No.38

SUS FA MAGAZINEThe Innovator of Aluminum38

2018 August No.38

SUS Corporation
Head office

Featured article

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

Making the
Production
Site More
Comfortable
Through
Electric
Automation

International Sales
TEL : +81-54-202-0810 FAX:+81-54-202-0807

USA
SUS America, Inc.
1822 Brummel Avenue, 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

VietnamStandard Units Supply (Vietnam) Co., Ltd.
Workshop X6, Hai Thanh leasing workshop area, Hai Thanh
Ward, Duong Kinh Dist., Hai Phong Vietnam
TEL : +84-313-632 403 ~ 404

Philippines
Standard Units Supply Philippines Corporation
Building R1-D Lot 13 Phase 1B, First Philippine Industrial Park
Special Economic Zone, Tanauan City 4232, Batangas Province
Philippines
TEL : +63-43-430-0290 ~ 0299

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

1902-2,000

SUS Corporation

40

CONTENTS

38

SUS FA MAGAZINE
2018 August

3 Featured article“Making the Production
Site More
Comfortable ThroughElectric Automation”

5 Concepts for Electric Parts
and Modules

A multi-directional
approach to
improvement

reason, SUS Corporation emphasizes a "simplicity"mass production. Therefore, in the future we willthat can be managed without expert knowledge ofdevelop and provide more universal units andcontrols. By using this together with GF, we havemore customization. In addition, when dealing

been promoting the development of electric parts

with multiple electric parts, we will continue to de-and controllers that can easily achieve the desired

velop "SiO Controllers" which are commercialized

movements. Recently, we have also started selling

control devices that operate more simply and inex-

Yasuo Ishida,"Electric Modules" that turn typical Karakuri move-pensively than a PLC. We also plan to launch aments into packages that utilize electric products.

type of controller that can achieve group control,

SUS Corporation

The idea behind this is that there are many com-linking multiple SiO Controllers. As we actively

Aluminum Pipe Structural Material GF is highly

mon tasks and actions even across diﬀerent indus-

seek out the opinions of our customers, we also

tries and products, and that the labor and time

seek to continue expanding the product lineups

required for improvement can be reduced by stan-required by the production site.

Representative Director ofvalued as a material that can tackle production site
improvements without having to spend too muchin time and money. Due to its high degree of freedom and expandability, its conﬁguration can

7 Expanding variety inelectric automation

change into the equipment and devices that people

9 Let's Combine Parts and Modules

where its implementation increases, GF is expected

11 Supporting improvementswith a wide range of movements
and mechanisms
13 Application Examples Linked
with SiO Part 1
15 Application Examples Linked
with SiO Part 2
17 Production Site INNOVATION

Fukui Murata
Manufacturing Co., Ltd.
SHIMA SEIKI MFG., LTD.

imagine using. And as the number of situations
to fulﬁl a variety of demands. The electric items
introduced in this featured article are products that
we have developed based on our customers' input.
Today, markets for items such as machine tools
and semiconductor manufacturing equipment areexperiencing an unprecedented boom, and incom-

dardizing this section. Fine adjustment and assembly are not required with these electricplug-and-play modules, so we sincerely hope thatthey can become a new option for making im-"Karakuri," a word coined in 17th century

What isKarakuri?

ducted and prototypes can be made by combining
these parts and modules (and speciﬁcations adjusted for each unit), these parts are not suitable forthe "Karakuri puppet" ‒ a doll which utilizes
move. "Karakuri Kaizen" is a movement

Currently, electric parts and modules are not indiparatuses. While a variety of studies can be con-cal devices. The most common example isthe principles of gravity, gears, and levers toprovements.
vidual devices, but are only one part of larger ap-

Japan, is a term used to describe mechani-

which is gaining ground in the Japanese
automotive industry. It aims to utilize the principles of Karakuri to make
improvements to the production site without the need for electricity.
Real-life factory workers are working together to create "Karakuri" mechanisms that improve production eﬃciency and create worker-friendly
stations at minimal cost.
Karakuri Kaizen is a registered trademark of the Japan Institute of Plant Maintenance (JIPM).

ing orders for the entire manufacturing industry
are likewise expanding. Therefore, labor shortages
have become a major problem. While demand forautomation and labor saving are rising, production
cannot be shut down and of course the time thatcan be spared on improvements is limited. For that

PIONEER CORPORATIONKAWAGOE PLANT

This booklet is based on what abridged edition of FA
Magazine ”Sing” originally issued in Japan in Aug. 2018.

1

SUS Corporation

SUS Corporation2

L it tl e e l e c t rifi c ati o n

me

an

sm
or
ee
f fic

ienc yMaking the Production Site More
Comfortable through Electric Automation
We would like to expand our lineup of electric automation and karakuri mechanisms.
These can be used in diﬀerent ways according to each situationʼ s needs to reduce thelabor and time required to make improvements. They can also support the constructionof simpler and more multi-functional equipment. Even now, we are expanding our lineup
of electric initiatives born from this desire. Wouldnʼ t you like to try exploring the possibilities that electric automation oﬀers in helping to create a more comfortable workplace?

3

SUS Corporation

SUS Corporation

4

Making improvement activities "smooth" and “easy”!

Concepts for Electric Parts and Modules"Karakuri" that factory workers create on their own using their combined knowledge. SUS’s Electric Parts/Modules development was started as an extension of this concept. Our main focus is to make sure it’ s"easy to do" and accessible to "anyone." Some of the features are introduced here.

01

Totes and items used on-site vary in size and weight. Unlike simple automation karakuri using parts
such as springs, etc., electric units have an advantage: they can handle totes of different weights. Furthermore, our karakuri electric module packages are equipped with functions to adjust the size according to the totes.

Providing the "mechanism" and "controller" together in one package

Turn thewrenchWhen handling driving devices such as actuators and motors, control is an obstacle. SUS delivers integrated and customized controllers as a set starting with our Power Unit, the first GF Electric Part. These
units are designed to be intuitive, so you can operate one even if you don’ t have any expertise in electricity or control.

Width changes【Controller】【Mechanism】

Dedicated controller
included standard

S u p p o r t i n g K a ra k u r i w i t hsimple movements thatinvolve the extension andretraction of a rod at one end

The operating range of the rod
can be changed simply by shifting the position of the Limit
Switch. No electrical knowledge
is required

Select your desired motion
from a list of pre-registeredoperating modes＋
Example: Power Unit (Rod Type)If the motions are simple, no programming is necessary.
Just connect to a power supply and switch; you can start using it right away.

02

03

One machine supports a variety of situations

Achieving the desired motion
with a simple combination of parts and modules
In order to accommodate a variety of situations we offer various electric parts with different payloads,
strokes and drive methods. We also offer a lineup of modules packaged as "90 Degree Turn," "Flip-flop,"
etc. These modules allow you to concentrate on making improvements by reducing design and labor,
and by allowing you to achieve your goals through a simple combination of functions.

【Electric Parts】【Electric Module】

Electric Stopper

Stop at a determined stroke

Electric 90°Turn TableNo need for fine adjustment.
Just attach the module andthe turning mechanism is ready to use.

T h e fl a g s h i p e l e c t r i c
module, an electric
Flip-flop Chuter including adrive or Power Unit, stand,and more, is ready for
immediate use.

04
05

The table width can be changed according to
the tote size making detailed designs
unnecessary.

Simply fasten
with a standard
connector

Easily connect to GF
Ease of installation is also an important point in thedevelopment of various electric mechanisms. Fittedwith the same profiles as Aluminum Pipe Structural
Material GF, these products are designed so that you
can clearly imagine how to implement them.

Compatible with more advanced uses!
To make step-by-step improvements possible, SiO Controllers come into play as control devices withsimple inputs and outputs! Parts and modules that move individually can be linked together with sensors and other devices. Our SiO Controllers can be configured by choosing from a multiple-choice menu
in English, requiring no programming or control expertise. With SiO, the focus is on making the devices
easy for users of all levels.

Conveyor has
six operating modes

With input from a sensor or switch,
you can detect an object anddetermine the movements of the conveyor.

