The Innovator of AluminumSUS Corporation
Head office
6F, S-patio Bldg. 14-25 Minami-cho, Suruga-ku, Shizuoka-shi,
Shizuoka 422-8067,Japan
TEL : +81-54-202-2000 (Main) FAX : +81-54-202-2002
International sales
TEL : +81-54-202-0810 FAX:+81-54-202-0807

USA
SUS America, Inc.
901 Cambridge Drive, Elk Grove Village, IL 60007, USA
TEL : +1-847-350-1525
http://www.susamericainc.com/

Thailand
System Upgrade Solution BKK Co., Ltd.
Head Office,Amata Nakorn Industrial Estate 700/71 Moo 5, T. Klongtamru
A. Muang, Chonburi 20000, Thailand
TEL : +66-38-457069
http://www.susbkk.co.th/Singapore
SUS(Singapore) Pte. Ltd.
19 Tannery Road 347730, Singapore
TEL : +65-6842-4348

China
SUS (Suzhou) Co., Ltd.
Block 25A# Industrial Workshop, Chuangtou industrial area,
Suzhou Industrial Park, Suzhou 215122, China
TEL : +86-512-82253336

India
Standard Units Supply (India) Pvt. Ltd.
43/1 Padasalai Street, Ayanambakkam, Chennai - 600095,
Tamil Nadu, India
TEL & FAX : +91-44-49524482

FeatureVietnamStandard Units Supply (Vietnam) Co., Ltd.
Workshop - Office X5, Hai Thanh workshop area, Hai Thanh
Ward, Duong Kinh Dist., Hai Phong City, Vietnam
TEL : +84-313-632 403 ~ 404

Philippines
Standard Units Supply Philippines Corporation
Building U-2 Lot 22B Phase 1B First Philippine Industrial Park
Special Economic Zone Tanauan City 4232, Batangas Province
Philippines
TEL : +63-43-430-1074 / 1076

http://global.sus.co.jp/● This print was made with recycled paper and vegetable ink to protect the environment.

1710-2,000

Electric control,
made easy
with SiO!

36

SUS FA MAGAZINE
2017 August

3 Feature

Electric control,
made easy
with SiO!

5 What is SiO Controller?
7 Examples of simple kaizen
using SiO
9 See real examples! Introduction
to kaizen using SiO
Considering Movement
Selecting Devices
Installation and Wiring
Programming
Writing
Executing

18 Potential for electric karakuri
using SiO
21 Connect power units to SiO
23 Production Site INNOVATION

Honda Motor Co.,Ltd.
Murata ManufacturingCo., Ltd.
Narita International
Airport Corporation

Bringing control
within reach"Karakuri", a word coined in the 17th century of Japan, is a term used to describe mechanical devices. The most common

What isexample is the "Karakuri puppet"一a moving doll which utilizes the principles of gravity, movement, and levers to move.

Karakuri?

karakuri to make improvements to the manufacturing workplace without the use of power. Real-life factory workers are"Karakuri Kaizen", a movement that is gaining ground in the Japanese automotive industry, aims to utilize the principles ofworking together to create "Karakuri" that improves production efficiency and creates worker-friendly stations at low costs.
Karakuri Kaizen is a registered trademark of the Japan Institute of Plant Maintenance (JIPM).

Yasuo Ishida, Director and President, SUS
In recent years, we at SUS have introduced

indispensable in carrying on these advantages

use, economical control devices that are more

the word “Karakuri Revolution” and made new

through the “Karakuri Revolution”, so we haveclosely tied to the production field, and we

proposals that bring the minimum necessary

started developing controllers to follow up on

hope to see our products used as a new means

motorization to traditional un-powered

electric parts. One of our accomplishments isfor executing kaizen.

karakuri mechanisms. The first step in thisthe “SiO Controller”, which is featured in thisprocess was for us to develop motorized parts.

special article.

We have released items such as “The PowerUnit” with the idea of linking to aluminum pipe

SiO Controller is an item for realizing easy,

structural material GF which our customers

low-cost, simple control that is necessary

have supported as parts for karakuri, and wefor motorizing karakuri. This concept differs

continue to expand our lineup even now. To

greatly from conventional control equipment

make these motorized parts easy to control, we

used for building large-scale automatedattached a standardized controller that comesequipment. We focused on creating

registered with multiple movement patterns,

specifications that enable use of SiO evenand which can be used just by plugging it in towithout a specialized engineer on-site.

a power source. However, as we have actually

We started development of this productpromoted practical use in combination within order to motorize karakuri, but

karakuri mechanisms, requests have come toits simplicity and the ability to use

us for control taken one step further, such as

it in a number of ways with someby linking this control with other mechanisms

adjustments means its applications

which require more than standard operations.

are not limited to karakuri. We at
SUS will continue to work towards

Originally, karakuri for kaizen were not

the development of easy tocreated by experts on production facilities, but
by people working in the manufacturing field
who shared their wisdom with each other. Thisnot only makes it possible to take advantageof the viewpoints of people actually doing
work, but offers significance unlike large scale
capital investment, as workers find motivationin using equipment they have made with theirown hands to do work. We at SUS consider
control devices that can be easily used without
knowledge of electrical engineering to beThis booklet is an abridged edition of FA Magazine“Sing”
originally issued in Japan in Aug. 2017.

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Feature

Electric control, made easy with SiO!

If you could do “electric control” without expert knowledge of programming
and wiring, what kind of kaizen would you use it for?
This feature introduces the SUS input/output control mechanism “SiO
Controller” which makes electric control easy for anyone.
Read on to find easy electric control made possible by SiO, including
installation and programming processes.

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Feature

Electric control, made easy with SiO!

Simple but deep

What types of SiO Controllers are there?

What is SiO (Simple Input Output) Controller?

SUS offers two types you can choose fromdepending on their application.

SiO Controller is simple input/output control system launched by SUS in June 2016.
Here we give an overview of the product in the format of a Q&A.

What can you do with SiO Controller?

Input Device

Output Device

Is it reacting?
Or not?

Press Button Switch

Send ON/OFF command

Is it detecting?
Is it notdetecting?

Photoelectric Sensor(Reflective Type)

Look at the ON/OFF status

Is it beingpressed?
Is it not beingpressed?

Sound off!

SiO Controller

Stop!

BuzzerLight up!

Turn off!

Lamp (Red)

Limit Switch

Set the conditions to output to
SiO Controller in advance.
When the status matches these
conditions, it sends a commandto the output device.

These are a few of the things it can do.
⃝Sound the buzzer⃝When the⃝When the limit
as long as thephotoelectric sensor
switch detects apress button switch
reacts 5 times, light
workpiece, stopis being pressed.
up the lamp.
the buzzer… etc.

What kind of places and situations can it be used in?

It is convenient for making simple work site improvements or automating
karakuri, where PLC would be considered to be over-engineering.

Large Scale

Medium Scale

Small Scale

Highlyfunctional but
hard to use

Manufacturinglines, etc.
Inspection
devices, etc.

PLC
Reducing
functions to makeit easily usable
for anyone

Simple work site
improvements
SiO

When building the system that uses electric control in a factory, it used to be common touse a PLC (programmable logic controller) regardless of what needed to be achieved. By
using an SiO Controller, it is possible to easily make small scale work-site improvementsthat don’t quite call for PLC but would be convenient if they could be automated.

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When control is donewith the same specs⃝Control program +Debug⃝Wiring = Labor Coast(8 hours) ¥54,000
SiO Program + Debug= Labor Cost (5 hours)¥22,500

What is SiO?

Look at the ON/OFF status of an input device to send
ON/OFF commands to an output device.

8 Inputs/8 Outputs
Connector : Flat Cable
While still keeping a small size of
SUC-162
just 60 mm × 73 mm × 22 mm, it
is capable of connecting 8 inputs and 8 outputs. Our lineup
includes 3 types with differing installation mechanisms (GF
connector/DIN rail/fastening screws). SUS also offers an
e-CON connector terminal block (SUC-162) as an option.

6 Inputs/4 Outputs
Connector: e-CON
This model has the minimum numberof inputs and outputs.
An e-CON connector terminal blockis built into the main unit, so devices
Examples ofcan be connected easily just by
installation on GF
plugging them in. Extruded aluminumis used for the housing. The same protrusions as aluminum
pipe structural material GF are installed on the side, and in
addition to enabling installation with standard GF connectors,
there are also DIN rail parts on the back.

More new models are in development!
Keep your eyes open for new models.
Do you need expert knowledge of electricity or controllers to introduce SiO?

No special knowledge or experience is required. Even
people making a program for the first time can use it easily.
Multiple Choice Simple Programming

You can use “SiO Programmer”, the dedicatedsoftware for Windows computers, to set output
conditions. Even first time users can easily makeprograms just by making the necessary choices. It
also has a simulator function, so it is possible tocheck operations even without an SiO Controller.

