No. 142 Plant

The Development of New Assembly Lines Based on KPS

Hiroshi Hirata
Susumu Yamamoto
Kazuyoshi Uoya
Nobuo Ishii

Production in the motorcycle industry is beset with many challenges. There is a wide range of models to manufacture, but small volume due to severe competition. Sales tend to be inconsistent as a result of economic fluctuations.
However, the current level of quality and production efficiency must be maintained. Now we have to accommodate the further complication of an aging population having fewer children.
Some assembly functions are especially difficult to automate, and these were targeted. Self-completion mini-lines were developed in order to reduce dependence on human skills while utilizing the knowledge of long experienced workers.
Two lines were finally introduced, a rotary type and a short conveyer type. Our achievement was an increase in the efficiency of the whole final assembly shop.
Furthermore, these lines were found to work as a good training area, with the combination of applied information technology and the availability of the skills of aged workers.

—Special Reports— K.T.R. No.142

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