＋
Connect

Electric WinchLong stroke lifting bywinding the wire

GF Conveyor＋

Photoelectric Sensor (Reflective Type)＋SiO Controller

5

SUS Corporation

Since the base is made from GF, you canquickly install the mechanism at therequired location using standard connectors.

Limit Switch

SUS Corporation

6

Selection + combination according to fit the application

Expanding variety in electric automation

We have been developing these products one after another since we began making electric karakuri in2012. Choose products according to their size, power, and application.

Electric Parts

GF Conveyor

Turn

Lifting-up andLowering-down
Unit

NEW

Compatible withlong strokes
using a rack &pinion system.

Inter-pulley pitch : 500mm to 2,000mm
Payload : Up to 30kg
P.9
Maximum speed : 350mm/sec

NEWSlider Type

Horizontal

The sliding portion has
the same notched profile
as a GF-N frame.

Stroke : 180/280/380/480/580mm
Payload : 42L Vertical: Up to 5kg
Horizontal : Up to 10kg
50L Vertical : Up to 6kg
Horizontal : Up to 12kg
Maximum speed : 42L 50mm/sec
50L 100mm/sec

Stroke : 1,000mm
Payload : High Speed Type : Up to 3kg
Low Speed Type : Up to 15kg
Maximum Speed : High Speed Type :200mm/sec
Low Speed Type :
40mm/sec

Corresponding tote or box

Vertical movement
is achieved bywinding andunwinding the wire.
Horizontal
movement can also
be supported byusing a counterweight.

Compatible tote or box

P.10

MAX size : W517mm × D670mm
Weight : Up to 20kg
P.9

Unmanned totes can be transported at a
uniform pitch, including up a gentle slope.

Incremental Conveyor NEW
Corresponding tote or box

MAX size : Length: 1,025mm
Weight : Up to 100kg *When not subjected to frictional
P.11

resistance on a roller conveyor(horizontal)

P.12

Control and Power Supply

Rod Type

Stroke : 100/200/300mm
Payload : High Speed Type Vertical: up to 1kg
Horizontal : up to 2kg
Low Speed Type Vertical : up to 5kg
Horizontal : up to 10kg
Maximum Speed : High Speed Type : 200mm/sec
Low Speed Type : 50mm/sec

Released in late August, 2018

SiO Controller

Power Supply Box / Power Supply Unit NEW

An input/output control device that issues an
ON/OFF command to the output device based on
the ON/OFF status of the input device. Use it when
you want to link multiple electric mechanisms
together, such as a stopper and a starter roller.

The Power Supply Box can output a total current of up to 4 A for six circuits. In addition, four out of
the six ports with circuits are designed to shut off with an emergency stop, making for asafety-conscious configuration. The Power Supply Unit is also equipped with 6 output ports capableof supporting multiple devices with a single unit. You can choose your required capacity from three
types of maximum output currents – 2 A, 4 A, 6 A.

Link Electric Mechanisms Together

Power cables for several units are bound together for a neater appearance.

Simple stopper that can beeasily installed at theposition where you want
the tote to stop.

Electric Stopper

P.9

For more details on application examples,
please visit the page on P.XX

Pitched Feed

【Action】

VerticalStarter Roller
NEW

MAX size :W510mm × D700mm × H200mm
Weight : Up to 10kg

Electric 90º Turn Table

Assisted movement with a GF frameon the main body.

SUS Corporation

After loading the tote onto thetable from the upper level, thedevice tilts towards theoperator, coming to a stop.
After pressing a switch, the tote
dispenses onto the lower level(directly below the upper level).

Electric
Flip-flop Chuter

Stroke : 1,000 / 2,000 / 3,000mm
Payload : Up to 20kg
Maximum Speed : 149mm/sec

Electric Winch

Rack & Pinion Type

7

【Action】

Ideal for overheadtransfer equipmentwith a maximum
stroke of 3m.

Stroke : 500mm to 2,000mm
Payload: Vertical : 3.5kg | Horizontal: 15kg
Maximum speed : 131mm/sec
P.12

Payload : Up to 10kg
Maximum speed : 417mm/sec

Flip-flop

Rotate the tote inside the tableby 90º before dispensing.

Power Unit

Installing guides and sensors
is simple wh en usin g GF
parts and frames.

Achieves horizontal motion
without the need toincline the rollers.

Incorporating typical simple automation karakuri movements into an electrical package,
Electric Modules can be easily introduced.

【Action】

Use these to achieve the automation goals you have in mind
with "pushing," "pulling," and "lifting."Long stroke

Electric Module

Stroke : 8mm to 40mm
Maximum Tote Collision Speed :Weight : Up to 20kg
Speed : Up to 600mm/sec
Speed : 10 to 48mm/sec

Short stroke

SUS Corporation

8

Systems you can achieve with these new items

Let's Combine Parts and Modules

tote is loaded onto the
3 Thetable and then the table tilts

STEP

Since autumn 2017, SUS has launched one electric module / mechanism after another. A variety of features are introduced here with a unified structure combining multiple new items.

towards the operator,
coming to a stop. When theoperator is ready, turning ona switch dispenses the tote
onto the lower lane of rollers.

2 Rotate the tote by 90º and dispense

STEP

Released in March, 2018

Electric 90º Turn Table
the
Check !
video

http://fa.sus.co.jp/jump/E03

1

STEP

This module incorporates arotating and dispensing mechanism to achieve a 90º turn. Whena tote comes onto the table, it
rotates by 90º. At the end of therotation, an Electric Stopper
lowers, dispensing the tote onto
the next roller.
The table has a function thatallows you to adjust its width andpitch to suit your totes or boxes.

theCheck !
video

Horizontally transfer
the tote placed on the rollers

Released in October, 2018

Starter Roller NEW

Launched in October, 2017

Electric Flip-flop Chuter■ Table + drive unit only
■ SiO + rack set

A tote flows onto thetable located at thetransfer position.

http://fa.sus.co.jp/jump/E04

View from the back...
Starter Roller

Sensorthe
Check !
video

When the tote isloaded, the table tilts
towards the operator,
stopping at a positionw h e r e i t i s e a sy t oload and unload thecontents.

http://fa.sus.co.jp/jump/E02

4 Transfer tote to the end of the structure

STEP
Starter Roller
SensorWhen the sensor* detects a tote, the Starter Roller
rotates and moves it on the rollers, stopping when
the sensor turns off. With a compact body of only
120mm, the Starter Roller is ideal for small equipment. By adjusting the mounting height, it can beadapted to any kind of roller. Maintenance is alsoeasy because the Starter Roller unit and gear unit are“cassette” types which can be easily replaced.
* Sensor prepared separately

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SUS Corporation

Released in September, 2017

GF Conveyor

When the sensor* at the entrance ofthe conveyor detects a tote, the GF
Conveyor activates, transporting thetote to the end of the structure. The
GF Conveyor has the same extrusion
profile as the 28mm GF-N at both thesides and at each end of the main
body. This ensures compatibility withother GF products. The GF Conveyor iseasy to incorporate into a simple automation karakuri mechanism. It connects easily, achieving horizontaltransport without the need for manuallabor.
* Sensor prepared separately

Link functions
with SiO

When the operator isfinished, turn on theswitch. The table will
tilt automatically todispense the tote, thus
reducing operator
effort.

The Electric Flip-flop Chuter is a popular exchange mechanism. Here it is available in a set* with a Power Unit
and SiO Controller. The SiO program needed for this function comes preprogrammed into the controller.
*You can also choose to use your own controller and power
supply in place of the SiO Controller.

SUS Corporation

10More about the expanding line-up

Supporting improvements with a wide
range of movements and mechanisms

In production site improvement, there are various kinds of necessary movements. One major issue is deciding the style that you are going to adopt. SUS helps you to carry out improvements by offering both a comprehensive line-up of parts that can be used for generic purposes and packaged modules that can achieve
standard movements.

