In this series, we’ll take a look at how products get made at SANYO DENKI.
Here, we’ll examine the manufacturing process for UPS (uninterruptible power supply) at a Fujiyama Works, located in Ueda, Nagano Prefecture. In this third section, we will introduce the entire manufacturing process of small capacity UPSs from assembly to shipment.
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Location: |
4016, Fujiyama, Ueda-shi, Nagano |
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Property Area: |
95,632 m2 |
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Main Products: |
Fans, UPSs (uninterruptible power supplies), PV inverters, servo amplifiers, stepping drivers, system controllers, etc. |
Highlighted in yellow is what is covered in this page.
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1. Acceptance Warehousing |
2. Unloading & Setting |
3. Parts Assembly |
Small Capacity UPS |
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A. Wire Processing
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4. Final Assembly Assembly & Wiring |
5. Final Inspection Inspection Aging |
6. Shipping Preparation Packaging |
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B. PCB assembly Component Mounting Soldering |
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Mid & Large Capacity UPS |
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4′. Final Assembly Unit Assembly Assembly & Wiring |
5′. Final Inspection Inspection Aging |
6′. Shipping Preparation Packaging |
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Small Capacity UPS
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Final Assembly
■ Assembly & Wiring
An in-house developed “production guidance system” is used for making small capacity UPSs. The “production guidance system” is designed to automate work procedures. Operators assemble each unit according to the instructions on the screen.
Production guidance system assembly line/ Instructions displayed on the screen
Parts to be used are indicated by an LED/ Tighten using the LED-indicated tool until the torque-up signal is activated then move to the next step
POINT
The “production guidance system” will throw an error if the correct components are not removed from the predetermined position. The system is designed to ensure that the error occurs in order to eliminate human errors.
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Final Inspection
■ Inspection & Aging
After assembly, the final inspection is performed. Based on inspection procedure sheets, units are carefully inspected to ensure they meet the characteristics (current, voltage, protection operation, etc.) of the specifications diagram.
Acceptance inspection
The battery is installed then given a test run to check its real-life functionality in a process known as aging.
Battery installation
Aging
POINT
The inspection guidance system and automatic inspection program provide step-by-step instructions and prevent inspection mistakes. Here as well, only specially certified operations are permitted to do inspections. Aging is a vital process for detecting initial defects.
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Shipping Preparation
■ Packaging
Goods are packaged after inspection. The package is inspected and moved to temporary storage. Goods are shipped as directed to accommodate the customer’s desired receiving day.
Packaging
Packaging complete
POINT
More inspection is conducted after packing to check for issues with the packing condition. The package gets checked again before being sent to storage.
“With the production guidance system, we can make sure only products of unified high-quality reach the hands of our customers.”
“Our inspection procedure sheets ensure that inspection gets done properly. We only want to make products that satisfy our customers.”
