Creating new value by applying core technologies
Yutaka applies its powerful precision stamping and precision welding technologies and uses structural analysis and various evaluation technologies as it takes on the challenge of developing new technologies for the next generation of automobiles.
The SPORT HYBRID i-MMD fitted in the Honda Step WGN hybrid and other vehicles comprises of two motors: one for driving and one for generating electricity. The rotor is an important part that constitutes the rotation axis of the motor.
The drive rotor converts electricity stored in the battery into driving force to move the vehicle, while the electricity generation rotor transmits the rotational force from the engine and during regenerative braking into the motor, where it is converted into electricity.
Yutaka created a clean rotor assembly line with high production capacity by achieving automation of every process from machining to measurement, and started mass production in July 2017.
Taking On Challenges Boldly for the Next Generation through Team Work
Ever since I was a child, I’ve loved “making things” such as plastic models, and in college I studied mechanical engineering.
After joining Yutaka, I was initially involved in developing production technology for exhaust products and torque converters before being invited to join an in-house project team working on mass production of rotors, a key component in motors, which was a new business for Yutaka.
Motors require more rigorously controlled precision and quality than other automotive parts. To mass produce motors composed of a laminated core, shaft, resolver and so forth, it is necessary to develop a mass production line that can assemble each part efficiently and with high precision, from scratch.
The in-house project team was formed from young experts in various departments within Yutaka in order to develop the rotor assembling line reliably and quickly.
Having said that, motor parts is a new business for us, and although the team was comprised of experts, our expertise in motor parts was limited. We encountered all kinds of set-backs at the start of development because we did not have sufficient test pieces and equipment in-house to conduct assembly trials. So we didn’t know what kind of countermeasures to prepare and we were grasping for a direction.
In this situation, the team members communicated across their departmental boundaries, implemented FTA and FMEA, and received valuable advice from the supervisor in charge, which enabled us to identify and address issues prior to starting assembly trials. In the event, we encountered unanticipated problems along the road to mass production, but I remember that each time we went to the relevant departments and received advice from them.
Now, we have a workplace with a good culture and I am looking forward to the challenge of new production technologies.