Implement a stroke up to 2,000mm!
Released in July, 2018

Power Unit Rack & Pinion Type NEW

An electric mechanism that enables a stroke of up to 2,000mm. These can be used both horizontally and vertically. If you want
to use it vertically, choose the unit with a brake and you won’t have to worry about the mechanism falling down when the
power is turned off. Similar to other electric mechanisms, the Power Unit Rack & Pinion comes with a controller, letting you
select from eight different operating patterns. You can also control it using the SiO Controller.
Pinion(built into drive unit)

Incremental Conveyor that supports both horizontal and uphill transfer.
Released in June, 2018

Incremental Conveyor NEW

Rack

When transporting totes on a chute, a certain degree ofinclination is required to ensure a stable flow. This canbecome an obstacle when you want to transport items
over long distances. In addition to being able to transport
totes horizontally, an Incremental Conveyor also allows
you to extend the transport lane, adapting it to a variety ofsituations by simply connecting extra frames.

Adjust the anti-back position
according to the tote or pallet

Controller

CHECK!
What is a rack & pinion?

Back-and-forthmotion

It is a combination of a small-diameter circular gear called a “pinion” anda rod-like gear called a “rack.” When
combined, these let you convert arotating force into a linear
movement.

Anti-back Unit

PalletRollers

Our Power Unit options are expanding to become easier and easier to utilize!
A frame fitted with an anti-back unit horizontally transports pallets of the same size at
a constant pitch via a back-and-forth motion using a motor.

【Application Example】Mounted on a Horizontal Chuter

When the switch is pressed, the Incremental Conveyor moves back and forth once, carrying the work to the far side.

Released at the end of August, 2018

Power Unit Slider Type 42L NEW

The Power Unit was the first electric mechanism released by SUS. Originally, only rod types were available, but since that timethe variety has steadily increased. The next product to be released will be the 42L type with a performance that is between
the Rod Type and Slider Type 50L. As choices and applications expand side-by-side, you will be able to choose the Power Unit
that is ideal for your situation.

Incremental
Conveyor

Anti-back unit catches thetote and moves it forward.

Rod Type

A Green Frame LS-S Slot (GFF - 035) isused in the Incremental Conveyor. It
is possible to connect two or more
GFF-035 together by using the
GFK-N72 connector.

Rod Type H

Slider Type 50L

Payload (kg)

Speed(mm/sec)

Model

with
Check o!
vide

http://fa.sus.co.jp/jump/E05

Slider Type 42L

Horizontal
200

2

Vertical1

Rod Type L

50

10

5

Slider Type 42L

50

10

5

Stroke (mm)
100

200
(180)

300
(280)

○

○

○

○

○

○

○

○

(380)

(480)

(580)

○

Slider Type 50L

100

12

6

○

○

○

Slider Type 50L (with brake)

100

12

6

○

○

○

Figure within parentheses ( ) refers to the stroke of the Slider Type.

11

SUS Corporation

SUS Corporation

12

Application Examples Linked with SiO Part 1

Intermittent stopper + flip-flop +vertical movement for totes① Intermittent Stopper Mechanism with Electric Stopper and Sensor
When the tote enters position A and the Flip-flop Mechanism is in operation, "Electric
Stopper 1" extends so that the next tote does not move forward. "Electric Stopper 1"
retracts and while the work in position B moves onto the Flip-flop table, "Electric Stopper2" extends, stopping the tote in position C, thereby ensuring that the totes proceed one ata time.

Here we introduce examples using electric parts, modules, and SiO Controllers. While individually they
achieve simple movements, combining them allows you to achieve a wide variety of forms and functions.
Use these examples as a reference when you are considering introducing these kinds of parts and modules to your work place.
withCheck o!
vide

① Intermittent
Stopper
Mechanism
for Totes

×2 ＋ Sensor×2

Electric Stopper 2

CElectric Stopper 1

BA

http://fa.sus.co.jp/jump/E06

Electric Stopper②＋③ Linking the Flip-flop Mechanism and the Vertical Movement
1：When the tote moves to position A, the end

A② Flip-flop
Mechanism

Power Unit
(Rod Type)of the "Power Unit (Rod Type)" (which supplies the power to the "Electric Flipflop
Chuter") extends, tilting the table towards
the operator.

2：The "Power Unit (Slider Type)" mounted at

the bottom of the structure retracts, lowering the "Electric Flip-flop Chuter."

3：At the lowered position, the "Electric

Flip-flop Chuter" table tilts to the dispense
position and the tote dispenses to thelower lane.

Motion of Power Unit (Rod Type)
Motion of table

Motion of Power Unit (Slider Type)Power Unit
(Slider Type)Electric Flip-flop Chuter

Vertical motion of Flip Flop Chuter

CHECK! The SiO lineup is also expanding
Released in June 2018

SiO

SiO3

SUS Corporation

NEW

SiO2

SiO3

Input:6points
Output：4points
Connector：e-CON

Input:16points
Output：16points
Connector：e-CON③ Vertical
Movement
Power

Control

13

SiO-N1

Power Unit Slider Type 50L

Input : 8terminals
Output：8terminals
Connector：Flat cable

Input:8points
Output：8points
Connector：e-CON

Currently there are four types of
SiO Controllers differentiated by
the number of I/O terminals andconnection method. Choose atype according to your requireds p e c i fi c a t i o n s . S U S i s a l s oexpanding our line-up of
input/output devices (options)which can be connected simply
by inserting an e-CON connector.

e-CON connector

SUS Corporation

14

Application Examples Linked with SiO Part 2

Horizontal transport + lifting action+ pitch conveyance along a rising slope
The second example is a case involving lifting a tote from the lower lane to the upper
lane, a specialized field of simple automation karakuri. It incorporates horizontaltransport and a rising slope, configurations that are only possible when driven byelectricity.

③ Upslope pitch
conveyance① Separation + Horizontal Transport Using GF Conveyor and Sensor
When conveyor 1 is in operation and the tote is loaded onto the table, conveyor 2 moves the next tote to conveyor 1.
When sensor 2 detects the tote, conveyor 1 stops and the second tote stops at the edge. By linking the movements ofthe two conveyors, the totes are unloaded one at a time.

with
Check o!
vide

Sensor 1

Sensor 2

Conveyor 2

http://fa.sus.co.jp/jump/E07

Sensor 3
Conveyor 1

Incremental Conveyor② Lifting Against Gravity Via Power Unit
When the tote is loaded onto the table from conveyor 1, the Power Unit lifts the table to the upper lane by pulling thewire.

Power Unit
(Slider Type)

Control③ The Incremental Conveyor Allows Pitched Transport Up an Incline

SiO3① Horizontal Transport

The Incremental Conveyor is mounted at the same inclined angle as the chuter, transporting the totes at a constant
pitch with its back-and-forth motion. To prevent the totes from sliding back down the slope, anti-back units are fixed
to the chuter at intervals matching the size of the totes.
Transport the totes up the incline one step
at a time with the Incremental Conveyor’s
back-and-forth motion.

② Lifting Motion
Power

GF Conveyor＋

Power Unit Slider Type 50L

15

SUS Corporation

Sensor×3

×2

Incremental Conveyor

Prevent sliding back down
the incline with anti-back units.

SUS Corporation16

Production Site

38

Fukui Murata
Manufacturing Co., Ltd.

Mother factory in the Murata Group

Connecting the hearts andskills of craftsmen to the
future with “The next
processes are ourcustomers.”
Fukui Murata Manufacturing Co., Ltd. plays the role of “mother factory” in the Murata Group. It is the largest“production base” in the group and is the closest “development base” to the facility. A number of improvements
were made by prioritizing communication with the people using the equipment and by paying close attention to
the details.

essential to the electrical andelectronic industries
Fukui Murata Manufacturing seems to be thelargest plant in the Murata Group, is that right?
The history of Fukui Murata Manufacturing dates
back to the Murata Research Center. It wasestablished by Murata Manufacturing at a ceramic
test center in Fukui Prefecture in 1951. Currently, itconsists of two bases: the Takefu Plant and theMiyazaki Factory, where a total of around 4,100
employees are working. For this interview, we will
introduce the improvement activities undertaken by
the Takefu Plant.
Laminated ceramic capacitors, the main products of
the Takefu Plant, are essential parts used inequipment handling electricity and radio waves.
Approximately 750 of these devices are being usedin smartphones and approximately 800 are being
used in laptop computers. Recently, the use of suchdevices in automotive-related applications has
increased, and demand is expected to grow in the
future. The Murata Group's laminated ceramic
capacitors occupy a very high market share of 40%.
As the world's No. 1 manufacturer, we supply
products of various sizes and capacities to the world.
As our products are very small, ingenious automationequipment is often used for inspection and otherpurposes, from the reﬁning of raw materials to thecompletion of the product via several processes.
However, operators also play an active part in many

