TRIZ Case Studyin the Development of Automotive Unit

Univance Corp.

Products Development Dept.
Sho Tsuchiya

AGENDA• Company Overview• Development Vision• Background• Case StudyⅠ• Case StudyⅡ• Summary

UNIVANCE COPORATION

1Company Overview
Customers•

Founded in 1937•

Capital: JPY 3.5 Bill.

•

Listing: 2nd Section of Tokyo Stock Exchange•

Main Stockholder:Iwao Suzuki 10.84%
Suzuki Corporation 8.28%
Daido Steel Corporation 8.12%•Head Office Plant:
2418 Washizu, Kosai City,
Shizuoka Prefecture, 431-0494, JAPAN••FY2013

Overseas Operations:
UNIVANCE INC. （USA）
PT.UNIVANCE INDONESIAUNIVANCE （Thailand） Co., Ltd.

•

Number of Employees: 2,328 (March 2014)•Main Products:
Transfer Cases and PTUs
Manual Transmissions
HEV/EV Gearboxes
Agricultural / Industrial Vehicle Units
Automotive Components

Sales Trend (Consolidated)(JPY Billion)

Japan

80

68.8
60.7

60

U.S.A.

Indonesia

Thailand

64.2

64.6

Plan

FY2012FY2013

FY2014

49.0

40

200
FY2009UNIVANCE COPORATIONFY2010FY201122

Company Overview
History•Buhler•UNIVANCE (Thailand) Co., Ltd. established.
•Began PTU production.
•ISO/TS•16949 certification obtained.
•Began production of hybrid truckgearboxes.
•Fuji Univance and I.S. Precision Machinery
merged to form UNIVANCE CORPORATION•ISO•14001 certification obtained.
•QS-•9000 certification obtained.
•Received TPM Prize.
•ISO•9001 certification obtained.
•P.T. UNIVANCE INDONESIA established.
•Started sales of SURETRAC LSD.
•UNIVANCE INC. established in the U.S.
•Received PM Prize.
•Began AXC sales (hydraulic torquesplitter).
•Changed company name to FUJI
UNIVANCE CORPORATION.
•Began compact truck transmission
production.
•Received Q-1 Prize from Ford.

•Began sales of AT overrunning clutches.

•Began10 ton concrete mixer reduction
gear production.

••TPM introduced.
•Received Deming Application Prize.
•Received Nissan Quality Control Prize.
•Began heavy duty Powershift tractor
transmission production.
•TQC program introduced.
••Began RV transfer case production.
•Began forklift transmissions business.
•Began agricultural machinery parts
business.
•Began assembly of mid-size truck
transmissions.
•Began machining of transfer case andmid-size truck transmission parts.
•Dedicated machine tooling plant built inKomi, Kosai City.
•Shares listed on the nd Section of
the Tokyo Stock Exchange•Fuji Tekko Co., Ltd. founded in Nagoya.

•Moved to Washizu (currently Kosai City).

•Co-developed induction hardening
technology with Shizuoka University.

•Began automotive parts business.

•Suzuki Iron Works Co. Ltd.
（• I.S. PRECISION MACHINERY INC.
） splitoff from Fuji Tekko Co., Ltd..

223UNIVANCE COPORATION

10009080705060u•Hybrid Truck
Gearboxes(Devel. + Prod.)•Heavy Duty AgriculturalTransmissions•Sewing•Machine• Parts•Mitsubishi•HONDA•UDTRUCKS•IsuzManual Transmissions (Production)••DAIHATSU •MAZDA•Ford•UniCarriers•KUBOTA•Fuji Heavy Industries
•CN
•KYBH

•37

•Automobile Parts•Aircraft •Sewing Machine•PartsParts•Suzuki•Nissan•Transmissions (Development + Production)•Drivetrain Parts•Aircraft Parts•Full Time Transfer Cases•PTUs•Commercial M/Ts

•Hybrid Truck Gearboxes•Part Time Transfer Cases•Transfer Cases (Development + Production)

Company Overview
Plant & Office Map•JAPAN•HeadPlant•Kosai Plant•Hamamatsu Plant•Shanghai Office•U.S.A•THAILAND•INDONESIA•UNIVANCE INC.

