Automobile
Automobile
Production bases of the vehicle
continue to expand.
continue to expand.
Automobile
Production bases of the vehicle
continue to expand.
continue to expand.
About Automobile Department
Logistics transportation as infrastructure, railway, agriculture, etc. are deploying on a global scale including in emerging countries.
Production bases of the vehicle parts are continuing to expand not only to Asian countries such as China, Thailand, and India but also to Central and South American countries such as Mexico and Brazil. Not limited to domestic manufacturers, foreign vehicle manufacturers are also continuing aggressive overseas deployment with the goal of “local production for local consumption.” On the other hand, concerning the production in areas that are not accompanied by technology and experience required for the vehicle manufacturing, instability of the quality due to the disparity of the skill level of workers there can be cited as a major challenge. That instability is occurring not solely because of a simple difference of the skill level but because of the disparity in worker motivation. In the ever-expanding production sites, it is an urgent issue to ensure stable quality.
Case Study : Press-fit nut
We aim to improve the quality and working environment in the new production sites.
“The vehicle manufacturers of the world are promoting the aggressive deployment of the production bases with a goal of local production for local consumption. Through a proposal tailored to the regional characteristics and technical level, we will contribute to the stability of the client’s quality.”
Case Study
Press-fit nut
Press-fit nut
We aim to improve the quality and working environment in the new production sites.
“The vehicle manufacturers of the world are promoting the aggressive deployment of the production bases with a goal of local production for local consumption. Through a proposal tailored to the regional characteristics and technical level, we will contribute to the stability of the client’s quality.”
Client’s Problem
“Unstable quality” and “load of the work environment” resulted from the difference of the technical level.
A client had aggressively been promoting overseas expansion but at the same time struggled for many years with the quality control of overseas bases, and Eto was approached for the consultation. The “weld nut” to be used in vehicle parts is commonly used in a number of fields because of the availability and price. Because the mounting of the “weld nut” requires high skill, skilled welders are required for it. However, there are only a few welders that can perform the technique in each production base, so there happens a case where a large difference occurs in the level of the technique of each welder. As a result, the quality becomes uneven, finally causing a cost rise from the poor yield ratio. In addition, the welding work has a “burden on the workers” and a large “impact on the environment” because of the heat generation and Co2 emission during the work, and the welding work itself is also accompanied by danger. Without influence by the base, both the “stability of quality” and the “safety of the working environment” are simultaneously sought.
Proposal
A new presentation of the construction method increases choices and leads to the optimal solution.
The problem that a client faces was more complicated than that of the “stability of the quality” and “improvement of the working environment.” The general technology and process have a reason to be generalized, but the optimal way differs depending on the production base. Therefore, Eto considered whether the current way was the best for the base from every point of view, such as from the regional characteristics and technical capabilities of the client’s base. At the same time, with a proposal of different technologies and processes, we increased the choices for the client and provided an opportunity for a wide investigation. We will introduce some of these efforts.
Presentation of different choices
The optimum value to the quality stabilization is not common for all of the bases. That is why we must have different choices.
In this proposal, Eto made a point of presenting a possibility of different technology. At the client base, because it was difficult to secure skilled welding technicians, who are sought for mounting a commonly used “weld nut,” Eto proposed a “press-fit nut.” This nut is not influenced by the skill level of the workers and a uniform quality can be expected, and since it can be processed with the general small pressing machine, a new large capital investment is not required. This proposal was adopted by the client, and a test introduction began.
Results of proposed
Quality stabilization is not all. It is an environmentally-friendly solution.
In order to ensure the stable quality, Eto proposed a “press-fit nut.” As a result, even workers with no special technique or skill became able to keep a certain level of quality successfully. In addition, since it does not emit heat or CO2, it has also led to the improvement of the working environment. While targeting the stability of quality as the biggest goal, an effect that provides a more pleasant working environment to workers has resulted.
It does not depend on technicians
Capital investment is unnecessary
It does not generate heat
It does not emit Co2
Summary
Respect the quality andthe worker similarly
Also in the future, at the various regions and production sites of the world, the uneven quality caused by the difficulty of securing stable technical level will continue to be an issue that the people in the site must resolve. To be able to obtain a certain level of quality without depending on the workers is a major goal at which production technology aims. While Eto is always aware of the cost, toward the challenge the client’s production site faced, we propose solutions that respect the work environment as well as the stability of quality.