Production Department 1,
Production Section 1
Senior Manager
Mr. Hiroyuki Hiroshima

Production Department 1,
Production Section 1
Improvement TeamMr. Shinichi Tokunaga

Production Department 1,
Production Section 3
Production Department 1,
EHS Promotion Secretariat
Mr. Yoshikuni Kurauchi

Materials Section
Senior Manager
Mr. Masayuki Tatsumi

Materials Section
Ms. Yoshiko Horiareas. Therefore, we produce equipment such as
work benches, racks, trolleys, etc. that arecompany at ﬁrst and after we started using them alittle bit at a time we began to buy them directly in
December 2012. Sabae Murata Manufacturing Co.,
Ltd. was the ﬁrst company in the Murata Group to
use SUS products, but actually it was the Materials
Department of Fukui Murata Manufacturing thatserved as the contact point at that time. Because I
felt the products were fascinating, I introduced SUS
to the other bases. Exhibitions and training courses
on things like the SUS 3D CAD Modeler Unit Design
software were conducted by the sales staﬀ at SUS.
The SUS staﬀ also attended to our ad-hoc requests
regarding delivery, assembly, ordering, and the like.
The amount that we used gradually increased,leading to the active transactions at present. The
fact that SUS deferred raising prices just whenanother company was raising the price of its
aluminum frames also played a big part in myopinion. Comments from the production site rate
SUS products as being highly resistant to rustbecause they are made from aluminum. They also
have a high aesthetic appeal and are easy toposition and assemble. Compared to materials suchas iron pipes, the cost is somewhat higher, but I
think the advantages that SUSʼ s products oﬀer
outweigh that cost.
SUS products are used in many areas, including work
tables and trolleys in the production site, as well ascoat hangers used by contractors and umbrella
stands at the entrance. As the design of the products
is very clever, there are even some things I wish I
could take home. I thinkitʼ s great when you canturn what you imagine into
something real.

customized for each process at the worksite, allwhile continuing to make improvements to these
items.

COMPANY DATA

Fukui Murata Manufacturing Co., Ltd.
13-1 Okamoto-cho, Echizen-shi, Fukui 915-8601 Japan
https://www.murata.com/ja-jp/group/fukuimurata/

When did you start using SUS products, and how
Interviewed on January 16, 2018

did you end up using them?
We bought the SUS products through a trading

17

SUS Corporation

The umbrella stand is designed to be easy to use; it is fitted withhooks for foldable umbrellas. After Mr. Tokunaga made the first one,the umbrella stand was expanded to other sections of the company.

SUS Corporation18

Production Site

38

hard to work with on a day-to-day basis. If you let

What kinds of improvements are currently

people voice their opinion, you will be able to think

being tackled?

of a solution. But if you give up from the beginning,
Please tell me about your improvement eﬀorts.
In recent years, we have been focusing our eﬀorts
on quality control circle activities (small group
improvement activities). In 2010, Fukui Murata
Manufacturing was the ﬁrst electronic component
manufacturer to win a gold prize at a national
competition. In addition, Fukui Murata
Manufacturing has an improvement reporting
system, which the quality assurance department
uses to compile the number of improvements andpublish the results every month. The target
improvements are not "suggested" improvements
but those that were actually executed.

Furthermore, these improvements are ranked andgrouped into diﬀerent classes, with prizes being
awarded as well.
Not only that, but in 2017 we started a study groupto teach the fundamentals of equipment production.
The group aims to raise eﬃciency and quality byteaching the trainees the basics from square one:
how to make drawings by hand, how to measure
dimensions, how to calculate the strength whenassembled, and how to check the ﬁnished product.
Although we ﬁrst started with the idea that itʼ d begood if about 30 people joined the group, thenumber of people attending has already reachedclose to 300.

you will not be able to move on from that basic,

One of our new initiatives now is the implementation

entry level.

of a WIP shelf incorporating the Pick To Light System.

For example, it would be good if examples featured

Previously, if you were using a machine forin Sing magazine were seen on the Internet. The

processing multiple products, then when one lot was

number of people who can pick up the magazine are

ﬁnished the operator would have to check the next

limited, and operators on the production site donʼ t

product to make and search for the necessary

have enough time to read them thoroughly, either. Ifmaterials. In the new system, by registering each

you have a place where you can get hints moreindividual lot in advance, you can instantly know thefreely, I think it would be useful to many people.

type of the product currently being made, the timeAlso, since itʼ s a wonderful feeling to see your ideas

taken for completion, the order of priority, and more.

in action making the work easier, you can also

When you mark the process as complete in the

expect a positive cycle that leads to a higher level ofsystem, it automatically informs you of the next

improvement based on the successful experiences

product that needs to be worked on. At the samethat you made into reality. Presently, many members

time, the system also shows you which rack the

who face challenges every day visit the improvement

required materials are on, thereby improving

rooms where pieces of equipment are created ineﬃciency and reducing works-in-process (WIP). Thisorder to discuss their issues. This is a wonderfulsystem is being implemented in several areas,

thing, but as there is a limit to the amount of work

starting with where is it needed most.

that one person can handle. Therefore, we are currently discussing how to proceed further.

Dropped products are attracted to a removeable
magnet sheet.

The work table for the inspection process is mesh so that the operator can drop
products which do not pass inspection down in-between the bars. This can prevent
products left on the table from being mixed with other products when changing the
setup.

A strong awareness of the idea that
“Customers = Production Site”
Improvements constantly continueeven after the installationMoves
in thisdirection

Pay attention to thehorizontal and verticalorientation of the mesh sothat objects placed on
top do not get caught
when you pull them
towards you. Attention todetail leads to functionality.

ly management staﬀ to participate in the study
group, we have received many comments like "I'mt proposals!
ber of improvemen
By far, No. 1 in num
the heart of kaizen!
Hereʼs the person at
Mr. Shinichi Tokunaga of the Improvement Team is a figure who is indispensable to improvement efforts in Fukui Murata
Manufacturing. Before joining the company, he worked as a craftsman in Echizen lacquerware for about 16 or 17 years, gaining
experience in various side jobs when orders for lacquerware were low. One of these side jobs was site work and design related
to machinery and construction, such as the installation of partitions in factories. He may even have been responsible for someof the projects in Fukui Murata Manufacturing.
After joining the company, he worked in the manufacturing process, becoming a member of the improvement team which wasjust then launched over ten years ago. But he was completely lost at the beginning. Mr. Tokunaga started from a place where
he did not even understand how to use the parts and gradually mastered them while
asking for help and studying by himself. Based on these experiences, he realized theimportance of acquiring basic knowledge and thus he suggested that a study group be
formed. Seeing this become reality in 2017, he is now a lecturer for that study group.
The main feature of equipment made by Mr. Tokunaga is that the working space and easeof use are taken into consideration. Furthermore, the design and manufacturing are
carried out with millimeter precision. Mr. Tokunaga said that his experience andcommitment when working as a craftsman are being put to good use.

glad I could learn again." This makes me feel strongly

As seen by junior employees: The way Mr. Tokunaga works

about the importance of learning. A compilation ofcase studies is also useful for encouraging improvement proposals from the production site. Recently,

How about the accomplishments of themore people understand that they can create theirstudy group?

ideal equipment out of GF. On the other hand, there
are also many people who are trapped by the mind-

19

The reaction from the production site has changed

set that “they have no choice but to accept equip-

greatly. First of all, although we are getting primari-ment as it is,” even if they feel that the equipment is

SUS Corporation

Group Leader,
Production Department 1,
Production Section 1
Mr. Akio Hirai

I was impressed the first time I saw the equipment created with work design in mind and theefforts being taken to meet the needs of the worksite. Not only in ease of use, but in things likethe calculation of payloads, manufacture was done without compromise for the sake of theoperators. Moreover, Mr. Tokunaga also goes to the site after installation, listening intently tothe opinions of others who would like to do more, and even carrying out the improvements. He ishighly trusted due to his earnest work style ensuring safety and security in the workplace, evenas many people bustle around the improvement area.

