21

ASEAN

DNTHSE

SE

CIM=0.7CIMCost Index of Manufacturing

Fig. 1

DNTH

Fig. 2

60

DNTHFig.

3DNTH

200422

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

41

Yoshio NAKA

Kazuki MAESOBA

Masaomi DOBASHI

Tatsuo YAMAZAKI

Hiroshi NAKAMURA

Keigo MORIGUCHI

*Method for Designing Production Lines in Low Labor Rate Countries

Prod

uctio

n co

st C

IM v

alue

DNJP(Japan)

(Relative value to Japan)

DNTH(Thailand)

DNIN(India)

TDS(China)

1.0

0.5

0.9 0.9 0.81.0

Fig. 1 Production cost CIM value at low labor country

1

2

3.1

Fig. 4DNTH

Table 1

Fig. 5

42

Vol.No.2004

Depreciation57%

Indirect material20

Labor23

Fig. 2 Production cost of typealternator at DNTH

Fig. 4 The structure of ordinary machine in DNTH

Table 1 An example of work element

Conventional machine In DNTH

DNTHWork set

Draw in base palletBearing press

Press load checkPull out base paletteConvey next process

DNJPOperator

CylinderLoad cell

Robot

CylinderCylinder

Load cellCylinderConveyer

Operator

OperatorOperator

Fig. 3 Comparation between conventional machine inDNTH and automatic machine in DNTH

Fig. 610

SE

Fig. 7

3.2 SE

SE08

Fig. 8SE

DAS

Fig. 9

43

DNJP(Automatic machine)

DNTH(Conventional machine)

Qualty check

Electrical equipment

Process equipment

Control

Conveyer0.89

1

0.88

0.90

0.920.95

Equi

pmen

t cos

t

Fig. 6 The cost compare between automatic machinein DNJP and conventional machine in DNTH

Min. target

Japan

ThailandTarget

Our approach

Ordinary approach

Convey

Process

ProcessPr

oduc

tion

cost

Automatic rate

Current in Thailand

Fig. 7 The approach of our method for designingproduction line

Bearing set

Palette convey from previous process

Assy

Push the palette into the machine

Press the bearing

Punch put back

Check the press load

Pull out the palette from the machine

Forward to the next process

Palette convey finished

Bearing draw finished

Bearing set finished

Finish the previous cycle

Bearing exist?

Palette push finished

Work position OK?

Punch upturn position OK?

Bearing press finished

Punch return OK?

Load check position OK?

Load OK?

Palette pull out OK?

1cycle finished?

Palette exist?

Draw the bearing

Palette convey OK?

Bearing draw OK?

OK

OK

OK

OK

Bearing set OK?

OK

OK

Palette push OK?

OKOK

OK

OK

Load check position OK?

OK

OK

OKLoad check finished

1cycle finishedOK

OK

Fin.

Punch return finished Fin.

Fin.

Fin.

Fin.

Fin.

Fig. 5 Control flow in DNJP machine

30

Fig. 10Fig. 11

Fig. 12

44

Vol.No.2004

Cause of Past Field Claim in DNTH

Unconsciousness of Rule or system

Forgetof Rule or system

Mistakeof Rule or system

Clump forget of retainer screw

Process skipping of the

pulley lock nut

Size mistake of the flame tap

Coil covering for Rotor

Wrong position Assembling

of the position setting jig

Terminal Screw Torque short

Fig.12 Expected examples of failure mode in DNTH

Conventional machine

FunctionWork check

UnitPhoto electric tube

autoPress

Load check Load celljig

auto

Load OK/NG

Work discharge

Press position Omega SW

Operatormanual

Inside springjig

Hand presstool

manual

Point sw

Lump

Developed machine

Unit

Hydraulic pressauto

Control circuitautoPhoto electric tubeauto

tool

tool

Operator

Fig. 11 Labor-intensive machine example

Fig. 8 Examples of consideration steps to maximize labor ability

05

101520253035

0 5 10 15 20Load kgf /each time

Ope

ratio

n lo

ad

poin

t Upper limit for maleUpper limit for female

Stator, Rr flame

Rr bearing bush, terminal sub- assy Dr bearing

under cover

Fig.9 An example for evaluation of manual operation

DNJPAutomatic machine

DNTHConventional Machine

DNTHDeveloped machine

0.9

0.7

Prod

uctio

n co

st

0.90.7

1.1

0.6

0.9

Depreciation

Labor

Indirect material

0.9

1.0

Fig.10 Production cost result

4.1

Fig. 13

QAFig. 14

11QA

N

N

N

DNTH

SE

4.2 DNTH SE

DNTHSE

N

13.1

DNTH

2

1

Table 232

Table 2

45

Mechanical assurance

N

Assurance rank for the process defects

Syst

em re

liabi

litylo

whi

gh

operator

Labor-intensive pokayoke

Mechanical checker

Fig. 14 Quality assurance matrix in low-labor country

Table 2 Quality assurance level of labor-intensivePokayoke in DNTH

1 2 3

Def

ects

Pokayoketimes

DNJP level2

1

2

Fig. 13 The idea based on probability

15

N=2

NDNTH

N=2

1

2

DNTH SE

1SQC:

3

1994p.43.

2:QA

2004pp.1-8.

46

Vol.No.2004

Fig.15 Quality assurance matrix in DNTH

47