Just plug in for easy connection

We use the industry standard e-CON connector※,eliminating the need for difficult wiring work. SUS
also offers optional input/output devices with an
e-CON connector installed in advance. It makes
easy connection possible, so necessary devices canjust be plugged in.
※Options are necessary for SiO-C.

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Electric control, made easy with SiO!

FeatureEasily retrofitted on existing equipment!

Examples of simple kaizen using SiO

Here we use two examples to explain what small-scale, simple work-site improvements using SiO are like.
Changing combinations of devices and programs will bring all new possibilities.

ExampleAnnounce standard
working time witha lamp!

Time Over Alarm
This example uses the timer function of SiO
Controller to light up a lamp when a set
time elapses after pressing the switch. By
setting the timer with the standard work
time of product assembly, it is possible tocheck whether work is completed by thetarget time with just a glance.

Operation Image

ExampleCheck whether aworkpiece is stuckwith sensors!

Chuter Anomaly
Detection

A photoelectric sensor monitors whether
workpieces are flowing at regular intervals
on the chuter, and when there is ananomaly, it makes a warning by lighting
up the lamp. The user can quickly find anddeal with problems such as workpieces
getting stuck, even from distant locations.

Operation Image
IN1: Photoelectric
Sensor

OUT1: Lamp

OUT1: Lamp

Normal Operation
The lamp does notlight up if the flowof workpieces is notinterrupted, and can passregularly in front of thesensor.

Set Time
Elapsedhk wit
Chec （１）
eo!
a vid

（１）

Lit UpIN1: Switch

http://fa.sus.co.jp/jump/E01

Press the switch at the start of assembly work,and the worker’s movement starts counting time.
When the set time has elapsed, it is announced
by the lamp lighting up. When assembly iscompleted within the set time, pressing theswitch again before the lamp is lit resets thetimer, which starts counting again from 1.

Program Input

Worker Movements① Press the switch② Perform assembly③ Make a record when thelamp lights up midway

S i n c e i t （2）is possible toknow the number of times
that assembly could not
be done in standard time,
it is possible to grasp each
one’s proficiency level.

The photoelectric sensors mounted in the centerdetect the workpieces passing through the chuter.
（2）
h
k wit
Chec
!
o
e
id
v

http://fa.sus.co.jp/jump/E01（3）

When IN1 is OFF (switch not being pressed) for 5 seconds, the lamp will light up until IN1 turns ON (switch
is being pressed). The timer can be set in 0.1 second increments from 0.0 seconds to 300 seconds.
（4）

Abnormal Operation
If a workpiece getscaught on the way andthe sensor cannot detect
it for a set period oftime, the lamp lights
up to announce theabnormality.

There is no need to havesomeone monitoring theline at all times, as its
status can be watchedfrom afar.

（3）

Program Input

If IN1 is OFF (workpieces do not pass in front of the sensor) for 10 seconds, the lamp lights up until IN1turns ON again (workpieces pass in front of and are detected by the sensor).
（4）

On the next page we introduce how to use SiO by following process of abnormality detection in Example 2.

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Feature

Electric control,
made easy with SiO!

Considering movement
When something goes wrong in the workplace, we first think about how we can implement kaizen. If somethingcan be realized with simple electric motorization then SiO has a role to play. We consider necessary operations
specifically to envision the device’s movement.
Problem

Workpieces sometimes catch on the chutercausing it to stop
Preventing workpieces from getting stuck
Kaizen
Method 1 ⇒ Adjust the tilt of the chuter to the best angle.
⇒ Review workpiece materials including containers⇒ Change to a roller conveyor that is compatible
with the workpiece … and so on.

KaizenMake workpieces easily foundMethod 2 even if the device stops⇒ Make a mechanism to notify people
nearby when workpiece gets stuck

Operationthat needs
to berealized

This could beachieved withsimple electricmotorization!

If the workpiece does not arrive at a certain
point even after a set period of time, it turns
on the alarm lamp that needs to be realized.

Selecting Devices
Once the operation that needs to be realized is decided upon, select a device. It is convenient to have accessories
to bundle cables, in addition to input/output devices.

AC Adapter (C1P-401P)
Supply 24 V DC to SiO2.
There are also kit
products with SiO2.

Output Device: Lamp
(Red) (SUC-199)
Lights up to indicate
the status.

ration to
From consideperations
the start of o

See real examples!

Introduction to kaizen
using SiO
From here we will introduce procedures for performing actual kaizen with SiO Controller.
Take note of our points concerning utilization as well.
How to use SiO Controller
Considering Movement ··· Imagine the system movement based on points you wish to improve

Input Device: Photoelectric
Sensor Reflection Type
(SUC-195)
Detects workpieces byreflection of light.

Installation Parts
Used for installing
to GF.

Controller: SiO2
Capable of controlling up to 6 inputs
and 4 outputs with just one device.

There is one input/output device for each set, so control is possible with a single SiO2. Various devices are mounted
afterwards to the GF chuter of aluminum pipe structure material, so we also offer mounting parts specially designed for GF.

Utilize convenient input/output devices
In addition to those used for detecting abnormalities, SUS offers many options, such as input/output devices andextension cables that can be used immediately after purchase, as SiO series options. Inquire with an SUS sales
representative for details.

Selecting Devices········· ··· Select and prepare necessary input/output devices and options.
Installation and Wiring ··· Assembling the system, installing devices, and doing wiring.
Programming······················ Create output conditions with the dedicated software “SiO Programmer”.
Writing····························· ··· Connect a personal computer and SiO Controller with a cable and write
the program.

Executing···························· Turn ON the RUN switch of SiO Controller to activate the system.

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Photoelectric Sensor Transmission
Type (SUC-196)

Proximity Sensor (SUC-194)

Limit Switch (SUC-193)

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10

Feature

Installation and Wiring

Electric control,
made easy with SiO!

Programming

Mount the arranged items in the necessary places, and then wire them. In accordance with the image of the movement
you need to realize, decide where to install each device while considering where to take the power supply and what
length of cable is needed.

Installing various devices

Lamp (Output Device)

Photoelectric Sensor (input device)

Conditions for controlling input/output devices with SiO Controller are created with “SiO Programmer”, dedicated PC
software for Windows※. Programming can be done by merely choosing the necessary items from the choices in order,
so it is possible to learn it in a short time without expert knowledge.
※Check the details of the operating environment on our website etc.

What is SiO Programmer?

Tool Icon
You can compare
data, monitor
input/output, savefiles and so on.

It is multiple-choice software developed exclusively for SiO Controller.
Program Editing
Set the conditions
to turn the output
ON/OFF.

Install the lamp in a conspicuous position
that is easily visible to surrounding workers
as much as possible. When attaching to
GF, it is convenient to attach to Green
Frame L slot (GFF-004) first.

Attach a sensor for
detecting workpieces to
the guide of the chuter.
By attaching the sensor to
the green frame S SS slot
(GFF-401) beforehand, it
is possible to install withthe standard connector
and easily retrofit later.

Bundling Cables

Memo Input
This is the input/output memo
column. The contents recorded arereflected in the program, input/output
monitor, and simulator.

SiO2 (Controller)

Decide the controller installation
location by looking at thebalance of input/output device
positions and cable lengths.
Here we have used the green
frame DIN (GFF - 031), which is
a combination of DIN rail and
GF, at the feet of the chuter andinstalled SiO2.

Leaving the cables from each device
untouched may cause workpieces to getstuck or people to trip. These should all behandled properly, such as by fixing them tothe system with a cable lock (GFE-010).

Read & Write Button
This communicates with
SiO Controller to read
and write the settings.

Other Settings
You can set various
parameters.

Main functions of SiO Programmer

1 Program Editing……………………………… This function edits programs that write to SiO Controller.
Edited data can be saved and printed.

2 Input/Output Monitor…………………… By connecting SiO Controller and a personal computer,you can monitor the status of the input/output device.

3 Program Reading/Writing …………… Read the program registered in SiO Controller and write
a new program to SiO Controller.

Wiring4 Simulation………………………………………… Program operation can be checked on a PC without
connecting to SiO Controller.

You can also use
your existing devices
For those who wish to use their
existing input/output devices,
we also have an optional e-CON
connector as a single item. By
crimping the wiring of the input/
output device, it is possible to use
it with SiO2.
The e-CON connector is installed
to the cable end of the lamp
(SUC-199) and the photoelectric
sensor reflection type (SUC-195)
beforehand, so it is possible tocomplete the connection with
SiO2 by just inserting it.

Connecting
input devices

Try using SiO programmer for free!
To use SiO Programmer, download software from SUS's
website to install it on your computer and use it. It is free fordownload, so you can try program creation, simulation even
before purchasing SiO Controller.
For first-time users, we also sell convenient kits with software CD, USB
cable, AC adapter set.

Connecting
output devices

SiO2 starter kit (SIO-K09)
Input connector 4 pin (SUC - 212)

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Feature

The operation
to be realized

IN1: Photoelectric Sensor

Setting the DURATION TIME（UNTIL): Set the condition to turn off the lamp

OUT1: Lamp

Abnormality
Detection

Electric control,
made easy with SiO!