SUS Corporation20

Production Site

38

Please tell us about your future goals andnot actively worked on low cost automation karakuri

your requests for SUS.

initiatives in the past because of the nature of the

Flowerclock

products we handle, going forward I think we needFor example, the pen stand for the work bench is

to examine and study suitable scenarios for its imple-

ﬁxed with 45 Degree Connectors, but in reality, itmentation. In the future, I would like to create anfeels easier to use if it leans a little closer to theenvironment where technology can be passed on tooperator. Although there are connectors that can be

the next generation while utilizing SUS parts. Last

set at any angle, those connectors somehow lack ayear, with the establishment of the study group, I felt

sense of stability. It would be good to have a greaterthat I had taken the ﬁrst step towards achieving thatvariation of angles. Furthermore, although we aregoal. First of all starting with grassroots activities, I

currently using tape on the frames for identiﬁcation

would like to promote human resource development

purposes, it might peel, leading to dirt andand environment building in the medium to longcontamination. I think it will be easier to use if theterm.

The Symbol of
Fukui Murata Manufacturing

The Board Holder(GFJ-A22) used foranchoring panels is
attached after machining because its diameter
does not match theanchoring holes in thedisplay.

A flower clock made with colorful blooms catches youreye when you pass through the main gate of the
Takefu Plant. It is a historical clock installed inconjunction with the visit of Emperor Showa and the
Empress in 1962. It serves as a visual symbol of Fukui
Murata Manufacturing for visitors.

Frame Guard was available in more colors such as
purple or dark green.
Since our requests are immediately conveyed to theperson-in-charge, I would expect easy-to-use itemsNEW

to become available. Brand new GF products would
probably be checked out right away.

Fixtures fit perfectly into the drawers of this trolley. It is also used forstoring items such as works still in progress and materials to be handed
off. There is also a plan to attach a CPU to the side for the display.

＋

Because of the shortage of labor these days, fromhere on out the most important resource is the“human resource.” Thatʼ s why we must continue topromote labor-saving activities. Although we have

Frame Guard fitted for use on the GF extrusion notches. The orange
color released in 2017 was released in response to a request madeby the Murata Group.

Back

Trolley for storing rectangular fireproof
containers. It is extremely lightweight compared to iron, making it easier to handle.
Another version of the work station introduced on page 19. Besides drawers in the lowest
section, it is also equipped with a pen stand.

21

SUS Corporation

provementgaʼs passion for imnaLearn from Mr. Toku

Since things will never get moving if it is just an idea on the design side, I
place emphasis on communications with the people in the production siteover anything else. I also believe that "drawings" are indispensable tools forthat purpose, and I’ m trying to convey their importance to students in the
study group. Since I was put in charge of improvements, about 2,000
drawings have been created. In addition, the date, manufacturer, andcontrol number are clearly marked on the equipment we have made using alabel-maker. For SUS, it’ s good that SUS 3D CAD Modeler Unit Design
software is available free of charge. I think the software could be used withmore confidence if it included functions for load calculation, etc.
Actually, since I am able to create whatever I am imagining no matter whatparts are available, I’ m not very picky about the kinds of parts I use. I am
always looking for cheap, good materials. However, since the SUS Aluminum
Pipe Structural Material GF has
a reputation for highfunctionality and is rated
highly by manufacturing staff,
its use has been increasing.
There are many GF work
benches and trolleys that are
being expanded to othersections. I am busy assembling
them. (Mr. Tokunaga).
Mr. Tokunaga looking at the PC in the
improvement room. Drawing data is organized
so that it can be referred to immediately.

Importance of drawing / parts list
■With drawings, briefings can be conducted

for the client, modifications can be madebefore production starts, and satisfactory
manufacture can be carried out.

■ These can be used when orders for thesecond and third units are received andwill be useful for upgrading.

■ By offering the client two proposals bydifferent makers, the options increase,
expanding the range of possible choices.

■ By maintaining communications with theclient / operator, the client / operator canparticipate in the design, leading toincreased motivation on the worksite.

■When a parts list is created, you can checkit to see whether suitable items have been
selected.

■ You can calculate the product price fromthe costs of materials and choose one witha higher cost effectiveness.
* Created based on Mr. Tokunagaʼs
study group materials

SUS Corporation

22

Boasting high technical capabilities of

Production Site

its own integrated production system,

39

Shima Seiki is the world's largest ﬂatknitting machine manufacturer

SHIMA SEIKI MFG., LTD.

You develop and manufacture computerized
ﬂat knitting machines that have been adopted

Ensuring ease of work withequipment tailored to avariety of production sitesfrom precision machining to
final assembly

all over the world. What kind of history

Shima Seiki Manufacturing is highly acclaimed throughout the world as a top manufacturer of “computerized flatto the global knitting industry.

office factory which possesses diverse precision machining and electronics technologies. It also carries out

services, not only including our mainstay ﬂat knitting

did you have?

goal of developing fully automatic glove knitting
machines. After successfully developing the worldʼ s
ﬁrst automated glove knitting machine in 1964, weentered the ﬂat knitting machine industry in 1967. In
1995, under the mission of “to create on our own
what no one else can” we developed the world's
ﬂat knitting machine” tocreate a knit with no stitching, earning the accolade“Oriental Magic.” Twenty years later in 2015, wedeveloped a 4-needlebed “WHOLEGARMENT ﬂatknitting machine” equipped with a moveable fullsinker system. This used to be diﬃcult to achieve
technically, and brought about revolutionary changes

knitting machines” for making knitted products. Improvement efforts are accelerating at the company’ s head

Currently, we oﬀer a wide range of products andintegrated production of its own products from software to hardware. We visited a factory that is working on

machines, but also our design systems that support

creating a conducive workplace with ideas tailored towards alleviating the burden on operators,

3D virtual samples, our automatic cutting machines,
our non-lithographic-plate-type printing machines,
and so on. In addition, we carry out all design,development, and production activities inWakayama, the place of our founding. Our headoﬃce factory has a variety of processes to fully
exploit our own technologies, from the processing
and manufacturing of precision parts to the assemblyof ﬁnal products.
It seems that you have adopted theProduction Headquarters
Production Manager
Mr. Akihiro Otani

Production Engineering
Department, Group 4
Deputy manager
Mr. Hideki Sowa

Production Engineering
Department, Group 7
Deputy manager
Mr. Takeshi Hashimoto

Production Headquarters
Production Vice Manager
Mr. Seiki Kimura

System Manufacturing
Technology Div. Secretary
Mr. Hiroyuki Ohno

System Manufacturing
Technology Div. Group 4
Mr. Shinobu Kawashimause of the Aluminum Pipe Structural Material
GF around 2016.
We like the fact that GF is beautiful in appearance,lightweight yet strong, and can be used in a variety

COMPANY DATA

of ways for diverse parts. Although we had been

SHIMA SEIKI MFG., LTD.
85 Sakata, Wakayama-shi, Wakayama 641-8511 Japan
http://www.shimaseiki.co.jp

interested in it for a long time, we had theInterviewed on February 20, 2018

had imagined, so we decided to try it once. Afteractually producing a prototype of an AGV transport
trolley, we felt that the material was easy to workwith and we were able to produce the prototype
easily. Compared to the iron pipe we used before,
the fact that ﬁne adjustments and extensions can bedone easily after completion is also an attractive
point. From there on, we introduced GF to othermembers, gradually spreading its use in line with the

Shima Seiki Mfg. was established in 1962 with theﬁrst “WHOLEGARMENT

the price diﬀerence with iron was not as large as we

impression that aluminum was expensive and thus

company's policy of focusing on improvement.
Not only that, but there are not many members on
the production site who can produce drawings. In
the case of SUS, I think one of the reasons why GF
became widely adopted is because things could be
implemented speedily. You created the drawings forus, helping up to turn our ideas into reality after wetold you what we wanted to make with just ideas
and simple, hand-drawn sketches
There are many buildings and a variety ofprocesses at the head oﬃce factory.
How are improvement activities
being implemented?
At Shima Seiki Manufacturing, we insist on in-houseproduction, and we carry out integrated productionof our own products from hardware to software.
There are lines that handle ﬁne electrical parts suchas boards, cables, and switches. On the other hand,
there are also factories that complete the ﬁnal
knitting machine by assembling various parts. The
latter also handles heavy items which require the useof a crane. There are many parts and types, and our
processes are very diverse. Against this backdrop,
instead of a centralized organization to manage our
production technologies and equipment, eachdepartment has developed its own wisdom to create
its own lines. Even now, personnel in charge of theworkplace come up with their own ideas on how tocreate a conducive workplace.
Although there were advantages in working
separately, we faced other problems such as a lackof standards concerning the height and depth of thework benches. Standardization was not maintained.
Therefore, in switching to GF, we are also working
on aligning these points.

we were unable to take the plunge in using it.
However, upon inquiring further, we found out that23

SUS Corporation

SUS Corporation24

Production Site

39

suitable for each process. Right angles and parallellines can be created by simply tightening theconnector and assembly is easy too. When building
equipment like work benches and trolleys, itʼ s rare
to make it right on the ﬁrst try, but I think

Case

1

improvements can be made immediately even after

Work bench customized
for each process whilestill adhering tostandardizations

installation. This raises the level of satisfaction in theworkplace.
Showroom where various kinds of knitwear with different materials,
uses, and forms are lined up.

