Home > Products & Equipment > Door Equipment
1. Outline
We have 2 lines in our plant. A line is for outside and inside panel of doors. There are material supplying machine and material washing machine at the front of the line. And these machines lead to 4 press machines (1500t and 800t). The products are finally inspected and stacked. High speed conveying robots are used between the press machines. The manufacturing capacity is 8,000 pieces per day.
B line takes charge of muffler, window frame of doors and door reinforcement parts. We use 4 press machines in B line. Between the press machines, we use high speed pendulum feeder which can be synchronized with press machines. The manufacturing capacity is 16,000 pieces per day. We are trying to optimize the operations by using automatic stacking device both A and B lines.
| Outer | blank material, draw, trim and pierce, flange and pierce |
|---|---|
| Inner | blank material, draw, form, trim and pierce |
2. Feature
Shorten times of outside arrangements. (For making limited production of diversified products by efficient operation of cranes)
Shorten times of inside arrangements. (For standardization of dies and elimination of adjustment work)
Automatic palletize by using robots. (For three-dimensional warehouse)
Adoption of HQDC “HIROTEC Quick Die Changer” which won the world championship in Die Changing Challenge Competition
We've come up with various ideas to make high quality products.
3. Capacity
A line 4 press machine 1500t*1500t*800t*800t (H&F)
| Conveying between press machines (6m) | high speed robot conveyer |
|---|---|
| Aiming shot cycle | -14.5SPM (12.0SPH: previous performance) |
| Aiming time of changing dies | 60 seconds (120 seconds: previous performance) |
| Products | Inner and outer parts of doors, parts of construction machines, door service parts |
B line 4 press machine 800t*800t*300t*300t (KOMATSU)
| Conveying between press machines | high speed pendulum feeder |
|---|---|
| Aiming shot cycle | -20.0SPM (20.0SPM: previous performance) |
| Performance per hour | target 800SPH (600SPH: previous performance) |
| Aiming time of changing dies | 60 seconds (120seconds: previous performance) |
| Products | muffler parts and small parts of doors. |
1. Outline
Automatic Die Changing Device (HIROTEC Quick Die Changer) is the device which was admired by world's automotive industry. This device can make various kinds of doors without stopping the line.
In 1991, we established a world record sponsored by U.S. automotive industry magazine “Automotive Industries”. The record time at that competition was 30 seconds and we keep breaking the past time.
In addition, we were awarded an honor of “One of the best” 2 consecutive years.
1. Outline
Automatic warehouse is the place where we keep previously pressed parts until next process. The capacity of parts is worth 2,250 cars. In accordance with production control system, every part is automatically conveyed to the next process.
2. Feature
| Stock space | Stock parts three-dimensionally and automatically so that we can apply smaller space effectively |
|---|---|
| Liftless | we dispense with forklift operation |
| Shelves | Shelves can keep 1,716 containers of parts. (Automatic warehouse A: 956, B: 760) |
| Traceability | We can trace when and where the parts exist by using computer system |
| Kit supply method | Supply parts to fit the lot |
1. Outline
To adjust changing of number and to avoid human error, we set up robot manufacturing line. Automatic palletize system for reduce the burden of work.
Automatic process of inspections
Nozzle servo method and sealer application automatic inspection
Sash automatic revision of measurement by using robot coordinates data
Automatic torque measurement by using servo nut runner
Automatic changing method of electrode welding
Hem machine is applied electric hem manufactured by our company.
2. Capacity
A1/A2/A3 lines only for mass production 10 kinds of auto parts can be produced with 1 line (left and right)
| Machine tact | 30 pieces per seconds |
|---|---|
| Capacity (3 hours overtime work) | 46,000 pieces per month (one line) |
| Aiming die changing time | 60 seconds (120 seconds: previous performance) Hem machine is linked system servo hem |
A4 line for fewer production 10 kinds of auto parts can be produced by changing one line
| Machine tact | 42 pieces per seconds |
|---|---|
| Capacity (3 hours overtime work) | 13,000 pieces per month (one line) |
| Aiming die changing time | 120 seconds (120 seconds: previous performance) Hem machine is linked system servo hem |
A5 line only for service parts
A6 line for fewer productions
The amount of all line's capacity is 156,000 pieces per month.
The numbers of employees are only 98, but robots are working almost all process and the employees are mainly in charge of preparations.
Speaking of robot, we can imagine ASMO, the robot made by Honda but our industrial robots are also excellent. They can convey heavy parts quickly and do the same monotonous task without any failure. And they can also inspect the parts.
The main feature is to manufacture various doors in one line. This is original way and few examples exist in the world.
We have 6 lines and there we make all doors and service parts of MPV, RX-8, Roadstar, Plemacy, Verisa, Demio, Tytan and CX-9.
