Factory Tour for Power Systems Vol.1

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.

 

Location:

4016, Fujiyama, Ueda-shi, Nagano

Property Area:

95,632 m2

Main Products:

Fans, UPSs (uninterruptible power supplies), PV inverters, servo amplifiers, stepping drivers, system controllers, etc.

 

 

Making an Uninterruptible Power Supply

 

The production begins with quality control. Highlighted in yellow is what is covered in this page.


1. Acceptance

Warehousing

2. Unloading

& Setting

3. Parts Assembly

Small Capacity UPS

A. Wire Processing

 

4. Final Assembly

Assembly & Wiring

5. Final Inspection

Inspection

Aging

6. Shipping Preparation

Packaging

B. PCB assembly

Component Mounting

Soldering
Finishing
Inspection

Mid & Large Capacity UPS

4′. Final Assembly

Unit Assembly

Assembly & Wiring

5′. Final Inspection

Inspection

Aging

6′. Shipping Preparation

Packaging


1: Acceptance Warehousing

Receiving Materials: Components procured by the purchasing department are delivered from suppliers.

 

Acceptance inspection

 

 Parts delivered to the acceptance area and Automatic warehouse

 

A row of power supply enclosures

 

—POINT—

Only the specified number of components are removed and undergo acceptance inspection. Shape, dimensions, and exterior appearance are checked, and even if one defective item is found in inspection, the entire lot is rejected and returned to the manufacturer. After the acceptance inspection, components are stored and managed in the automated warehouse.


2: Unloading & Setting 

Parts are unloaded as required for the production schedule.    

 

Necessary parts are sorted onto serving carts for each production order. At this time, technicians will prepare PCBs and wires processed in the wire processing station, which is introduced in “3. Parts Assembly.”

 

—POINT— 

Each day, around 2,500 components are unloaded automatically.

This vital task is essential for efficient assembly work. Necessary parts are delivered in the order of use according to the production order.

 


3: Parts Assembly: A. Wire Processing

The wire is cut to a fixed length and fitted with crimped terminals and connectors.

 

Left: An automatic wire processing machine for thin, two-sided wires/ Right: A worker is cutting thick wire

  

Left: Crimping terminals/ Right: Thin wire crimping terminal  

 

Left: Completed thick wires/ Right: Completed thin wires 

—POINT—

Technicians will prepare a wire processing list that specifies the type, length, terminal type, connector type, and many cables used with every kind of machine. Following this list, more than 100 thick wires and 700 thin wires are processed every day.


 

Voice

 

“We follow strict guidelines when processing wires. Bottom line: if something doesn’t meet our standards, it won’t be passed on.”

 

 

 

 

 


 

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