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Corporate September 26, 2000 |
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Honda Introduces Its Renovated Auto Production Line at Suzuka
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Tokyo, September 26, 2000 - Honda Motor Co., Ltd. today unveiled its redesigned
Suzuka No. 1 production line featuring the new technologies and processes being
integrated in Honda's global production system. The revamped Suzuka No. 1 line,
which went into operation in May, is the model for Honda's new production lines in
North America and Great Britain. It incorporates new production technologies that
focus on two themes -- increased efficiency and flexibility -- which in turn are linked
to two strategic objectives:
1. Faster response to market trends
2. Maintaining the highest standards of Honda quality
Honda's new production system has two additional benefits:
1. It reduces the impact of the production process on the environment.
2. It creates a safer, more pleasant and therefore more productive working
environment for Honda associates.
The Suzuka No. 1 line has already been replicated at plants producing the Civic in
the United States and Canada, and will be introduced in Great Britain by the end of
this year, to coincide with the new Civic's production launch.
Bottom Line Results
The new production equipment and technologies in use on this line have led to the
following impressive results, as well as dramatic improvements in the welding,
painting, and body assembly processes:
* A 50% reduction in special investment associated with the introduction of new
vehicle models, and initial investment required for building a new production line
line
* A 30% reduction in production time from the initial process to final vehicle
inspection
* An increase in the number of models that can be manufactured on a single line
(from five to eight)
* A 20% reduction in carbon dioxide emissions from the production process
* Significant improvements in the quality of finished vehicles in areas such as body
precision and rigidity (for example, gaps between the body panels and doors have
been further reduced for improved fit.)
* Increased productivity through improvements in the working environment
Specific Production Process Improvements
Welding
* Introduction of highly flexible welding equipment that can be used in the production
of multiple vehicle models
* Introduction of simple tools for specific applications to reduce special investment
necessary for the introduction of new vehicle models
* Use of electric servo guns and electric robots for optimal control to speed up the
welding process
* Optimization of the number of weld points for increased body precision
* Employment of general-use pallets to make the body conveyor process
compatible with multiple vehicle models
Painting
* Reduction of special investment for the introduction of new vehicle models to zero
through employment of simple and general-use conveyor equipment
* Shortening of the overall length of the line through use of more compact pre-
processing methods and short ovens
* Reduction of work tasks in the quality verification process through improvements
in body washing methods and the introduction of dust vacuum robots
* Use of environment-friendly water-borne paints in both the intermediate and top
layers to reduce VOC [volatile organic compounds] emissions volume to 20g/m2
(Honda is the first auto company in Japan to do so.)
* Increased comfort in the working environment through the separation of hot
process areas from other working areas.
Body Assembly
* Introduction of more general-use vehicle body conveyor equipment (This has
eliminated the need for additional investment associated with the introduction of
new vehicle models.)
* Use of sub-lines to minimize variations between vehicle models in the number of
processes performed by the main line, thus shortening the main line's overall length
* Reconfiguration of the line to create five process zones [wiring & tubing, interior,
chassis, exterior and complex]. Similar assembly processes are located in each
zone, so that quality is assured before vehicles move to the next area.
* Reduction in the number of operations that require working in uncomfortable
positions.
SUMMARY
By the end of fiscal year 2001 (ending March 2002), Honda will have invested 36
billion yen over a three-year period in new production technology at its two principal
automobile production plants in Japan, Suzuka and Sayama.
This investment is part of Honda's commitment to its "green factory" concept, which
seeks to fully renovate the production process to meet the needs of 21st century
production.
Before the end of this year, these reforms will further improve the quality of finished
vehicles at both plants, affecting nearly every production process.
Similar efforts are underway at Honda production facilities overseas, with their
introduction at major plants scheduled for completion in 2003.
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