•UNIVANCE (Thailand) Co.,Ltd•： Plant•： Office•PT. UNIVANCE INDONESIAUNIVANCE COPORATION44

Development Vision
Progress with attractive and competitive products
by development and technology
Technology tofunction effectively

Development of power train systems and units
that contribute to fuel efficiency improvement
Lightweight・Compact
Friction reduction technology

High performanceclutch technology

High efficiency・High response
Electric shift technology

UNIVANCE COPORATION

5BackgroundTo get to market products that are attractive andcompetitive ,“ Cost reduction ““ Improvement of the technical competitiveness by
establishing our new technology”
are required.
We plan the speed up of solving problems bylearning and using TRIZ.
UNIVANCE COPORATION6

Case Study Ⅰ“Reduce friction torque”
We have studied the reducing friction in a transfer case unit
in 2013.
Transfer case for full-time
Transfer case for part-time

UNIVANCE COPORATION

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Case Study Ⅰ
Theme『Friction Reduction』

TRIZ Fully Follow Up
Essential issues(Extract the root cause)

Creation ofIdeas using
TRIZ

Function attributeanalysisCreation of ideas using
Invention principles

Cause result
analysisCreation of ideas using
evolutionary patterns

Creation of ideas using
IFR and other techniques

Arrangement of idea

Ideas utilized

Idea uniting and concept selection of each subsystem(Select and connect)
Main system concept

System:Absolute evaluation

Absolute grading of the final system concept

Commodity concept selection after one year, 2-3 years or 5 years
UNIVANCE COPORATION

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Case Study Ⅰ
Cause-result analysis
Purpose：The cause and the result of the problem are clarified.
：Primary cause：AND
Friction by a multiple discclutchFriction by an oil pump

UNIVANCE COPORATION

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Case Study Ⅰ
Results

生活場面への置き換え

生活場面からのアイデア

T1

ideas

T2
バリケードを設置して一列に並ぶようにする
入口で人数制限する
入口の大きさを狭くする
別の出口を設ける
別の入口を設ける
チェックを止める
チェックするスピードを上げる
壁が壊れて外に逃げ出す入ってくる人を時間で区切る
整理券を配る
入場者の条件を制限する
出口へ誘導する人を配置する
チェックする時間帯を決める
案内板を設ける
人を殺して減らす

潤滑油の流れを整流する
O/Pギアの回転数を一定にする
吸入口を狭くする
吐出口を増やす
吸入口を増やすSFTに入れず潤滑油を垂れ流しにする
吐出口を大きくする / SFT外径を小さくする
潤滑油をリークさせる
時間でO/Pを止める
圧力が一定以上になると吸わなくなる
圧力が一定以上になると吸わなくなる
SFTが吸引する
時間でSFTの回転を止める
吸入後のポート形状を変更する
潤滑油を中で蒸発させる

バリケードを設置して一列に並ぶようにする
出口でチェックする人を一定人数にする
入口で人数制限する
別の出口を設ける
別の入口を設ける
チェックを止める
チェックするスピードを上げる
壁が壊れて外に逃げ出す
入ってくる人を時間で区切る

潤滑油の流れを整流させる
吸入後のポート形状を変更する
吸入口を狭くする
吐出口を増やす
吸入口を増やす潤滑油を垂れ流しにする
吐出口を大きくする / SFT外径を小さくする
潤滑油をリークさせる
時間でO/Pを止める

