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Assembly
Production plan creation
We create an assembly order table, list
the components required for each
assembly line, and create a production
plan.
This order table allows us to manage the
complex steps required to assemble over
2,000 engine models.
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Assembly
Part selection
We use barcodes to manage the assembly
order table. When barcodes are read in
engine component pick-up areas, lights
light up in the locations where the
components required for each engine are
kept so workers can go pick them up. We
also arrange Automated Guided Vehicles
(AGVs) in locations where they can be
used to automatically carry components
to the line.
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Assembly
Assembly
The line displays assembly instructions
for engines with different
specifications on screens, thus enabling
workers to accurately assemble different
engines one at a time.
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Assembly
Cylinder head assembly
This shows our automated cylinder head
assembly process.
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Assembly
Defect prevention device
Fool-proofing (poka-yoke) is a way of
thinking and a method for creating a
state where mistakes do not occur.
We carefully designed the Kubota engine
assembly line, which produces a wide
range of products in small quantities,
to prevent assembly errors. The correct
components must be attached to engines
carried along the line at each specific
step before the engines can advance to
the next step. For example, in our Sakai
Plant, we have installed fool-proofing
devices in approximately 200 locations
and introduced mechanisms to ensure that
workers are only able to use the correct
components and tools.
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Assembly
Nutrunner
We have implemented nut runners in the
assembly process that tighten all joints
with nuts at once.
This video shows the joining of
crankshafts to cylinder heads.
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Assembly
Torque check
We check torque values on the line
during the assembly process. Each and
every engine is carefully inspected to
see whether it has the required torque
values. We also check the tools workers
are using.
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Assembly
Traceability
To manage engine performance, exhaust
gas response, and safety, we have set
regulations for each factory and carry
out traceability according to strict
standards for things like nut runner
tightening record traceability and
injection timing traceability.
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Assembly
Leak test
After assembly, we place engines in
water to check for leaks.
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Assembly
DPF
At Kubota, we also manufacture DPFs
in-house, which are very important
components in emission regulations
around the world. At our Sakai Rinkai
factory, workers assemble components
while riding on Automated Guided
Vehicles (AGVs).
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Assembly
IPU
Injection Pump Units (IPUs) are
components that send fuel into diesel
engine combustion chambers at high
pressures. Kubota has also created an
independent line for producing these
components in-house for mounting in its
V3 Series of Kubota engines.
