A factory of the future with a good blend of expertise and automation
DS1 is a self-contained start-to-finish factory with a floor space of 23,600 m2, consisting of two sections: a parts machine shop and an assembly shop, and handles the whole process: raw materials input -> parts processing -> kitting & sub assy -> unit assembly -> final assembly -> witness inspection -> shipment.
Environmental temperature is controlled and kept at a constant temperature both in the parts machine shop and the assembly shop to keep constant parts temperature throughout the process from processing to assembly in order to achieve stable quality.
The machine shop facilities are equipped with 40 units of advanced processing machines including Okuma's large Double-Column Machining Centers boasting of high speed and high precision, Horizontal Machining Centers, Multitasking Machines and Grinders, together with FMS, robots, loader, automatic feed system of cutting fluid and automatic recovery system of chips, realising a machining system that operates 24 hours a day, seven days a week.
To utilise the advanced factory where it is necessary to deal with variation and diversity, and to produce small batches of a wide variety of products, the following techniques are indispensable:
By merging the state of the art of information technology with the shop knowledge (know-how) cultivated as a production goods manufacturer and radically practicing front loading, we have implemented our techniques of "New Direct Machining" to reduce the preparation work on the machine and our "New Production Control System" to link the production by planning and the flexible production by order. In addition, we have established a "Visualising system" which enables utilising the shop knowledge in order to quickly respond to the current production status which is changing on a day-to-day basis.
DS1 has doubled productivity and increased production capacity by 30 per cent to 120 units per month, worth 3 billion yen. Lead-times have been halved, shortening delivery times and enhancing customer service.
DS1 has about 500 pieces of solar photovoltaic panels mounted on the wall surfaces and about 3,800 pieces on the roof of the building which serve as a mega solar power plant generating a maximum power output of 1,037 kW. In addition, green panels are laid out under the photovoltaic panels which are contributing to the reduction of CO2.
Heat insulating panels are used for the exterior walls of the building. The factory is also equipped with other facilities such as LED illuminations, inverter-controlled air compressors and air conditioning systems with an electric heat pump. Furthermore, bellow tents are used to prevent direct inflow of outside air when transportation vehicles for shipping machines go in and out the factory, contributing to energy saving.
With these efforts, we realise the reduction of energy costs, including electrical power consumption in the factory building by 30%.