2)Launching of ENG non-mass production line ・・・ Introduction of defect-free (Poka-yoke) line regulated by AGV

  The target product is with many kinds, small volume, large man-hour and variety of processes. In such case, a defect-free system is absolutely necessary from the point of view of the quality assurance. So, a regulated, not human-attention typed defect-free was adopted for the new line.



defect-free management BOX Start restriction sensor

3)Launching of CVT assembly line ・・・connection with automatic machine by making detachable of the assembly jig

4.Improvement using AGV for the rest of assembly

1)Transportation improvement at T/A mass production line
  By using AGV as a transporter between processes that means the basic function of AGV, the sub works in the mass production line of T/A, were moved among the processes to balance the organization of job and reduce the loss of organization.

2)Gear processing (processing -- heat-treatment -- processing)

3)Foundry (LPC casting- cooling - finishing)
 In the foundry of a bad environment, the work is transported between casting process, cooling process and finishing process. To cover the condition that the work is very hot and core sands are scattered, the AGVs with sweeping function were adopted.

5.Introduction of AGV used this time

6.Aiming at the improvement for tomorrow

 ・Working environment that doesn't give worker stress
  ・The stock in the line is small due to the high productive efficiency like average mass production, even it is non-mass production.
  ・It doesn't dig into one's purse.The improvement is advanced aiming at such a line now.

When this new line was set up, the press-fitting work in

the middle process was demanded to do by press-fitting press,

not by vibration tool from the point of view of both the

accident and the quality.

To fit this process in the simple type AGV, receiving jig was

separated from AGV and made it easy to slide into the


press from AGV.

By doing so, the automatic machine became to be able to work

without attaching and detaching.

 Moving the jig from equipment to AGV

Automatic Guided Vehicle CarryBee Variation (AGV)

Automatic Guided Vehicle CarryBee Variation (AGV)

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CarryBee is an unmanned carrier system which can rationalize conveyance between processes, parts supply to production lines and cellular manufacturing (assembly on AGV).

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