NIDEC

Data
Management

Centralized Data Management

Production status, equipment operations, productivity, and other indexes are constantly "visualized" at all locations inside the factory. In addition, detailed data such as waste loss and the use of consumable items are sorted real-time as well. This system of managing manufacturing process-related data at a central location to promptly capture small changes supports the factory's daily autonomous improvement activities and its comprehensively lean high-efficiency production system.

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Smart
Logistics

Smart Logistics

This smart logistics system performs everything from raw-material management and storing to automatic supply of such materials to the production site. With automated guided vehicles ("AGVs"), goods are transferred between the warehouse and the production site efficiently, automating conventionally manual operations (e.g., raw-material transfer and empty box collection) and significantly reducing labor and inventory at the workplace. In addition, AGVs' operations and inventory/distribution/transfer requests are monitored real-time. With movements in all processes visualized at a central location, the factory enjoys an excellent traceability and a smooth component and material transfer in its entire facility.

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AI Image
Inspection
System

    High-Efficiency AI Image Inspection System

    With an AI system introduced for its post-welding surface inspection, the factory can now perform its product judgment (performed visually so far) in a completely automatic way. The high-accuracy AI analysis completely prevent complex products from being left uninspected and the escape of defective units. Thus, this system drastically reduces labor in the inspection process while securing an overwhelmingly high inspection speed and an extremely high inspection level.

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    Digital
    Control

      Digital Control Technology for Consistent Quality and Waste Reduction

      This is an automatic line that produces 20 million units monthly with a stable quality and in an eco-friendly way. With the resin-molding line housing 17 horizontal molding machines, the factory has in place a totally unmanned production system, including raw-material supply, molding, packaging, and waste-material collection. Furthermore, by reusing leftover materials real-time, the system achieves a highest-level production efficiency while reducing environmental load without generating any waste materials.

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      Automatic
      Sorting

        Automatic Sorting of Finished Products

        The warehouse to keep finished products produced in the factory is equipped with an automatic sorting function that moves autonomously as goods are delivered in from the production site automatically and also based on the shipping plan. The automatic sorting function enables optimum allocation changes based on the shipping order for the following day and shipping destinations, as well as efficient shipping preparations. Thus, in addition to simply keeping goods inside, this system supports the factory's quick and accurate product distribution system.

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        System
        Control

          Control Systems for Production Efficiency and Safety

          The factory employes an automatic production system that handles items in complex operations under a high-heat environment and transfer heavy materials, securing workers' safety and improving production efficiency to the highest extent. The three robot arms integrated into individual machines automatically remove products from their molds, perform trimming, and deburr before completing the dangerous physical processes. Further, with raw-material supply optimized with an unmanned transfer system, the factory has human operators focus on high-level final judgment to secure an unfaltering safety level and a high-efficiency production system.

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          Smart Factory
          Concept

          Since the launch of production in 2001, Nidec Automotive Motor (Zhejiang) Corporation, or NAMS, has sent out a total of more than 200 million EPS motors into the world from the city of Pinghu, China.
          Based on this record, the factory integrates its passion and cutting-edge technology to constantly evolve into a next-generation smart factory.
          Watch how this flagship factory flexibly evolves with the changing times.

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          Labor-Saving AGVs with Automatic Transfer Systems

          Raw-material transfer, collection of finished products and empty boxes, and other manually performed works are now automated thanks to automated guided vehicles ("AGVs"). In addition to a monitor-based tracking system, the AGVs use AI to optimize their routes, enabling speedy transfer of products to the workplace. AGVs are also flexible enough to use identification QR codes to add routes and change layouts.

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          Automatic Production Line

          The factory's resin-molding and aluminum die-casting production lines integrate state-of-the-art robot technologies with a digital control system. From the input of raw materials to high-accuracy processing to packaging, the factory's dedicated, system-integrated equipment operates the entire process autonomously. In particular, for heat-generating operations and physically demanding processes, optimized automatic units are allocated, making the production lines consistent and unmanned. It is this high-level automation that enables this factory to produce high-quality products always stably and efficiently while securing safety of the workplace.

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          Assembly Production Line

          This is the factory's electronic power steering (EPS) motor production line, which can produce 18 million units per year. In this area that produces basic components supporting functions to make the car turn, an automatic inspection system is used with a PQM server-based quality management system to prevent record errors and reduce time for inspection significantly. By visualizing workplace management, introducing face authentication-based automatic consumables management, and using other digital technologies, the factory has eliminated waste and redundancy completely, establishing a high-efficiency system with an absolutely minimum amount of production loss.

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          Automated Finished Goods Warehouse

          This is a 3D finished goods warehouse, with a capacity of 5,500 pallets, that plays a central role in production and logistics. Linked with an internal system, this warehouse monitors everything from inventory volume to exclusive areas to incoming and outgoing goods to inspection status, thoroughly visualizing information. Further, automated guided vehicles ("AGVs") are used in the entire process from the arrival through the departure of goods, ensuring an efficient and accurate transport and a significant labor saving, and optimizing the entire logistics operations.

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          Digital Operation Center

          At the Digital Operation Center located next to the production site, all data of the factory, ranging from manufacturing status to finance to PSI plan to personnel information, can be obtained real-time. The monitors occupying the wall show latest figures to help the factory's management hold meetings quickly to discuss risks and other issues every day. NAMS is a pivotal facility whose front-line operators work with management to operate at an overwhelmingly high speed.
          Information

          The "Model Factory" Mr. Kishida, NCJ's President, refers to - It is a production base where frontline employees think creatively to realize issue-solving ideas one after another.
          The accumulation of such proactive improvement actions is the very basis of this constantly evolving smart factory.
          Please watch how Nidec engages in its constant, endless innovation.

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