-
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