Workpiece Movement

If the workpiece does not
move for 10 seconds, thelamp lights up to notify
the surroundings of thisabnormality.
Workpieces are detectedwith photoelectric sensors.

Memo Input : Enter English notes so that the operation is easy to imagine

In case of abnormality detection, workpieces not
flowing is considered to be an abnormality andworkpieces flowing is considered normal, so sensors
are selected as DURATION TIME.

Setting the OUTPUT TYPE : Set how to turn on the lamp

Lamp is also
displayed in the
output type

(Lamp) wasreflected in OUT1

Lighting up
Flashing

Since there is nomemo input, it isdisplayed as OUT2

Lastly, choose how to light the lamp. If
it is not changed, "ON" will be enteredautomatically.
If you select "ONOFF ALT", it is possible
to not only turn on the lamp but also flash
the lamp.

Easy to adjust the flashing interval
by just entering numbers

Corresponds
to insertion
slot number

Input "Sensor" in IN1
and "Lamp" in OUT1

Settings are made so that workpieces flow and"OUT1 (lamp) turns OFF when IN1 (sensor) turns
ON."

Setting CONDITION1/CONDITION2 : Set the condition to light the lamp

T h e f l a s h i n g i n t e r v a l w h e n " ONOFF
ALT" is selected can be changed with"PARAMETER". Specify ON time and OFF
time between 0.2 seconds and 100
seconds, respectively.

[Completed Program]
Choose to click
OUT1

Select SENSOR
from the choices

Select OFF fromchoices

In abnormality detection, the only output device to be used is the lamp, so the program is completed with this.
If you use more than 2 output devices, repeat the same operation.

Select CONTINUES
from choices

Enter 10.0

Understand the content of the program in sentences

Select "OUTPUT" (OUT 1: Lamp) for which you want to set the condition and enter "CONDITION1". This time we want to turn on thelamp when the "CONDITION1" are met for a certain period of time (work did not flow for 10 seconds), so we select "CONTINUES" in the"CONDITION2" menu and enter 10 seconds.

There are more useful functions!

In addition to the "Timer Function" used for abnormality detection, SiO Programmer
also has a "Counter Function" that enables settings such as "Turn on the lamp after
10 workpieces pass".
Try different combinations for a variety of settings.

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Place the cursor on the output button and the setting contents in the program are displayed in sentences. Use this as a reference
when creating programs.

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Feature

Electric control,
made easy with SiO!

Writing

Simulation : Test the program on a PC
INPUT BOX

Input/Output Display Screen▼ It is possible to check the status of input/output, the elapsed seconds of thetimer, etc.

Connect SiO Controller and the PC on which SiO Programmer is installed with the USB
cable and register the created program in the controller.

Writing data on the controller
USB Connector
RUN Switch

Equivalent tothe controller
RUN switch

Click on the simulator icon in the upper right corner of the SiO Programmer
screen to display the "I/O DISPLAY SCREEN" and "INPUT BOX". Click the "RUN"
button in "INPUT BOX" to start the simulation. The simulator can be executedwithout connecting SiO Controller.

Whether the lamp lights up when the workpieces do not flow for 10 seconds
Click the RUN switch → the CONDITION2 items starts counting the elapsed seconds

Clicking the RUN
switch automaticallystarts counting

RUN shows ON
status in green,
OFF status in gray

After 10 seconds, the lamp turns ON and it stops counting

USB cable (SUC-121)

Insert the cable into the USB connectorof the controller and connect it to the PC.
When writing, keep the controller's RUN
switch to STOP.

Check input/output status on the monitor screen

Input/output status of various devices connected to the controller is checked. With the controller connected to the computer, clickon the input/output monitor icon in the upper right of the screen to start the monitor screen and monitor the input/output status.

Monitor Screen

Check the status of the controller's RUN switch

Check the status of the
input device
After 10seconds, checkthat the lamp
is litAfter 10seconds, thecount is reset

After the lamp is lit, the next workpiece flows in and the lamp is turned off.
In state 2) of CHECK 1, turn ON the sensor → Check that the lamp goes out

Click the sensor
button to turn it
ON

Checking output device andinternal output status

Checking sensor response

Check that the lamp
turns OFF

Do not turn on the lamp when workpieces flow within 10 seconds
Turn ON the sensor before 10 seconds have passed → Check that the count is reset

Click the sensor
button to turn it
ON

Check that thecount is reset to 0

Check whether the photoelectric sensor can detect the workpieces correctly. Herewe confirm that the "Sensor" part of the input check turns red (ON) when the hand isheld over the photoelectric sensor, and turns gray (OFF) in the absence of anything.

Check Lamp Operation

IN1: Photoelectric
SensorOUT 1: Lamp

Make sure that the sensor is turned OFF → The count is resumed

Cli ck the senso r
button again toturn it to the OFF
statusResume counting
from 1 when thesensor turns OFF

Double-click the "Lamp" button on the screen to turn the button green, forcing it into
the output state.

Movement on the simulator was checked.
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Feature

Electric control,
made easy with SiO!

Executing
When checking input/
output is completed,turn ON the controller's
RUN switch and operate
the system. Pleasecheck the status on
the monitor screen asnecessary. It will becomplete if it works asplanned.

Warn with lamp
when abnormality
occurste!

CompleSensor detects
movement of
workpieces

The controller will not
operate until the RUN
switch is turned ON.

Extra
FeatureExample1

Making additions and changes is easy
If you wish to announce anabnormality not only withthe lamp but
also with soundbecause thework site is large

Add a buzzer to output
device 2 (OUT2). Turn on thebuzzer in conjunction withthe lighting of the lamp to
broadly announce occurrenceof abnormalities.

Buzzer (SUC-206)

Program Input

Added the output condition of OUT2 so that the buzzer sounds under the same conditions as the lamp. By changing the numberof seconds of "CONDITION2", you can also shift the timing at which the lamp and buzzer turn ON.

Example2

If you wish to announce
that workpieces havearrived so that people do
not have to stay in theinspection process

The lamp (OUT1) isinstalled in a position
where the worker incharge can see it easily.

Move the sensor (IN1) that detects
workpieces from the middle ofthe shooter to the end (the arrival
position of workpieces)

Program Input

When IN1 is ON (workpieces arrive at the end of the shooter), the lamp will light up for 60 seconds.

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xamples ofIntroducing E cations Feature]
Kaizen [Appli

Potential forelectric karakuri
using SiO

Combining various electric parts with SiO makes it easy to interlock with sensors andcreate the movement that could not be achieved with only standard controllers.

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Feature

ExamplesElectric control,
made easy with SiO!

Program Input

Electric Stacking Unit
（１）

OUT1 : Power Unit (Ascend)
OUT2 : Power unit (Descend)

IN1 : Inflow Sensor（2）

IN3 : Discharge Sensor
IN2 : Middle Sensor

In the "Electric Stacking Unit", forward and backward movements of the power unit are regarded as different
outputs and assigned to outputs 1 and 2, respectively.
In addition, we use "internal output (FLAG)" to classify cases according to the position of the table, for lowering
the table.

Condition for OUT1 to turn ON (table rises) or OFF (stops rising)hk wit
Chec （3）
!
o
e
id
v

http://fa.sus.co.jp/jump/E01

This unit stacks the workpieces supplied to the table from the upper stage of the chuter in 2 levels,（4） and then discharges
them to the lower stage. Using the power unit slider type power, you can raise and lower the table without using humanhands, and can stack the flowing workpieces automatically. Because the position of the table is determined by the sensor, it
is possible to support workpieces of different weights with one unit.

Operation Image

ON condition"IN3 (discharge sensor) turns ON"

OFF condition"IN1 (Inflow Sensor) turns ON" ⇒ "Forward LS※ ON"

It moves within
the range of thelimit switch

After checking with the discharge sensor that the workpiece entered thelower stage, raise the table to the top.
Even if the empty table rises, the inflow sensor does not turn ON, but instead
stops when "Forward LS" that detects the limit of advancement turns ON.
※Therangeofmovementofthepowerunitslidertypeisdeterminedbythepositionofthelimitswitch(Forward
LS/Backward LS) attached to the main unit. Even though the "Continue to move forward" and "Continue to
moveforward"commandsareissuedfromSiOController,thesliderautomaticallystopsasitreachesitslimit.

Limit switch(Backward LS)
SliderLimit switch(Forward LS)

Condition for OUT2 to turn ON (Table descends) or OFF (Stops descending)
ON condition"IN1 (Inflow Sensor) ON" and "IN 2 (middle sensor) OFF"OFF condition "IN 2 (Middle Stage Sensor) turns ON"

Inflow Sensor

Once checked with the inflow sensor that the workpiece has flowed into the table at the top position,
lower the table to the middle stage sensor position.
ON condition "IN1 (inflow sensor) ON" and "IN2 (middle sensor) ON"

Middle Stage Sensor

OFF condition 3 seconds passed
When checking with the inflow sensor that the workpiece in the second stage has flowed into the table
at the middle position, lower the table to the position where the workpiece is discharged.
Descends for
3 seconds
with a timer

When the first workpieceflows into the table from theupper stage, the inflow sensor
detects (ON) the workpiece.

