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Business Operations Improvement

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Improvement of inspection position aligned with the disability

Product and material microscope inspection operations

Expansion of occupational range productivity

Before improvement Improvement of inspection position aligned with the disability, and expansion of occupational range, before improvement

Work table used by non-handicapped person.

After improvement Improvement of inspection position aligned with the disability, and expansion of occupational range, after improvement

The line of sight position of wheelchair operators, and the working table height, were taken into consideration to enable wheelchair operations.

Introduction of new devices to the factory with issues

Thermal caulking operation of cases and foundations

Quality Productivity

Before improvement Manpower reduction in moving from taking one workpiece to taking two  Before improvement

(1) It took a lot of time to adjust when changing procedures.
(2) Heater temperature management was difficult.
(3) Counter display was difficult to see.

After improvement Manpower reduction in moving from taking one workpiece to taking two  After improvement

(1) Introduction of exclusive parts made adjustment when changing procedures unnecessary.
(2) Stabilized through increased heater installation.
(3) Installed easily visibility touch panel, enabling visualization of conditions.

Use of jigs for bracket mounting operation to workpiece

Bracket mounting

Quality Expansion of occupational range Productivity

Before improvement Jig added to bracket terminal  Before improvement

For persons with disability with little power in their fingertips, mounting operations were difficult.

After improvement Jig added to bracket terminal  After improvement

With a bracket-mounted jig, it is now possible for anyone to perform the operation, with the operation shortened from 8 seconds per item to just 3 seconds.

Improvement of inspection process

Operation to insert workpiece into inspection device after fitting operation

Productivity

Before improvement Use of elevator for insertion into inspection device  Before improvement

(1) Workpiece after fitting operation
(2) Shifter
(3) Belt conveyor
(4) Inspection device
Because of the existence of a shifter process, the number of workpieces inserted was limited.

After improvement Use of elevator for insertion into inspection device  After improvement

(1) Workpiece after fitting operation
(2) Belt conveyor
(3) Inspection device

The belt conveyor was extended, and the shifter process eliminated, increasing the number of workpieces that are inserted.

Stabilization of soldering operation with use of fixing jig

Lead wire soldering operation

Productivity

Before improvement Stabilization of soldering operation with use of fixing jig  Before improvement

When performing the soldering operation, the act of looking into the operations area caused fatigue for the operator.

After improvement Stabilization of soldering operation with use of fixing jig  After improvement

A fixing jig enabled alignment with the operator's line of sight position, achieving reduction of operator fatigue.

Use of jig for simplification of stamping operation

Lot number stamping operation

Quality Productivity

Before improvement Simplification of stamping operation  Before improvement

Because it is a manual operation, scattering of the stamp location occurred.

After improvement Simplification of stamping operation  After improvement

With a fixing jig, equalization of the stamp location shortened the operation from 10 seconds per item to just 4 seconds.

Utilization of jig for simplification of parts assembly method

Shaft assembly operation

Expansion of occupational range Productivity

Before improvement Simplification of parts assembly method  Before improvement

Operation for holding down a small part with the fingers required experience, and operators were limited.

After improvement Simplification of parts assembly method  After improvement

With a jig holding down the part, it became possible for anyone to perform the operation, with the operation shortened from 10 seconds per item to just 7-8 seconds.

Review of line for productivity improvement

Line integration

Productivity

Before improvement Construction of simplified line with multiple processes  Before improvement

The previous line positioned persons at each process.

After improvement Construction of simplified line with multiple processes  After improvement

Multiple processes can now be performed in a single process.

Facility improvements for increased efficiency

Wiper height inspection

Expansion of occupational range Productivity

Before improvement Use of rotation method to improve business operations efficiency  Before improvement

When changing procedures, the inspection facility needed to be moved, which was a difficult operation for wheelchair operators.

After improvement Use of rotation method to improve business operations efficiency  After improvement

The inspection facility can now be rotated, making changing procedures simple even for wheelchair operators.

Streamlining of applying bonding agent to lead wires

Applying bonding agent to lead wires of switches

Work scope enlargementQualityProductivity

Before the improvements リード線へのボンド塗布作業の簡素化する改善 改善前

This used to be a difficult work process requiring two workers with experience in bonding agent application who must operate standing.

After the improvements リード線へのボンド塗布作業の簡素化する改善 改善後

Introduction of bonding devices streamlined the work process by achieving semi-automation. This enabled work performance by a single wheel-chaired worker and achieved work scope enlargement. Execution of the work process was enabled also through workers not pre-determined for this process.

Improvement of the stamping process

Product type and lot number are stamped, followed by the combining of the products

Work scope enlargementQuality

Before the improvements 捺印工程の改善 改善前

Combining the products used to be time consuming, the adjustment of the stamping machine's rubber stamp was difficult, and the work required pre-determined personnel. (45 seconds per combining process) The stamping ink required time for drying. (2 hours drying time)

After the improvements 捺印工程の改善 改善後

By introducing laser markers and combining automation devices, the time for printing stamp adjustments and ink drying time could be saved. This has allowed workers to incorporate the pre-processing work, thus achieving work scope enlargement. Execution of the work process was enabled also through workers not predetermined for this process.

Work process improvement for wheel-chaired workers

Work comprised of caulking the pins of components A and B to the products and assembling component C

Work scope enlargementProductivity

Before the improvements 障がいに合わせ移動をなくした作業結合改善 改善前

Sideway movements to execute the next work process used to be difficult for wheel-chaired workers. (5 seconds per sideway movement)

After the improvements 障がいに合わせ移動をなくした作業結合改善 改善後

The introduction of jigs that move the positions of products obviates the need for wheel-chaired workers to move.

Improvement of inspection devices by adjustments consistent with the disability

Work process of assessing product conformity using inspection devices

Work scope enlargementQuality

Before the improvements 障がいに合わせた検査機の改善 改善前

A buzzer used to sound when a product was found non-conforming during an inspection. Non-conforming products were collected in designated red containers but the process was left to workers discretion.

After the improvements 障がいに合わせた検査機の改善 改善後

By additionally equipping inspection devices with rotating warning lamps, thus alerting inspection workers by sound and sight, the scope of work is enlarged to workers with a hearing disability. Causing inspection devices to stop operating if a non-conforming product is not placed into the designated red container helps prevent human error.

Reduced work load of press-fitting

Work process of press-fitting of switch cases

Work scope enlargementProductivity

Before the improvements 圧入組合せ作業負担軽減の改善 改善前

Press-fitting of products used to be done manually. This required physical strength and made this heavy work. (6 seconds per item by a trained worker)

After the improvements 圧入組合せ作業負担軽減の改善 改善後

The adoption of press-fitting jigs enabled work execution also by workers not predetermined for this process and reduced the work load. (2 seconds per item).

Terminal automated inserter  Before improvement

Terminal automated inserter Before improvement Terminal automated inserter Before improvement Terminal automated inserter Before improvement Terminal automated inserter Before improvement