Creating an operator-friendly workplacewith the high degree of freedom

Pull air inthat can only be achieved with GF
What are the things that you strive forwhen producing a piece of equipment?
I already talked about the standardization of
The fully GF work bench was constructed alongside the new factory. It is customized to fit
the work while maintaining uniformity through pre-determined depths and other basic
specifications.

equipment earlier, but at the new factory completed
at the end of 2017, we actually deﬁned a design
standard stipulating that all work benches have to
be made with GF. In addition to making it easier toWork bench for soldering. To ensure that theoperator does not inhale the smoke, the bench isdesigned to pull the nearby air away through aduct on the top.

Terminals are provided to individual operators, making use of
the unique operational management
system. The work
bench has a dedicated stand for the monitor, the placement of
which may be altereddepending on theprocess.

Air is blown out from holes in
the frame

review and change the layout, I have also heard
comments from the production site saying that "GF
made it easier for us to move from one work bench
to the next, creating a sense of uniformity andneatness." We plan to systematically implement thissystem for the other processes as well.
The most important thing that I strive for when
making any kind of equipment is how I can reduce
the workload and make it easier for operators. Evenon a single type of workbench, the best set up for

Case

2

Dedicated step stool ofjust the right size

Case

3

Parts storage rack designed toaccommodate loading and unloading
Replenishinventoryease-of-use varies depending on the nature of thework being done and the type / size of the tools
being used. Therefore, we pan out each and every
workbench by listening to the feedback from theoperators while keeping to the basic design.

RemoveWhen arranged in a row, there is a sense of
uniformity even though each work bench has been
properly customized according to its speciﬁc use.

In addition, although there are not many yet, simple
automation karakuri mechanisms have also been
produced. Creating something with that high a
degree of potential is honestly interesting. With
regard to karakuri, I also went to the Karakuri
Improvement® Initiative Exhibition with the intentionof actively incorporating these ideas in order to savelabor and energy in the future. The other day I
bought a miniature karakuri made of GF to study themechanism and actually assembled it. I hope to give
shape to the structures I am imagining by using theminiature as a kind of hint.
Please tell us your requests for SUS.
There are parts that we have not fully utilized
because of the diversity of our products. It would begood to have some guidance on how to use themwith examples, etc. Also, we handle a variety ofparts / products from small to large. Even if a single
item is light, the unit to be transported is kind oflarge. I think that we can widen the range ofapplications if these parts can cope with heavier
loads. Likewise, for electric parts, if there was a
product with a larger payload, it would be useful for
raising and lowering heavy loads that impose a large
burden. Since the power supply is also an issue, itwould be great to have a battery available as well. In
the future, I would like to work on automation using
electric mechanisms and the SiO Controller, so Iʼ dappreciate any advice I can get from SUS on theseapplications.

Even though there is this sense of unity, that does
not mean operators are forced to use standardized

Dedicated
step stool
The GF-G series is used for the step stool which helps operators reach the wire work on the equipment. The width,height, etc. are customized to the design.

25

SUS Corporation

Trolley for loading
and unloadingThis is a storage rack for heavy parts which weigh about 20 kg per box. By fixing
the direction for replenishment and removal, parts can be loaded and unloaded
on a first-in first-out basis without the need to restack. By using a three-tiered
trolley, parts can be removed by simply sliding the trolley into place, thereby
reducing the work load.

products. These kinds of installations are growing in
number one after another.
How about the ease of using GF?
The parts are diverse with a high degree of freedom
so I like the fact that I can create equipment that is

A trolley with a handle cut into the worktop makes loading andunloading easier. A variety of measures have been established to
improve each individual process.

SUS Corporation

26

Production Site

Case

4

39

Case

6

Reduce movement loss
with a rotary table
Work can be consistently
carried out at a fixed distance

Reducing the strain of assembly work bysuspending an extendable impact driver to the frame

Retracted Structure

8

Customized
trolleys forchairs.

In this stage of assembling an automatic cutting
machine, hundreds of screws are tightened with
an impact driver weighing about 7 kg. The
strain was reduced by suspending the driver toa gate-type frame using a tool balancer.
Rotates around the center
Cutting machine fits
under the structure

5

Eﬃcient
garbage bin
installation

Case

Adjust the width to fit
the equipment being assembled

The tool is kept at aconvenient height,
allowing well-balanced
lifting and lowering.

7

Garbage bins arestacked on two levels
to save floor-space.
Since the bins containmetal trash and otherheavy objects, thestandʼ s strength wasenhanced with GF-G
frames.

Extended Structure

Suspend the driver,move left or right

Case

Case

This trolley allows items to be loaded and unloaded without the operator
moving from their station by rotating the loading surface. When the trolley
is full, it can also be transported as-is.

Suspend with
Fishing Gut Wire

Case

9

Stops at aneasy-to-use heightParts trolleys that can beused from both sides

In storage

Customized trolleys
are produced together with the purchaseof chairs used inmorning meetings andlunch breaks. Thesecan be taken out andreturned easily, exactly when you need touse them.

Case

10

Linking AGV trolley

In useA parts trolley that makes
effective use of the space
available and can support
processes on both sides
with a single unit. Drawers
are color-coded to distinguish the direction they
are pulled out.
With the cover removed

Slide Connector

27

SUS Corporation

This ascending / descending cart stores two different types of parts on the top andbottom. The frame section containing the cardboard box and the outer framework of the
cart are connected by Slide Connectors, allowing it to slide up and down.

A prototype trolley connected to an AGV
for carrying items. Three units can belinked up. They will be covered in order toprotect them from rain and dust whenmoving between factories.

SUS Corporation28

Production Site

39

Use the joy to turning
your ideas into reality as motivation
to gain experience andimprove yourself!

Case

11

What does the future hold for you?

Work trolley
customized withthe “3 Tei” in mind

Members at the work site will have to come up withideas within a limited amount of time and work on
improvements. After switching to GF (although it
took a while before it became widely used), we

What challenges are you currently working on?

started to hear positive comments like “Canʼ t we dothis kind of thing, too?" I think the reason for thisAs production booms, limits will also appear in thechange is because of the versatility of GF and thefactory space, and the problem of how to use

support of SUS, allowing us to experience the joy ofexisting space eﬃciently is a big issue. Therefore, weturning what we were imagining into something real

are currently working on an initiative to optimize theon our own.

size of things like racks and work benches to makeEven if itʼ s just something small, itʼ s nice to see yourthem as small and slim as possible. At the sameidea taking shape and playing a part in creating thetime, since it is necessary to secure suﬃcient working

workplace. This sentiment was probably the driving

space to ensure reasonable working conditions, weforce that led to revitalizing improvements. Without

would like to create measures that take into

this, I donʼ t think the use of GF would have spreadconsideration things like the position of the rack,

so rapidly, even if instructions had been given from

how things are going to be placed, etc.

the manager. Even though we still rely on SUS for

We plan to use AGVs to save on labor and energy,

detailed designs very often, in the meantime, we

and we will also incorporate simple automation

want a system which allows many members to

karakuri mechanisms to item-transfers. Currently,

create equipment from square one using the

production is still carried out with a view on how toavailable parts. To that end, there is still the issue onlighten the burden on operators, but in future wethe management side of how to secure the time

would like to pursue ways to increase productivity

required. We believe it will be good if the workforce

while developing and expanding the use of karakuri

and management work together towards the samemechanisms.

goal.