The table descends until
the middle stage sensor
turns ON.

When the inflow sensor detects
the second workpiece (ON) while
the middle stage sensor is ON, thetable descends for 3 seconds.

Utilization of virtual output (FLAG) for setting 2 or more conditions
SiO Programmer can only input up to 2 conditions for 1 output device. Use internal output (FLAG) when you
want to make slightly more complicated settings, such as using three or more conditions.

When lighting the lamp with 3 sensors turned on

Discharge Sensor

There is no change in the
output device just because
FLAG1 turns ON

Return to ①

When the discharge sensor
detects the workpiece, thetable will rise to the top andreturn to the initial state.

19

SUS Corporation

When it descends, the front side of thetable is pushed up by the frame andtilted automatically, and the workpieceis discharged to the lower stage.

When sensors 1 and 2 are turned ON, turn FLAG1 ON, and when sensor 3 isturned ON, the lamp is set to light up. Since FLAG1 is an output for recording thestate "Sensors 1 and 2 ON" inside the controller, the state of the output device
does not change even if it is turned ON.
If you want to check whether FLAG is being output correctly, use the simulation
screen and monitor screen. As with typical input/output, English memos can be
attached to internal output.

SUS Corporation20

Feature

Electric control,
made easy with SiO!

（2）

Opportunities grow for motorized karakuri!

Easy installation/Electric power assistance of speed start

Connect power units to SiO

Review of the features of the power unit

Here we introduce procedures to move electric parts using SiO Controller, with the subject of the power unit.
Connection can be done easily with an optional cable.

Items used for connecting power units and SiO Controller

Output cable for the
power unit (SUC-191)

AC Adapter (C1P-401P)

Movement which is
not in the pattern isconveniently produced by
the combination with SiO!

The output signal is sent from
SiO to the power unit.

Used for the power unit.

Power unit controller

Controller SiO2

Input cable for the
power unit (SUC-192)

Used for SiO2.

9 operation patterns are set in the
power unit beforehand, and it is possible
to operate immediately by simply
connecting the power supply and turningon the switch.

AC Adapter (C1P-401P)

We use an aluminum pipe
structural material GF-G (43mm type) frame for the body.
Installation is made easy withstandard connectors.

LS Stopper

LS Stopper
Limit Switch(Forward LS)

To adjust theoperating rangeof the rod, simply
loosen the screwof the limit switch
and slide it.

（3）

Limit Switch(Backward LS)

The rod moves back and forth,assisting movements such as"push", "lower" and "lift".

Rod Framehk wit
Chec （4）!
video

Operation Image

The output signal of the power
unit is sent to SiO.

http://fa.sus.co.jp/jump/E01

Switch Box (SUC-203)

Pressing the switch moves therod forward to its maximum
position. Push the switch
again with the rod fully
extended, and it retreats tothe initial position and stops.

Power Unit Body

IN1 : Forward LS

The operation to be realized

Driving power unit
with one point switch
Operation
Procedure

When using the standard
controller of the power
unit, operations requiring
2 switch boxes are
realized with 1 switch box.

IN2 : Backward LS

OUT1: Forward
movement of power unit
OUT2: Backward
movement of power unit

Program Input
IN3 : Switch box

When "Forward LS" is ON, "Switch" ON turns the rod back to "Backward LS" ON.
When "Backward LS" is ON, "Switch" ON turns the rod forward to "Forward LS" ON.

In the power unit, different forward and backward movements are considered to be different outputs, and forward
LS and backward LS are considered to be different inputs. This is also the case when using electric stopper.

How to connect cables

Condition for OUT1 to turn ON (rod forward), OFF (stop)

Condition for OUT2 ON (Rod goes backward), OFF (stop)

ON condition "IN2 (Forward LS) is ON" andON condition "IN1 (Forward LS) is ON" and"IN3 (Switch) is ON"
OFF condition "IN1 (Forward LS) turns ON"

Insert two branchcables into I1, I2Connect the "Power Unit Input Cable" to the "LS Signal
External Output Terminal" in the controller of the power
unit and insert the other end into the input terminal of
SiO Controller. Forward/Backward LS is IN1/IN2.

Insert 2 branch cables
into O1, O2Connect one end of the power unit input cable tothe switch connector of the controller and the otherend into the output terminal of SiO Controller. The
Forward/Backward command is OUT1/OUT2.

Turn on the switch when the rod is retracted to theshortest position to make the rod extend to the longest
position then stop.

New ProductIntroduction"IN3 (Switch) is ON"

OFF condition "IN2 (Backward LS) turns ON"
Turn on the switch when the rod is extended to thelongest position, to make the rod retract and stop at its
shortest position.

Convenient in combination with SiO "Power BOX PS 6-100"

SUS has released a power supply box which is convenient for power supply when using multiple AC adapterssuch as motorized karakuri!
Use it together with motorized parts and SiO Controller.

Feature 1 Output current is 4A
It can output up to 4A total with 6 circuits in one power supply box.
Even when using multiple motorized parts at once, it is possible torealize clean power wiring.
Feature 2 Emergency stop circuit is standard equipped for safety
Of the 6 ports, 4 have specifications that can shut off the power by
emergency stop.Combined with the optional emergency stop switchbox, it is possible to easily construct the emergency stop mechanism
required for the motorized karakuri device.

Connect the e-CON connector of theswitch box to I3 and connect the motor
cable of the power unit to the standard
controller.

21

SUS Corporation

Connect the power supply AC adapter
to the power unit and SiO Controller,
respectively. When using electric parts,
it is necessary to secure a power supply
separate from SiO controller.

Feature 3 Easy installation on GF frames
The same protrusions as the GF frame are on the bottom of the box,
and it can easily be installed with standard connectors. It is also
highly compatible with electric motorized karakuri.
SUS Corporation

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32 / 33 / 34

23

SUS Corporation

32

Honda Motor Co., Ltd.
Saitama Factory, Yorii Plant

25 ≫ 30

Bring the joy of building to the factory!
Going back to the start of manufacturing byfocusing on the challenge of “karakuri”

33

Murata Manufacturing Co., Ltd.
Yokaichi Plant

31 ≫ 36

A factory that continues to evolve by
actively scrapping and building
Pursuit of safety like nowhere else

34

Narita International Airport
Corporation

37 ≫ 42

Create an airport that is pleasing bothfor workers and passengers by giving
shape to their latent needs

SUS Corporation24

Production Site

32

Honda Motor Co., Ltd.
Saitama Factory, Yorii Plant

Bring the joy of building
to the factory!
Going back to the start ofmanufacturing byfocusing on the challengeof “karakuri”
The Saitama Factory, Yorii Plant is the newest factory of Honda Motor Co., Ltd. (hereafter “Honda”)
in Japan. In this factory, which is equipped with the latest equipment using Hondaʼs revolutionary
technology, work is gaining speed on “karakuri” (originally-devised tools) which could be seen as theexact opposite. In this article, we cover examples of karakuri that are active in the factory, as well as
thoughts on the monozukuri (manufacturing with a sense of craftsmanship) behind it.

Yorii Automobile Plant
Assembly Frame
Department
ManagerMr. Takanori Onoe

COMPANY DATA

Yorii Automobile Plant
Assembly Frame
Department
Staﬀ Engineer
Mr. Kenichi Kase

Yorii Automobile Plant
Assembly Frame
Department
Staﬀ Engineer
Mr. Takeharu Iwata

Yorii Automobile Plant
Assembly Frame
Department
Engineering Coordinator
Mr. Takuya Maenishihara

Honda Motor Co., Ltd. Saitama Factory, Yorii Plant
2354 Ohaza-tomita Yorii-machi Ohsato-gun Saitama-ken. 369-1216 Japan
http://www.honda.co.jp/

Yorii Automobile Plant
Assembly Frame
Department
Mr. Mitsuo Onda

Demonstration machines we presented at theK araku ri K aizen ® Innovation Exhibition arearranged in a corner of the plant so that they canbe visited at any time. This place was also used
for in-house presentation including practice.

Overcoming weaknesses found byexchange with other companies
Promoting the cultivation of humanresources through monozukuri

SUS Corporation

four models of compact cars, such as the Fit andthe Vezel. We have many state-of-the-art robots
and automatical machines in the plant, and we areproud of the high level of production technology.
However, as we have been interacting with various

It seems that Honda is starting to put emphasis on

manufacturers for about 2 years now, we have comekarakuri now.

to realize that the actual efforts at the Yorii Plant
are lacking compared to other companies in terms

Last autumn, the Yorii Plant was the ﬁrst Honda plantof kaizen (the process of constant improvement)

to appear at the Karakuri Kaizen

Innovation

activities, which are the essence of the manufacturing

Exhibition. The opportunities to work on karakuri

workplace. We felt a sense of crisis about our ideals

have only grown since then, but we started full-scale

for monozukuri at the work site fading away as we®

production at the Yorii Plant after deciding to appear

go continued our pursuit of improved efficiency.

at last year's exhibition. The Karakuri Kaizen ®

Therefore, we will introduce kaizen activities

Innovation Exhibition is an event that started in 1993

that employ karakuri that are operating at otherand has a well-known history, but there are many

companies in order to communicate to the younger

people in the company who do not even know it

generation the joy of building things, the feeling ofexists, and eﬀorts have just begun.

accomplishment and skills related to kaizen.

