An Automated Line for Painting and Coating / 1988

Technology Reflecting Real-World Experience

An Automated Line for Painting and Coating / 1988

Exciting Results from the Coating-Line System

Suzuka Factory introduced its high-efficiency coating line system to mass production in May 1988, dramatically reducing the number of steps needed to complete a car body. In particular, the coating process for the outer panels, which formerly employed a combination of skilled operators and machines, underwent a significant streamlining.

Exciting Results from the Coating-Line System

The coating line for the new Odyssey minivan went into operation at HCM in September 1998. Here, a minivan is being painted on the EVB metallic bell spraygun line, which achieved significant improvements in coating efficiency. The new coating line also produced an exceptionally clean work environment.

Installed on the line at the intermediate coating and overcoat application stages were several outer-panel-top multicoat robots, which were used to apply coatings over horizontal surfaces, along with outer-panel multicoat robots for vertical surfaces. Of the two, the former solved longstanding problems in the conventional reciprocator by adopting a configuration featuring several sprayguns. This permitted the robot to coat sections at the front and rear of the body that earlier machines had failed to reach. Moreover, the added function of moving the gun arm up and down according to body orientation made it possible for the coating material to be sprayed onto the body surface at a constant right angle. To enhance coating efficiency on the side surfaces of the body, gun arms were installed on the right and left sides of the line. Thus, the new system allowed the distances between these guns to be changed according to the target model, achieving an optimal coating effect. With that, the outer-panel coating line became fully automated, removing the need for operators to work manually.

The multirobots then employed in the inner-panel coating process were equipped with slim arms offering smooth movement and the ability to perform precise, high-speed coating in tight spaces around the body. One of the more significant factors in the achievement of an effective new coating system was the development and installation of dedicated opener/closer robots designed to open and close the hood, trunk, and doors during the coating process.

"In the process of coating the inner panel we had always used door jigs to keep the door in a closed or opened position while the coating was being applied," said Arai. "The robot technology we introduced to the process was developed by combining the wisdom of people experienced on the line, including the use of coating jigs. I believe the total effect of all these efforts was a greater degree of support for Honda's production technology."

The new, high-efficiency coating line employed a number of cutting-edge technologies. By developing its own coating facilities and machines, Honda achieved a significant savings in labor across the entire line. The new system consolidated operations that used to require two lines, yet it still met the production requirement of 1,100 units per day. Furthermore, the overall length of the coating line was reduced by approximately 36 percent. And, because of the reduced line length the time needed to move a workpiece through the coating process was reduced to around 33 percent of what it had been, meaning less liquid inventory. These achievements led to a dramatic reduction in the amount of energy needed to operate the line.

The high-density, integrated body-painting system introduced to Suzuka Factory's third line received the Ohkouchi Memorial Award for Production in 1991.

The Challenging Spirit of Honda

1990 - 1999
  1. The Birth of Twin Ring Motegi / 1997The Birth of Twin Ring Motegi / 1997
  2. Entry to Champ Car Racing / 1994Entry to Champ Car Racing / 1994
  3. Odyssey / 1994Odyssey / 1994
  4. Establishment of Honda Taiyo, Kibo-no-Sato Honda and Honda R&D Taiyo / 1992Establishment of Honda Taiyo, Kibo-no-Sato Honda and Honda R&D Taiyo / 1992
  5. Hosting Hosting "Orei-no-kai" / 1991
  6. The NSX / 1990The NSX / 1990
1980 - 1989
  1. The VTEC Engine / 1989The VTEC Engine / 1989
  2. Honda EV Plus: The Dream of an Electric Vehicle / 1988Honda EV Plus: The Dream of an Electric Vehicle / 1988
  3. An Automated Line for Painting and Coating / 1988An Automated Line for Painting and Coating / 1988
  4. Four-Wheel Steering System (4WS) / 1987Four-Wheel Steering System (4WS) / 1987
  5. The Airbag System / 1987The Airbag System / 1987
  6. The ZE Engine (GX110 / 140 / 240 / 270 / 340 Series) / 1983The ZE Engine (GX110 / 140 / 240 / 270 / 340 Series) / 1983
  7. Formula One Entry / 1983Formula One Entry / 1983
  8. Development of Honda's Franz System Car / 1982Development of Honda's Franz System Car / 1982
  9. The World's Smallest Welding Line / 1982The World's Smallest Welding Line / 1982
  10. Transfer Lines for Modular Components / 1981Transfer Lines for Modular Components / 1981
  11. The Car Navigation System / 1981The Car Navigation System / 1981
  12. City / 1981City / 1981
  13. The F200 The F200 "Komame" Mini-Tiller / 1980
  14. Establishing Honda of America Manufacturing / 1980Establishing Honda of America Manufacturing / 1980
1970 - 1979
  1. The Oval Piston Engine / 1979The Oval Piston Engine / 1979
  2. Returning to the World Motorcycle Grand Prix / 1979Returning to the World Motorcycle Grand Prix / 1979
  3. The HR21 Lawn Mower / 1978The HR21 Lawn Mower / 1978
  4. Creating Hometown Forests / 1977Creating Hometown Forests / 1977
  5. The ME Engine (G100 / 150 / 200 / 300 / 400 Series) / 1977The ME Engine (G100 / 150 / 200 / 300 / 400 Series) / 1977
  6. Introducing the Accord / 1976Introducing the Accord / 1976
  7. CG125 / 1975CG125 / 1975
  8. Establishment of Honda Engineering / 1974Establishment of Honda Engineering / 1974
  9. Company Leaders Honda and Fujisawa Retire; Kawashima Assumes Presidency / 1973Company Leaders Honda and Fujisawa Retire; Kawashima Assumes Presidency / 1973
  10. Announcing the Civic / 1972Announcing the Civic / 1972
  11. Introducing the CVCC / 1972Introducing the CVCC / 1972
  12. Holding All Honda Idea Contests / 1970Holding All Honda Idea Contests / 1970
  13. Launching the Office of Safe Driving Promotional Operations / 1970Launching the Office of Safe Driving Promotional Operations / 1970
1960 - 1969
  1. The Dream CB750 FOUR / 1969The Dream CB750 FOUR / 1969
  2. Launching the Honda 1300 / 1968Launching the Honda 1300 / 1968
  3. The Hondamatic Transmission / 1968The Hondamatic Transmission / 1968
  4. Entering the Auto Market at Last / 1966Entering the Auto Market at Last / 1966
  5. The E300 Portable Generator / 1965The E300 Portable Generator / 1965
  6. Formula One Entry / 1964Formula One Entry / 1964
  7. Kyoto: Celebrating the Company's 15th Anniversary / 1963Kyoto: Celebrating the Company's 15th Anniversary / 1963
  8. Establishing Belgium Honda / 1963Establishing Belgium Honda / 1963
  9. Launching the S360 and T360 / 1962Launching the S360 and T360 / 1962
  10. Employing the Employing the "My Record" Project and Expert Certification / 1960
  11. The R&D Center Goes Independent / 1960The R&D Center Goes Independent / 1960
1950 - 1959
  1. Establishing American Honda Motor Co. / 1959Establishing American Honda Motor Co. / 1959

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