Monitor standFrame width
matches the jig
Work trolleys are made withthe “3 Tei” (Fixing Three "Tei"in placing or storage, i.e.
"where", "what" and "Howmany"). This way, anyone cando the same process. The
normal positions of jigs andtools are fixed by partitioning
the top of the table with aframe, and a monitor standfor the terminal is also
provided.

Jig area

Case

12

Cover loading platform allows loading and unloading at a ﬁxed height
Load dozens of covers

Linear Slider

The platform is lowered to a position
where the weight of the cover isbalanced by the force of the spring

The “cover loading platform"
enables loading and unloading at a fixed height by using
springs. It was retrofitted to areusable blue rack used withpartner companies to savemoney. Preparations forfull-scale operation are in
progress while the optimum
strength of the spring, etc. isbeing verified.

This partition was constructedto contain foreign matter
generated in the adjacentprocess. In the past, it used aniron plate, but the visibility waspoor and the height was insufficient. Using GF, installation
was carried out without theneed for large-scale construction and material flow was also
improved.

29

SUS Corporation

SUS Corporation

30

Revitalize the site with unique

Production Site

systems where operators are integral

40

to evaluations

simply. Also, besides the joints being simple andstain-resistant, the fact that GF is easy to clean
without paint peeling oﬀ is also an important point.
GF looks good, making the workplace seem brighter
after it was introduced. Because itʼ s an aluminum

PIONEER CORPORATIONKAWAGOE PLANT

Add Plus One to youreveryday routine!
Get excited about
improvements with avariety of techniques

The company celebrated its 80th anniversary inmaterial, Iʼ s great that it can be recycled. After it was

20 1 8 . Fi rs t o f a ll, plea s e tell me a bo ut yo uroﬃcially adopted [as a construction material], we

company proﬁle, including your current business

replaced our equipment. Now, new facilities arefocus and so on.

made up almost entirely of SUS parts.

The history of Pioneer started with dynamic

When making equipment,

speakers. Since its founding until the present, as

what points do you insist on?

"pioneers" we value the spirit of manufacturing in
inspiring people. Our corporate culture as the ﬁrst to

Recently, car safety devices such as hazard buttons

launch many leading products in the world andare often incorporated into car audio products. As

industry is a deﬁning feature of our company.

they are directly linked to the safety of the car, we

Currently, our main business is focused on car

have to take greater care than before in dealing withelectronics, especially car navigation and audio

foreign contaminants and defects. For that reason,systems. In addition to our own brands, we alsocleaning has to be carried out thoroughly, so ease of

supply OEM products to car makers. We have beencleaning and maintainability are also important. In

promoting the development of technologies that

addition, workplace safety is a key point, so user

leverage upon our knowledge of optical technology

friendliness is considered from the perspective of theand car-mounted products we have cultivated up to

operator.

today. We are focused on the dawn of self-driving

Founded in 1938, Pioneer Corporation was the first company in Japan to successfully develop dynamic speakers.

vehicles.

for the development, design, and production of mainly car navigation and car audio systems. We interviewed

I heard that a lot of the Aluminum Pipe Structural

The Kawagoe Plant we visited on this occasion was established in 1970. It is the key production base responsible
members of the production site where improvement activities are promoted by a variety of approaches not
limited to equipment alone.

Material GF is being adopted in your workplace.
Iron pipes were used in the past. We handle
precision instruments, so when we were looking for
products that are easy to use, we paid attention to
products that prevented static electricity and foreigncontamination. Thatʼ s when we came across GF. We
started using GF because it is easy to handle, e.g.
horizontal and vertical portions can be produced

Production Management Division
Manufacturing Innovation Division
Global Production Department
Mr. Hideki Matsue, Manager

COMPANY DATA31SUS Corporation

Production Management Division
Manufacturing Innovation Division
Global Production Department,
Production Engineering Section 1
Mr. Keiichi Ishizuka, Manager

Production Management Division
Manufacturing Innovation Division
Global Production Department,
Production Engineering Section 2
Mr. Takeshi Akutsu, Manager

Production Management Division
Manufacturing Innovation Division
Global Production Department,
Production Engineering Section 2
Mr. Kousuke Kamada

PIONEER CORPORATION KAWAGOE PLANT
25-1 Yamada Kawagoe-shi, Saitama 350 ‒ 8555
http://pioneer.jp/

Interviewed on April 27, 2018

Product guide

The results of various activities are posted at the entrance to the
production site, and we are working together as one to create avibrant workplace.

High-end audio car navigation system

Cyber Navi χ Series

Carrozzeria "Cyber Navi χ Series" is a high-end audio car navigation
system jointly developed with the elite audio "Carrozzeria χ" andhome audio "TAD" systems. Based on the technology and expertisethat Pioneer has cultivated, and in addition to reviewing thedesign concept, we have adopted the very best high-quality soundcomponents never before used in car-mounted devices, thereby
exceeding the standard for car navigation and achieving an
overwhelming audio performance.

"AVIC-CZ902XS" Recommended retail price: 248,000 yen (excluding tax)

SUS Corporation32

Production Site

40

Case

1

Uniﬁed materials and standards make a bright and orderly production line

A row of work benches lined up from the far side of the picture. Assembled products are sent toward the nearside in sequence, going through the ﬁnal inspection process on the frontmost work bench before completion.
How do you gather your operatorsʼ viewpoints?

“Received” list are commended. In this way, teammembers develop a habit of mutually rating actions"Operator's Voice" is an initiative we are undertaking

and sending one another cards. A real awareness of

to reﬂect the views of operators in the workplace.

the “Plus One” initiative has taken root in the Global

This is an activity to get the workplace to highlight

Production Department.

places where improvements are deemed necessary.

Improvement activities also fall under the Plus One

After clearly stating what action needs to be taken

initiative. Since the idea is to constantly add

and when, the real-life results are evaluated. The

something positive to the current situation, products

measures donʼ t necessarily need to be related tothat can quickly take shape from an idea (like GF)

the equipment. We are aiming for a workplace thatare also a very good match. As GF products can be

is easy to work in, including mechanism

easily corrected even after completion, I feel that wedevelopment. During implementation, instead of acan make improvements with a sense of speed andvague question like "Do you have anything towithout fearing failure.

comment on?" a diﬀerent theme is set each month.
For example, we ask questions like "Are there any

I heard that in recent years youʼ ve become

places where you are likely to get hurt?" or "Areenthusiastic about simple automation karakuri

there any places where the procedures are

initiatives.

confusing and you are likely to make a mistake?"
Evaluation after implementation is carried out in four

The reason why we ﬁrst introduced karakuri waslevels: S, A, B, and C. We seek out feedback to

because of a TV program broadcasted in 2015. An

ensure that this is not a one-way process. A highexecutive oﬃcer in the production management

rating motivates the line manager, and having adivision saw the eﬀorts being made by otherchance to quantify the outcome of the improvementcompanies and issued a directive to incorporate

is beneﬁcial, too. On the other hand, if the result iskarakuri automation. Itʼ s been said recently that

not what you expected, management will provide

manufacturing is on the decline in Japan. There wasadvice on how to improve the situation further.

an aim to empower the work ﬂoor by focusing on

Case

2

Customized trolley forchecking torque strength

The height of the trolley carrying the torque-checking
machine can be adjusted in three steps. Previously,
the results of each test were written on paper, but
the mechanism was changed. Now, the machine isconnected to the tablet terminal which automaticallyaccumulates data.

improvements using karakuri and by training people
Are there other activities that you are conducting

in creative thinking. With data collection as theto encourage improvements?

starting point. We visited the karakuri improvement
initiative exhibition organized by the Japan InstituteWe have a variety of initiatives such as an awardsof Plant Maintenance and built up our knowledge bysystem, small-group activities, an improvement

reading books and watching DVDs issued by the

proposal system, and more. We are also conducting

institute. In addition, we visited the SUS showroom

our own Plus One activities in the Global

and participated in seminars, continuing on from

Manufacturing Department. In addition tosimple imitation to gradually accelerating our

improvements, we have an initiative known as "Plus."

initiatives. Having said that, although we started with

Staﬀ are encouraged to use pleasant greetings tomuch enthusiasm, the equipment that we initiallycreate "a workplace that is more cheerful, brighter,made was criticized as being “large, stiﬀ, and heavy.”

and vibrant.” A morning greeting campaign was also

From that point on, we returned to the needs of the

conducted by the manufacturing department. In

workplace and gradually began to makeaddition, there is a system to send a "Plus One Card"

improvements with the aim of creating something

and rate Plus One actions. Previously it was onlythat is truly easy to use.