In our Suzuka and Kumamoto factories, although

It is our goal to solve problems in the workplace andthey did not participate in the exhibition, they

improve eﬃciency, of course but our primary goal isstarted introducing karakuri even before the Yorii

to lead human resource development and revitalize

Plant, and we frequently shared information on thethe workplace. Among such activities, we feel thatﬁrst challenge.

aluminum pipe structural material GF, which is easy
to assemble and can freely give shape to workers'

Why do “karakuri” now?

ideas, is a very attractive component. The karakuri
synchronous cart, our ﬁrst karakuri, was also madeThe Yorii Plant is Honda's newest domestic factory,

25

which started operation in July 2013, and producesof GF.

SUS Corporation

26

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32

▼Operation Mechanism

Presented karakuri at theexhibition for the ﬁrst time
Shared awareness, accelerated
kaizen① Reciprocating motion of the stand1

Force of the Overhead Conveyor

Special Award Winner at the
Karakuri Kaizen® Innovation

Overhead Conveyor

Balancer

Wire

Synchronizer

Stand

Stand

Exhibition!

What brought you to adopt SUS products?

"Karakuri Synchronous Cart" that
reduces time spent walking

Base
Force of the Balancer

The "Karakuri Synchronous Cart", which consists ofa stand to place parts on and a base which serves
as a rail, was exhibited by the Yorii Plant last year.

Synchronizer

By hooking the "synchronizer" attached to the standto the overhead conveyor, the movements of the

The stand is propelled forward by the force of theoverhead conveyor, and pushed backward by the forceof the balancer. Our problem was that there is only 3
meters of stroke with just the balancer, which does not
do the necessary work, but we solved the problem byextending this to 6 meters with a running block.

② Automatic synchronization releasestand and the vehicle are synchronized, making
parts easy to reach. After moving a certain distance,Standthe synchronizer automatically falls down, theIdler
Progressing
direction

Stand

Release stopper (immovable)※Fixed to the base

When the stand moves a certain distance, the releasebar ﬁxed to the stand hits the release stopper ﬁxed near
the end of the base, and the force is transmitted to thesynchronizer via the idler and the wire. Synchronization
is canceled when the synchronizer collapses anddisengages from the overhead conveyor.

vehicle and the workbench, and saves time that wasBase

how the factory looked. We also liked that they could
be reused instead of just becoming industrial waste.

Synchronizer② Wire is pulled
and synchronizer
collapses

Stand

Stand

Releasestopper
Realization of making
parts easy to reach
without pushing the cart

Base

Utilizing the force of the overhead conveyor, the base that advanced with thevehicle is released from synchronization when it reaches the end of the base, andreturns to its original position by the force of the balancer.

Near the synchronizer, a lift bar is installed for raising thecollapsed synchronizer. The roller rolls on the diagonalframe attached to the original position side of thebase, so that the lifting bar is pushed up, returning thesynchronizer to its initial state.

Number of reciprocations ofvehicle and workbench
Walking distanceWalking time

How did you start working on karakuri?

responsible for the process of assembling automobiles,
First, the main members visited various factories atcompanies, even a single workbench contained a lotof improvements and ideas of workers, and we wereshocked to discover viewpoints we had never seen
before. There were also many examples using GF.
After that, we started on actual production based onwhat we had learned. First we sketched on paper
and made a prediction that it will "move like this",but when we made it, it did not move that way at all.

▼ Eﬀect of introduction① The release bar of thestand hits the release
stopper of the basehave a vision.

as well as the culture and attitude of kaizen. At other

Frame installed diagonally on the original position side of the baseReleasebar

the fact that they could do something like this if they

other companies, and started from learning examples

Lift Bar
Roller③ Go backmoving, everyone at the workplace was impressed by

was the "Yorii Assembly Frame Department", which is

Returndirection▼ Karakuri synchronous cart movement

GF. Even before that, professional staff knew about
SUS products, but when they actually witnessed it

The ﬁrst department to make karakuri at the Yorii Plant③ Automatic synchronization

SUS Corporation

reason is its clean appearance. Since 8,000 visitors
come to the Yorii Plant annually, we were conscious ofwhen we began exploring ideas to utilize karakuri andRelease bar (movable)※Fixed to the standThis reduces the number of trips made between a27

from several manufacturers when setting up Yorii, it
was decided to introduce 400 GF workbenches. One

we asked them to introduce examples produced bysynchronization possible again.

Synchronized with theoverhead conveyor, thestand moves forward

Based on past experiences, as a result of consideration

the factory around the summer of 2015. It was a time

is pushed up while the stand is returning, making

previously spent walking.

Plant, and had a track record of using SUS products.

as part of karakuri is the exhibition held by the SUS in

Baseto the original position. The collapsed synchronizer

also has the Ogawa Plant and Sayama Automobile

One of the reasons for spreading to the workplace

SynchronizerStandsynchronization is released, and the stand returns

The Saitama Factory to which the Yorii Plant belongs

Because we did not know the strength, there was not

Before kaizen

After kaizen

3 times

Once

18.1m
11 seconds

8.4m
5.1 seconds※ per vehicle

enough reinforcement at the beginning, and it broke
down often. However, we quickly improved, and we
felt it was a valuable experience that allowed us toexperience the real pleasure of monozukuri.

SUS Corporation28

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32

What kinds of activities are currently going on?

workplace. Although it

is still just an ideal, we

The other day, eight people including members

want to gradually give

support staff who work between specialized areas

Please tell me again
about your motivation
moving forward.

shape to it.

who participated in the Karakuri Kaizen® Innovation
Exhibition, launched a "kaizen support" team. They are
How are the usability and reputation of GF?
We think that GF is a useful senes. Moreover, because
it is easy to handle, it also has the merit that even if
trouble occurs at the workplace, it can be maintainedby the operator. The reputation of the completed
karakuri is excellent.
Since we handle a
lot of heavy items as
an automobile plant,
each line worker raises
the question of how
durable it is against
heavy objects. We
think that the rangethat can be used
What is decorated on the bulletin
widens to a large
board is a monozukuri map that shows
extent if it can answer
areas which have benefited fromthat.
kaizen in the factory. There are colorcoded magnets on the ﬂoor plan of theAdditionally, it was
factory, such as "Synchronous Cart",
very convenient that
"Karakuri", and "Chuter". The number isgradually increasing.
it came not only as
the single product GF
but also as a set with the free 3D drawing software
UnitDesign. Currently we have about 5 members who
can use UnitDesign, but we plan to train more.

This group picture was taken at a presentation held at the company inadvance of the Karakuri Kaizen® Innovation Exhibition. Everyone involved,
from the factory chief down to young employees, came together in solidarity.

out with the sponsorship of the factory chief at thetime. Along with practicing for the main presentation,
the aim was to share the eﬀort with many members,
so it was ﬁlmed and broadcast within Honda.
Also, at the exhibition venue, there was the problem
of how to reproduce the atmosphere used at theworkplace in order to convey the eﬀect of the karakuri
in an clear manner. Therefore, we built a mechanism
to explain the movement of conveyors with GF. Thiswas produced not by the main members but by
younger workers, so many employees cooperated as
we approached the exhibition.
On that day, we were overwhelmed by the many
people who devised other companies' improvements,and started to feel uneasy, thinking "Is our idea too
simple?" However, after the opening, many visitors
came to our booth and listened closely to us, so we
had a great time despite the diﬃculties.
The core members of the exhibition came to be widely
recognized as "the karakuri crew" within the company,and have received many requests. Although it is noteasy to come up with good idea, they are working
hard together to come up with new solutions.

Please tell us what the challenge of Karakuri Kaizen®
Innovation Exhibition brought you?

In the beginning, we did not know what kind of event it
was, but the factory boosted everything along, and wewere motivated to ﬁnish. About two weeks before theexhibition, a preliminary presentation was also carried

2"Ninja House" active in prevention of parts being left unattachedlike production technology and the worksite, Althoughkaizen activities were carried out every day in thecompany, there was a problem. It was rather largely
dependent on the discretion of the individual, andwas not incorporated into a system. Regarding kaizen,
there were few opportunities to show oﬀ or to receive
evaluation even if we achieved results. Therefore, weare trying to rebuild a system that enables us to sharetechnologies and continuously improve, includingorganization creation.
One such measure is the "Monozukuri Room" whichstarted operation in April. In addition to being able tostock materials to create equipment for kaizen, we
hope to make it a place to enjoy fun ideas. For thatreason, in addition to exhibiting the basic mechanismsof the karakuri made with GF and trees, "Kaizen
Support" staff will be stationed and consultation will
be accepted. Basically, you cannot communicate
while concentrating on production. Gathering in the
Monozukuri Room and working on ideas with senior
and junior employees will also lead to revitalizing the3▶
Part 1

Push the door

This is a new karakuri made after the exhibition. Two doors are installed in front of the two types of parts placed on the workbench. The door on
the back will not open, unless the door in the front is pressed, preventing unattached parts from being left unattached.

