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.
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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. |
Making an Uninterruptible Power Supply
The production begins with quality control. 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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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.”