Case

3

Transport trolley
between processes

This trolley carries items set up at a remote location
to the necessary processes. Previously, when the
production model changed, the drawers on thetrolley were changed, too. But because this meant adrop in loading eﬃciency, the place where the items
were set were given numbers and arranged in a way
so that they could be used in order. This reduced thenumber of transfers.

Pull out to use

Change the heightof the trolley by changing
the position of the frame

paper-based, but now submissions can also bemade on the computer system. The number of cards
are counted, and those at the top of the “Sent” and33

SUS Corporation

SUS Corporation34

Production Site

40

We hear that electric mechanisms have also been
adopted recently.
Integrating electric mechanisms is an extension of
the idea of using “equipment that meet the needs of

Case

4

Automatic supply / dispense chuter incorporating an electric mechanism

the workplace.” For example, when trying to lift aheavy object using the principle of a lever, a certain
length is required. This creates a new problem: theequipment has to become larger to accommodate

Electric Winch

the lever. But, if the walking distance of the operator
is extended by insisting on Karakuri, this is likeputting the cart before the horse. Furthermore, in aplace handling heavy loads, there will inevitably be a
lot of breakdowns necessitating a lot of maintenancework. In order to solve these problems, we adopted
products such as electric winches, lifting-up andpulling-down units, electric stoppers and the like.

Pack finished productsthat have passed
inspection in thecontainer

At present, gravity-powered karakuri mechanisms
and electric automation parts are both used on the
production site. We feel that these are practicalapplications matching each need. Pioneer aims toElectric Stopper

improve space eﬃciency. We are promoting thecreation of compact equipment that I believe will be

Foot Pedal

easier to use if it incorporates electric automationthat can carry small, heavy items.

Challenges continue as we strive
for greater heights
There are many group companies overseas. How
are information and ideas being shared?
Information about the Kawagoe Plantʼ s improvement
activities are being shared on a global level. Throughour intranet, we have made it possible to see site
maps and videos / drawings of equipment, even bypeople overseas. We believe that anyone who canintroduce these ideas to their own work placeshould please use them. Our stance is that thesematerials should be used wherever implementationis possible. Some of our members who have visited
Japan on business trips have also returned homewith this information. In addition to preparing
materials that summarize basic karakuri knowledge,
we are also conducting production presentations.
Actually, the person who started the “Plus One”
activities used to be the manager of the Global
Production Department. Now, he is the president ofa subsidiary in Thailand. In that sense, I think that
“Plus One” activities are not only meant for Japan,
but for the whole world to revitalize the workplace.

When the container is full, the operator steps on the pedal to dispense it to the upper section. The empty table receives an empty container fromthe lower section and stops at a position where it is easy to use.

Finally, please tell me more about the ideal
workplace you are aiming for.

Sensor

Ideally we want to create an environment where

Dispense the fullcontainers

operators can concentrate on their work without
excessive movement, but we have not reached that

Supply empty containers
SensorPress a switch tocall the AGV
An electric winch is used to raise
and lower the table.

Two members of the
Customer Satisfaction
Committee assist witha factory visit. They
give customers (mainly
auto manufacturers) an
introduction of theinitiatives being undertaken by the workforce.

be necessary to utilize overhead spaces and otherdead areas. On the other hand, cleaning may takemore eﬀort if the height is increased. I think itʼ s

By taking on simple automation karakuri initiatives, I
feel that ideas for this kind of improvement havedeveloped more rapidly than before. Going forward,

separation of the containers is achieved with electric stoppers on the chuter side and karakuri mechanisms on

we aim to create an environment where operators

the AGV side. Initially, the separation of the containers on the chuter side was also done with a karakuri

can work comfortably.

mechanism, but because it underwent hundreds of repetitions, malfunctions were unavoidable. Therefore, we

SUS Corporation

order to raise the eﬃciency in limited spaces, it may

matter and other problems.

work of restacking the wide, diﬃcult-to-handle containers, decreasing the workload and raising eﬃciency. The

35

production line are continuing challenges. Also, intaking into consideration contamination by foreign

This is an example of an improvement in automating the supply and dispensation of containers. It eliminates thefor control purposes so that the AGV does not move away when containers are still in the upper section.

the transportation process and creating a compact

necessary to implement this in a well-balanced way,

Automatic supply and dispensation are achieved with various sensors that
detect the position of the containers and the table.

changed the model to an electric one so we could focus on reliability. The chuter sensor is linked with the AGV

goal yet. This may go without saying, but reducing

Miniatures that allow workers to learn simple automation karakuri
mechanisms are displayed in a common area.

SUS Corporation36

Production Site

Case

5

40

Case

7

Elevator chuter using
two electric winches

Case

6

Reduces set-up laborby using a rotatingstorage rack

This rotating material storage rack uses
rotary connectors in the center. Containers
can be placed on three sides.

A sliding inspection table that
supports both left-hand andright-hand models in a single unit

When the product is set on the table and the cables areconnected, the camera automatically distinguishes themodel and inspection starts. As the shape of the
product is diﬀerent for left-hand and right-hand models,
the table is designed to slide to the left or right toaccommodate the correct one.

Check it out!
Equipment with simple automation
karakuri or other mechanisms isdistinguished by a yellow ping-pongball so that even people who are notfamiliar with the manufacturing site
can quickly identify it when they visit
the site. Name cards are also attached
t o h e l p a t t ra c t t h e a t t e n t i o n o fvisitors.

Similar to Case 4, this is achuter automaticallyinterchanges full and empty
containers. Because theproducts being handled areheavy, two electric winches
are used to provide thepower necessary.

Case

8

Production line starting point
Automatic supply of necessary jigs with
one switch + reduced walking thanks to portable racks
Ascending andDescending Unit

Power Unit
(slider type)

Table for placing
the items forinspection

Production line ending point
Overhead transfer unit to return the
jig automatically and eﬀortlessly
For Right-handDrive (upper section)

Jig Holding Arm④Automatically
identify the type of jig
and dispense it to theappropriate section⑤Dispensed
jig returns tothe starting
point of the line

For Right-handDrive (upper section)

When the switch is pushed, thepower unit activates and the rackmoves to the operator side. When
not in use, the rack is put to theside to create a passageway.

③Ascending andDescending Unit
raises the tablewith the jig.

This line produces products for right-hand andleft-hand products using diﬀerent jigs for each.
The jigs are stored separately in the upper andlower sections in the Overhead Transfer Unit
composed of two sections at the top of the line.
Movement at the start of the line
When the switch is pressed for to the item
being produced, the jig for the right-hand modelor the left-hand model is dispensed andsupplied to the line via an arm attached to
Ascending and Descending Unit.
Movement at the end of the line
When the process is complete, the empty jig islifted up by the Ascending and Descending Unit
until it is overhead, then dispensed. Next, the jig
returns to the start of the line.

For Left-handDrive (lower section)

For Left-handDrive (lower section)

BeforeAscending andDescending Unit

Electric
Stopper

The jig is sandwiched on bothsides by electric stoppers and thensupplied to the production line.

37

SUS Corporation① Products flow fromthe starting pointof the line.

②Empty jig reaches
the end of the line.

Prior to the introduction of Overhead Transfer Unit,
operators carried jigs along the wall up to the chuter.
This resulted in an annual loss of 2 million yen due tounnecessary walking. Even now, the old transfer line
remains installed, just in case it’ s needed in an
emergency.

SUS Corporation

38