29

SUS Corporation

In the Showa period(until the late 1980s), there was a corporate culture
where kaizen could be learned naturally in casualexchange at the manufacturing site. However, as
companies grow bigger and expand to the world,
efficiency is emphasized, and we feel that suchfundamentals have faded away.
Initiatives for karakuri should return to the origin of the
manufacturing industry. We have been rallying people
to the cry of “Letʼs do whatʼs obvious, and do it right,”
and slowly that circle has grown. Honda's corporate
philosophy shows the "three joys" that we pursue.
These are "the joy of buying" for customers, "the joyof selling" for sales staﬀ, and “the joy of making". We
would like to continue activities in the future withthe aim of creating an environment where members
working at the manufacturing site can feel "the joy ofmaking".

Quality improvement with careless mistake prevention! "Simple Shugoshin (Guardian)"
Progress directionof the conveyor▶
With no tools
With tools
Center tire
becomes locked

Lock oﬀ and advanceto the next vehicle

This hand-cart that does not advance after completing work unless the tool is put on it is a simpliﬁed version of the karakuri called "Shugoshin(Guardian)" which was shown at the exhibition. Furthermore, like the ninja house, a mechanism to prevent parts from being left uninstalled isincorporated in the upper part of the hand-cart. Production was handled by the line workers themselves.

Product ProﬁlePart 2The "Monozukuri Room". Although it
has just been installed, there are still
few users, but they hope to develop
monozukuri from here.

New and advanced. New Fit launched June 29th.

Supporting safe and comfortable driving witheight advanced functions. ＞＞＞
1. To avoid collisions

2. To avoid sudden

3. To stay aware of

4. To avoid roaddepartureaccelerationpedestrians
Collision Mitigation Brake
Unintended Start Prevention
Pedestrian Accident
System(CMBS)
Function(USPF)
Reduced Steering(PARS)

Road Departure
Mitigation System(RDMS)

7. To stay aware ofstarting traﬃc

8. To make sure you
donʼt miss anything

5. To keep fromgetting too close

Adaptive Cruise Control(ACC)

6. To avoid wobbling
Lane Keeping Assist
System(LKAS)

Leading Car Start Alerts(LCSA)

Road Sign Recognition
Function(RSRF)SUS Corporation30

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33

Murata Manufacturing Co., Ltd.
Yokaichi Plant

A factory that continues
to evolve
by actively scrapping andbuilding
Pursuit of safety likenowhere else
Yokaichi Plant supports factories both in Japan and overseas as a core base for supplying
raw materials and elements of Murata Manufacturing, a major electronic component
manufacturer. I asked employees of the Ceramics Production Department 1, Manufacturing
Division 2 which is responsible for the manufacture of ceramic elements, about the kaizen
activities of the factory and equipment they particularly give attention to.

Ceramics Production
Department 1
General Manager
Mr. Toshiyuki Ishibe

COMPANY DATA31SUS Corporation

Ceramics Production
Department 1
Manufacturing Division 2
Senior Manager
Mr. Kazuhiko Utsumi

Ceramics Production
Department 1
Manufacturing Division 2
ManagerMr. Satoshi Kitagishi

Ceramics Production
Department 1
Manufacturing Division 2
Mr. Hirotaka Okamoto

Murata Manufacturing Co., Ltd. Yokaichi Plant
4-1, Higashiokino 4-chome, Higashiomi-shi, Shiga-ken. 527-8558 Japan
http://www.murata.com/en-jp

GF cart (left) and SF cart (right) actually used in
the process. The GF cart in the photo is a partiallymodified version of the equipment which wasrequested to SUS to assembly for the first time,with a load capacity of 320kg.

Product adoption started fromSing
Design and assembly services thatsaved the company from its plight

Group, and about 50 years have passed since its

What role does the Yokaichi Plant play in Murata

market, we have gradually expanded its functions.

Manufacturing, which has sales, development, andHowever, since the factory's neighborhood is a

production bases throughout the world?

The Yokaichi Plant was opened in 1962,is that right?
It is a historical establishment among the Murata
opening. Along with the expansion of the electronics

residential area, we cannot expand the premises
to expand the facilities. Therefore, at the Yokaichi

Our company, an electronic parts manufacturer, has

Plant, we promote a process of scrap-and-build

105 sites in Japan and overseas, and our products

to rebuild aging buildings as necessary. When

are used in various products such as mobiletransferring a process that had been done in an oldphones, personal computers, home appliances, andbuilding to a new building, we are concentrating

automobiles. Murataʼs motto is “New electronicso that production can be made more efficiently,

devices begin with new electronic components; newinstead of just relocating or transferring as it is.

electronic components begin with new materials.” soWhen doing so, it is impossible to make the most

we put a strong emphasis on materials. The Yokaichiof the limited space on ready-made work desks andPlant manufactures ceramic materials as raw

shelves of ﬁxed sizes. Yet, if we use aluminum framesmaterials and ceramic elements which are sinteredthat can be customized in length, we can realize

raw materials and supplies them to domestic andthe equipment for each site, so we have used it asoverseas processing plants. It is located right in thematerial for kaizen.

center of our group companies which are dispersed
throughout the country, and it is in a convenient area

Please tell me more about the circumstances of SUS

just a few hours by car to a processing factory withproduct adoption in the Manufacturing Division 2.

a high supply ratio. In addition to playing a role as acore supply base for raw materials and elements, it

We knew that members of other departments wereis also a factory that makes ﬁnished products suchreading "Sing" in the Yokaichi Plant and thought

as noise removal ﬁlters and temperature sensors.

that we wanted to read it as well, so we started to

SUS Corporation32

Production Site33

request the information. At that time we were using

Currently, I hear that the adoption of aluminumcompany to do assembly, but we could not find aand replacing seals. Products we have designed

a square frame from another company, so we didpipe structural material GF is also increasing.

company that would meet the desired price. Thenand produced in the company must not injure ourthey told me "SUS offers assembling too", which

workers. Since the Yokaichi Plant handles especiallynot plan to adopt SUS products. As a matter of fact,
it was our stance that it was good enough to read

Originally, we were using only SF, but now GF is

led to placing a mass order. Since the work to beheavy objects within the Murata Group, we work

the pages of magazines, but the sales representative

becoming mainstream. We discovered GF in theloaded on the cart can reach up to several hundredon production with safety as the most importantof SUS came visiting with Sing and a catalog in hand.

venue of the SUS seminar held in December 2014.

kilograms, we originally planned to order a moreconcern in all our products, not only equipment. We

There is a specialized organization "Kaizen Group"

We liked the appeal of it being lightweight but

robust SF cart. However, we decided to use it as

think that it is important for employees who work inin charge of kaizen in the Manufacturing Division 2

having rigidity, and ﬁrst decided to make one shelf.

the main trolley because it was found that thethe factory to come to work healthy, and for us toto which we belong. Although we called ourselves

When assembling for the first time, we had a hardstrength of GF carts was greater than expected,

make sure they go home healthy after a dayʼs work.

a group, only Okamoto was aﬃliated with it at thattime with measurements and learning how to use thein addition to being much lighter and offering costtime, and he was doing everything from design

connector, but we were able to assemble it safely

beneﬁts. After introduction, it was easy to grasp the

Please tell me about efforts to conduct kaizen on

to picking up necessary materials, ordering, andwith support from the salesperson, so we realized

handle because of its round shape, and it was very

processes in the workplace, including Kaizen Groupassembling on his own. That's why, when a sales

the convenience of GF. The shelf was remodeled

lightweight and easy to handle even for women, so

activities.

representative from SUS learned of Okamotoʼsafterwards, but even now it is used in the workplace.

it has become popular on the work site.

incredible schedule, he made us a proposal saying, “If

The adoption of SUS products including GF further

The Kaizen Group was launched in Manufacturing

you can draw a sketch, then we can do the design”,

advanced afterwards when the Kaizen Group had

Division 2 as an organization responsible mainly forso we started requesting SF carts. The square framea big project and was busy. Despite having been

is a familiar shape as it was used conventionally, andbusy with the production of working desks, 70

it is compatible with conventional products. In thismore carts were needed. We decided that the task

way, adoption of SUS products has started.

was beyond our capacity, decided to ask a partner

Examples of use that demonstrate
the Kaizen Groupʼs skill

1

SF dangerous goods repository 18 L can turn table
Conventionally, it was necessary to lift and tilt when transferring
contents, which was a heavy burden on workers. In order to ﬁx this,we created a dedicated storage area.

made by workers and members who were goodat equipment production, but in order to ensure
safety, we decided to form a group of memberswith professional skills. The job is mainly to improve

When producing equipment, please tell us points

the efficiency of the workplace related to process

you are improving or focusing on.

consolidation. Apart from the Kaizen Group that

We are dedicated to making equipment that isWhen using it, ﬁrst
pull it forward.
Then stop it witha stopper, and ﬁx
it at that position.