T3

Creation of ideas methods

NumberCreation of ideas using Invention principles

77

Creation of ideas using evolutionary patterns

128

Creation of ideas using IFR

100

Creation of ideas using an ultimate ideal solution

16

Creation of ideas using SLP

14
期待効果

確認項目

効果

コスト
期間
確認 製品 確認 開発

SFT内のO/Pを必要吐出 → 小さくでき圧減
る・回転数に対するSFT
内への吐出圧△○△

短期 短期○○△

短期 中期○△△

中期 長期

System evaluation

サブシステム案
1. O/Pﾌﾘｸｼｮﾝ低減
SFT穴あけ方・穴の径1-1 ・油穴長さ
・穴形状
・流入溝形状1-2

ｽﾄﾚｰﾅｰ位置変更（ｴｱﾚｰｼｮﾝ起こす）

ﾕﾆｯﾄ上部からの潤滑
1-3 （SFT内からを止める）
外部潤滑回路によるTotal number of ideas
335pieces

Effective ideas

O/P廃止
霧状のｵｲﾙで充満O/P吐出圧を1-5調圧させる

1-4

1-6

O/Pｷﾞｱの接触面積を減らす

2WD時にO/P
・ｴｱﾚｰｼｮﾝ時の音の確O/P→ ﾌﾘｸｼｮﾝ低 認
効率減
減
潤滑確認（2WD時）・SFT穴ﾒｸﾗにして、各O/P
O/P必要部への潤滑性＆量→ ﾌﾘｸｼｮﾝ低吐出減・内部潤滑に対してのﾌ減
ﾘｸｼｮﾝ変化O/P必要
O/P
・噴霧装置の設計、→吐出減
ﾌﾘｸｼｮﾝ低 効果確認
O/P
O/P必要
・過去のﾃﾞｰﾀ確認、無→ﾌﾘｸｼｮﾝ低 ければ実施
吐出減
O/PｷﾞｱO/Pﾊｳｼﾞﾝｸﾞとｷﾞｱ
摺動抵抗 → ﾌﾘｸｼｮﾝ低・形状変更
減らす
減・表面処理△△△中期 長期○△△

中期 中期△△△

中期 中期○×△長期 長期△△△

中期 長期

2. 2WD時のﾌﾘｸｼｮﾝ低減
2-1

2WD時に多板を回さない

2-2 ﾌﾟﾚｰﾄの形状変更

UNIVANCE COPORATION

2WD時の2WD時ﾕﾆｯ・2WD→4WD時にうまく多板引き
ﾄ→締結できるかずりﾄﾙｸ
ﾌﾘｸｼｮﾝ低・応答性0Nm
減2WD時の2WD時ﾕﾆｯ多板引き
ﾄ→・耐久性、応答性確認
ずりﾄﾙｸ
ﾌﾘｸｼｮﾝ低0Nm
減10Case Study Ⅱ「Downsizing」＜TRIZ case study in 2014＞
・We tried out the second theme with new members added
so that more engineers become able to get ideas using TRIZ.
・ Get result in a short term
＜Study theme＞
・ Downsizing of gear boxTarget「Outer diameterφ125㎜×Full length108.5㎜｣

UNIVANCE COPORATION

11Case Study Ⅱ
Theme『Downsizing』

TRIZ Fully Follow Up （Shortened version)
・It customizes so that it can carry out for a shortperiod of time.
5 days4 daysEssential issues(Extract the root cause)

Creation ofIdeas using
TRIZ

Function attributeanalysisCreation of ideas using
Invention principles

Cause result
analysisCreation of ideas using
evolutionary patterns

Creation of ideas using
IFR and other techniques

Arrangement of idea

3 daysIdeas utilized

Idea uniting and concept selection of each subsystem(Select and connect)
Main system concept

System:Absolute evaluation

Absolute grading of the final system concept

Commodity concept selection after one year, 2-3 years or 5 years
UNIVANCE COPORATION

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Case Study Ⅱ
Cause-result analysis
Large in diameter！

Long in full length ！

UNIVANCE COPORATION

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Case Study Ⅱ
Idea selection and combination

Pasted 「Development lead time-effect table」 root cause different ideas,
Selected short delivery times and high effect ideas.

The big diameter because of cam gear is on output bearing

Spring length is Long

EffectEffectDevelopment Lead time

Development Lead timeWorking load is lowered

The big motor because of small gear ratio
EffectEffectDevelopment Lead time

OthersLong press fit length
EffectDevelopment Lead time

EffectTotal 83 ideas
Development Lead time

Development Lead time
UNIVANCE COPORATION

14Case Study Ⅱ
Results

Target「Outer diameterφ125㎜ × Full length108.5㎜｣≪Before≫≪After≫

φ166
φ118
108.5
★Achieved★

108.0
UNIVANCE COPORATION

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Summary【Impressions】
・ This approach is effective, because the problems become clear byinvestigating root causes.
・Shortened version of TRIZ allowed us to do the activity without
troubling daily business routine.
・Full version of TRIZ activity with sufficient time would generate
more ideas.
(I felt the activity time was not enough for this case.)
・New ideas are generated by referring to patents of other fields.
・New ideas emerge easily by referring invention principle andpatent information.
・Development speed would be improved by continuing this activity
which enables us to get more ideas in shorter time.
UNIVANCE COPORATION

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謝辞・株式会社アイデア
シニアコンサルタント 井坂様
シニアコンサルタント 片桐様

UNIVANCE COPORATION17

Thank you

UNIVANCE COPORATION

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