As you rotate
90 degrees, you
can pour as it isbecause the spout
is in front. Thenjust return it withthe same process
and you are done.

SUS Corporation

kaizen. Traditionally, workbenches and carts wereexists only in Manufacturing Division 2, Murata

Rotate the frameon the fixed baseto the right.

33

Thorough pursuit of safety!
Equipment designed with the user
ﬁrst in mind

Manufacturing as a whole, there is also an in-housesafer than anywhere else. For example, carefully

qualification called "Kaizen Professional" whichcalculating strength in detail such as loadqualifies the skills of and selects employees withcapacity, always attaching end covers, and if itpractical kaizen achievements. This system began

is a cart, a structure that does not overturn. We

in order to share the achievements of each factoryalso manufacture the size accurately so as not tothroughout the company and enhance synergistic

remove 1 mm from the speciﬁed dimensions. Wheneffects. We hold study sessions as part of "Kaizen

installing shelves and other fixtures, we always

Professional Activities" that nurture members who

implement earthquake resistance measures, and all

are good at kaizen. Kaizen Professionals are learning

improvements are introduced only after thoroughthe skills necessary for reviewing the site from all

review and safety conﬁrmation by the Kaizen Group.

aspects of safety, quality and efficiency, such as

Furthermore, we regularly inspect carts in use

expert knowledge such as work design and points

About MURATA Cheerleaders' technologies
This robot was developed to introduce the company's superior products and high technicalcapabilities in an easy-to-understand manner. It maintains an exquisite balance with a gyro
sensor measuring the tilt of its body, so it always appears to be on the verge of collapsing
but never does. It also learns its position in relation to its surroundings with an ultrasonicmicrophone and infrared sensor in real time, realizing strong team work so that it always looks
like it will collide but never does. In addition, it is equipped with many products of the company
which are used in various situations such as communication modules, capacitors, inductors, etc.

SUS Corporation34

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33

of view for improving occupancy rates. Okamoto is
concurrently in charge of a kaizen group and serves

employees, we cannot cover them with the kaizen

be held at the Yokaichi Plant is not so far oﬀ. Goinggroup alone. In order to raise the skills of the wholeforward, we aim to create a better workplace fromcompany, we would like to have an assembling

various aspects such as process consolidation

workshop organized by SUS held. In addition, thethrough aggressive scrap and build, realization of

karakuri technology exchange events where kaizen

new kaizen ideas born by deepening knowledge ofpros gather will continue, and the day that it will

SUS products, and unchanging pursuit of safety.

as a kaizen professional for the Manufacturing
Division 2. Inside each process there are also
small group activities that are mainly conducted byworkers, so if we want to improve efficiency, we
make use of the skills of expert kaizen professionals
and realize quality improvement in the workplace.

The Kaizen Group's workplace, where they have designed andassembled many pieces of high-quality equipment. On the wall, acertificate awarded by the director of the plant acknowledges thisachievement.

At the end of April this year, you held the first

Please tell us what you would like to change in the

karakuri technology exchange event gathering

future, or want to put your strength in the future.

Examples of use that demonstrate
the Kaizen Groupʼs skill

Material storage shelf and partition realized by collaboration between GF and AZ
Since it is diﬃcult to adjust hanging sliding doors with an opening of 1 meter or more, it is a project with few deliveries in SUS. However,with the reliable adjustment technology of the kaizen group, the hanging sliding door which opens and closes smoothly was completed
despite having an opening of 2 meters.
Hanging sliding
doors with an
opening of 2 m
supported byupper and lower
frames.

kaizen professionals from across Japan, didnʼt you?
Since we introduced equipment after repeatedly
It was held at the Okayama Murata Manufacturing

examining the specifications many times, and weCo., Ltd., the most advanced factory in Murata

are continually reﬁning them day by day to meet the

Manufacturing, where the concept of Karakuri has

needs of workers, we believe that our workplaces

not penetrated far yet.* Many Karakuri units andhave improved relatively at the present moment.

parts using SUS products were exhibited and it was

However, as the distance traveled shrinks, the leada good opportunity to be inspired by how to use thetime will be shorter and the utilization rate will

parts. Among the exhibits, a lot of interest was given

be improved, so we will continue to consolidate

to a cart equipped with a mechanism that lifts items

our working space in the future. In that case, it iswith just a light force. However, as we reported,meaningless if workability gets worse. The most

we are dedicated to safety more than anything atimportant thing is the equipment made with the user

the time of equipment production, so we introduce

in mind. As one way to create a site that is reallydevices to the process having first confirmed thatconvenient for workers and improves work eﬃciency,

they are safe and unchanged no matter how many

we will positively consider karakuri kaizen in thetimes we use them. Karakuri seems to have a slight

future.

artistic aspect as well. It is diﬃcult to support withCurrently, there are more and more departments

technical data, and there is still unease because

adopting equipment that uses SUS products in thethere are many parts related in a complex way.

Yokaichi Plant. For that reason, many questions

For that reason, we hope that we will enrich theare being posed by various departments to thetechnical data that is increasingly posted in catalogs

kaizen group which has long been handlingso that we can calculate all the numerical values

aluminum frames, such as how to assemble them.

even when we use them in various ways for various

The guidance given will be further developed by

movements.

members who return to their department, but since

2

InsideAdjusted bygrinding downa part of thepulley unit kit
installed inside.
The inside of thepartition is used asa shelf for material
storage.

Front

Anchors are driven as
earthquake resistancemeasures. It is also
possible to remove it
when moving storage
shelves and partitions.

Opening 2 meters

Left Side

Right SideGF

the types of parts are diverse and there are many

In order to carry in andout material from theback shutter, casters
were attached to all thefoot suspensions, making
it movable.

※In Vol. 34 of Sing
（Japanese version
only）, we will discuss kaizen cases
and karakuri of the Okayama
Murata Manufacturing.

From our dedication tosafety, all carts are ﬁtted
with stoppers to prevent
movement, including
ready-made products.

35

SUS Corporation

AZ

In order to secure a passage
for visitors, we produced
the partition, which waspreviously made from plastic
corrugated cardboard, with
GF and AZ using aluminumcomposite board. Because
it is lightweight, looks good,and has a sense of unity, it ishighly appreciated by otherdepartments and people inother processes.

SUS Corporation36

Production Site

34

Narita International Airport
Corporation

Create an airportthat is pleasing both forworkers and passengers
by giving shape to theirlatent needs
Narita International Airport has as many as 39 million passengers annually as the number one
gateway to Japan's skies, with more than 600 aircrafts on average arriving and departing per day.
And gradually from last year, adoption of SUS products has begun in that airport. We listened totheir environmental kaizen tailored to their needs, which are being promoted while taking advantageof the high versatility unique to aluminum frames.

COMPANY DATA37

SUS Corporation

Marketing Division
Passenger Terminal
Management
Department
Property Marketing 1
Senior Manager
Mr. Tatsuya Saito

Marketing Division
Passenger Terminal
Management
Department
Passenger Services
ManagerMr. Toshihiko Saito

designed to ﬁt the place it is installed.

We want to solve passengerʼs
problems!
Challenging newly started
equipment

open, organize, and repack overweight suitcaseson the floor of the departure lobby of the airport.
Doing this on the floor is not only a burden onthat customer, but also hinders the flow line forother passengers, so we thought "we have to dosomething about this!"

I was surprised to hear that you are using SUS
aluminum frames at Narita Airport.

Please tell me about the ﬂow to delivery.

What made you choose SUS?
At the beginning, we handed out photographs of※In the text, when referring to Narita International Airport Corporation, we use “NAA”, and when referring to the airport
itself we use “Narita Airport”.

Marketing Division
Passenger Terminal
Management
Department
Passenger Services
Senior Manager
Mr. Takao Aoyama

The packing table of Terminal 1. The table isMarketing Division
Passenger Terminal
Management
Department
Property Marketing 1
Mr. Takeshi Tsubota

Narita International Airport Corporation
NAA-Bldg., Narita International Airport, Narita-City, Chiba-ken 282-8601, Japan
http://www.narita-airport.jp

Actually, we first knew SUS products not by theexamples used at overseas airports to convey thealuminum frame, but by smoking booths. When

image. NAA requests how they want the size andconsidering how to practice kaizen in the smoking

materials, and the detailed design and production

areas installed at Narita airport, it happened thatare left to SUS. First of all, we had them make a

the smoking booth of SUS really caught our eye.

half size prototype based on this request, and while

We liked the stylish look, and we wanted to heardiscussing this with people involved, we approached

the details, so we visited a showroom in Nihonbashi

the finished product. It is good that it was easier

Kodenmacho, Chuo-ku, Tokyo. For the ﬁrst time, we

to give a concrete opinion because images canlearned that SUS is a company that makes various

be shared if there is an actual product. We were

proposals using aluminum. We were also very

particular about not only ease of use, but safety as

interested in the karakuri lined up in the showroom.

well. Since people of a wide age range from many

We naturally decided to consult with them aboutcountries come to Narita Airport, we took care to

packing tables, which were the ﬁrst items delivered,avoid injury in case of emergency, such as attachingas to whether it could be used to solve some

R shapes at the corners.

problems we had at the airport at the time.

A total of 10 packing tables were installed and used

The packing table is a work bench for organizingin the first and second terminals of Narita Airport

and repacking luggage. Due to strict restrictions on

at the end of May 2016. A weighing scale was also

imported goods and checked baggage items in the

installed next to the table, so customers can checkaircraft in recent years, we have seen customers

the weight of luggage themselves, then reorganize

SUS Corporation

38

Production Site34

the conditions, so we did not know who to ask.

proposal that suited our demands by finding out

Although we tried talking to a small factory, ourwhat our problem is and engineering and producing

cost and safety needs were not met, so we madethe ﬁnal equipment completely in house.

no progress. Then, we happened to learn about
SUS by chance, and we decided to ask them, but at▼ Before installation

the beginning we only half believed that they coulddeliver what we wanted. However, as prototypes
were ﬁnished that ﬁt what we actually talked about,our trust increased gradually and we felt that we
could trust them more, until they finally produced
something that satisﬁed our demands.

▼ After installation

SUS has various materials such as aluminum
structural material SF and aluminum pipe structural
material GF, and they have the technology toengineer and design necessary equipment by
combining these. We also think itʼs great that they
have the ability to draw out the customerʼs request.
We felt like they were able to quickly make a

Realize the core needs ofthe airport with the power ofaluminum

Packing area set in the departure lobby of Terminal 2. The framework of the table was made of SF, and stainlesssteel was used for the top plate. A weighing scale that ﬁts the design of the table is lined up in the back.

was answered that ﬂexible proposal using aluminum
frame was possible, and it was surprising that theoriginal cart was actually finished reasonably andmore quickly than we imagined. As for carts fortape stations, as well as packing tables, we got

Besides the packing table, it seems that you haveprototypes first, the intent of this was reflected

and repack their luggage before heading to boarding.

are aboard an aircraft and "people of airline staff",

consulted regarding equipment that you never haveproperly, and the examination after that went

Because this facility was not available in the past, we

but various requests come from each of them fromused before.

smoothly.

renamed the installation place as the "Packing Area"

day to day. We regularly hold meetings with theand posted signs. This eﬀort has attracted attention

airline companies, and with the aim to create a

The second is a special cart that stores and

How was the completed cart for theinside the company, such as being featured in the

comfortable airport, we are engaged in varioustransports tape stanchion. A tape stanchion is atape stanchions?

“Green Port Report”, NAA's publicity magazine which

discussions not limited to just equipment.

pole that separates a row of people, etc. At Narita

provides information on Narita Airport, as well as

In fact, we were considering selection of packing

airport, it is mainly used around check-in counters

The cart is mainly used by female staff of airline

aviation, travel and the transportation industry.

tables before consulting with SUS, and because wewhere boarding procedures are carried out. When

companies. So, when we showed it to the airline

wanted to make them easy to use and safer forthey are not being used, they are put together on thecompany at the prototype stage to get their opinion,customers, we were planning to have them custom

back of the counter, and how to arrange and store

we were impressed that it was very well received

Under what kind of circumstances is equipment
such as packing tables selected and introduced?

made. However, normally when we introduce

these tape stanchions was a challenge. Furthermore,

and we even got smiles. We are very pleased withnew equipment, we do it not with the idea ofsince each one is heavy and bulky, not only do they

the carts now in service.

"making", but “buying" ready-made items that match

take a lot of time and eﬀort to carry, but there is also

What we, NAA requested was that it be as easy

or improvements to large facilities such as buildings

the problem that if you drag them, they will scratch

to use as possible for people who are not very

are advanced in a long-term plan. In the background,

the ﬂoor. There are cases in foreign airports of using

strong, to give the cart a small turning radius, andthere are judgments that consider future demand

specialized carts to carry tape stanchions, so wefurthermore to finish it compactly while increasing

prospects, trends in the airline industry, the service

had an image of what kind of thing we would likethe number of tape stanchions that can be stored

life of the facility, etc., and we respond with ato make, but what we did not understand is how toin one unit. Since there are two types of tape

give it shape. Because the packing tables which we

stanchions used at Narita airport, one which can bewere working at the same time had already earned

stacked and one which cannot be stacked, we asked

New development, updates, and repairs, and kaizen

special organization called the Facility Maintenance
Department. Yet, equipment such as packing tables
is often introduced because of opinions from users.
Users of airports can be roughly divided into two
categories in the form of "general passengers" who39

A GF cart for three-seat bench which is used in airport lobbies
frequently. Although it is still a prototype, it is easy for one person
to carry a bench weighing dozens of kilograms, which reduces loads
such as when changing or cleaning seat surfaces, or changing layouts.

SUS Corporation

A prototype of
the weighing scaledelivered just before
the interview. It isbased on a readymade scale that was
originally in use.

a good reputation, we also decided to consult withfor proposal for two types of carts with different

SUS on these carts.

shapes. We were impressed that they not only

When we informed the salesperson of the request, it

included ideas such as ease of use when pushing

SUS Corporation40

Production Site34

to make this as neat as possible. Although it is still

We intend to keep working actively in the future tounder consideration, we may also consult with SUS

improve the degree of satisfaction so that customers

following this.

coming to the airport can use it without stress,

Actually, the other day, when we were giving tours toand to create an environment where staﬀ of airline

representatives from another airport, the cart for thecompanies can work just a bit more eﬃciently andtape stanchions caught their eye and they started

eﬀortlessly.

talking about it, saying they wanted something likethat. Since there are many common issues among
airports, the equipment we ordered SUS is also
appealing to other companies in the same industry.
What we were not expecting was that we received
an opinion from a prefectural governor who saw
the packing table in NAA's publicity magazine andSince the stacking style tape stanchions are slightly inclined bystacking them, a frame for supporting the column is attached, so thatit does not collapse even if it shakes.

remarked "This is nice." We felt that there are still alot of users that cannot imagine how to solve theirproblems despite being in trouble, and latent needs
that users themselves have not noticed. We think

What do you think about aluminum as amaterial and SUS products?

that we can dig into these needs and give shape tothem.

By partitioning the garage with a GF fence, it became possible to keep
clean the rental wheelchairs which were prone to getting cluttered.

There is a rule that the equipment in an airport must
be incombustible. Aluminum is a metal, so it can besaid that it is a very suitable material in that respect.
Also, especially for carts, the light weight was amajor beneﬁt.
SUS is a company that has developed products
according to the needs of the factory, so it is good tohave a wealth of materials such as aluminum frames
and parts. We got the impression that items that

The fence for the wheelchair space uses
a hinge connector at the corner, and its
speciﬁcations enable it to open and expand
the space.

can satisfy our request are available in a standard
A GF cart that is used in the departure lobby (South Wing) of the
Terminal 1. It can hold up to 20 stacking style tape stanchions thatcan store the base part in layers.

product line. After the packing table and the tapestanchion cart, we are also asking of a rail for thewheelchair space, and we think that such flexible

the cart but also ideas that we did not notice, suchas ease of use when loading tape stanchions andsecuring safety. We felt like SUS carefully consideredeverything after listening to our requests, including
what our troubles were and what we wanted. As aresult, they made a cart that was easy for Japanesepeople use, quite diﬀerent from the foreign carts we
had referenced at ﬁrst.
Furthermore, not only were we able to introduce
what we really wanted, but by using the SUS
aluminum frames and the proposal that combinesthem, we found that we can realize the needs we
had given up on relatively easily, and this awarenessalso was very fruitful. Today, a positive atmosphereis being created in which we actively tackle tasks
that we did not know how to do in the past.

41

SUS Corporation

For tape stanchions that cannot be stacked, we
produced carts with height diﬀerences on the table onwhich the bases of the tape stanchions are placed. By
staggering, we can store 10 in 1.

support is unique to SUS.
What kind of kaizen can be done in the future?
Airport facilities and services evolve with the times,
and we think that this will continue in the future. If
the major parts such as facilities like buildings andthe whole airport system change, the necessary
facilities will also change and we will receive avariety of opinions from our users, so our kaizen will
never be over.
What we are thinking now is organizing aroundcheck-in counters. Currently various guidance items
and ﬁxtures are lined up around the counter, whichleaves the impression that there is no sense ofunity. From now on, we are going to discuss things

SUS Corporation

42