Automation without failure through work breakdown | Production line construction "Thermix"
Break down the tasks before deciding on the equipment. Design a production line where labor-saving measures are "established."
When considering labor reduction solely in terms of "how many people can be reduced," it often leads to failure as the burden on the site does not decrease even after implementation. Termix breaks down on-site tasks into operational units before equipment selection, categorizing them into automation, semi-automation, work support, and manual tasks, thereby designing a system where labor reduction is achieved across the entire production line. We excel in handling large works in the automotive, aerospace, and construction machinery sectors, and we cater to a wide range of industries including industrial machinery, machine tools, home appliances, and building materials. We design transportation, supply, positioning, processing, inspection, discharge, and recording from three perspectives: equipment manufacturers, FA integrators, and line builders, including factors that require human intervention such as work supply, abnormal recovery, product changeover, and initial product confirmation. - Automation does not reduce the burden on-site → Break down tasks including supply and abnormal recovery, and redesign. - Want to solve labor shortages through labor reduction → Automate repetitive and heavy tasks while leaving decision-making tasks to humans. - Want to eliminate variation in inspections → Design for OK/NG discharge, re-inspection, recording, and signal coordination. - Want to modify the line while utilizing existing equipment → Address constraints of existing layout, flow, and maintenance space. - Confirmation omissions occur during product changeovers of various types → Design operations for condition checks and initial product confirmations during changeovers. We welcome consultations and requests for materials.
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【Functions and Features】 - Work Breakdown: Organizing processes by operational units to visualize time, worker dependency, quality variation, and load. - Design for automation/semi-automation/work support/manual operations separation. - Element-specific design for transportation, supply, positioning, processing, inspection, discharge, and recording. - Signal coordination between upstream and downstream processes, buffer design, and supply shortage detection. - Abnormal recovery, maintainability, HMI, and ensuring workspace/safety. - Line modifications utilizing existing equipment (layout, flow, wiring and piping, maintainability). - Handling, transportation, and positioning of large and heavy workpieces (automobiles, aircraft, trucks, construction machinery). Preventing a situation where the burden on the site does not decrease even when equipment is operational, and reflecting labor-saving effects in operations. This leads to improved equipment utilization rates, reduced quality variation, suppression of rework and minor stoppages after startup, and enhanced traceability through inspection records. 【Features】 - Designing for labor-saving as a production line by connecting not only equipment but also supply, transportation, inspection, maintenance, abnormal recovery, and operations. - Providing a unified perspective from equipment manufacturers, FA integrators, and line builders. - Starting from work breakdown, making it clear "where the ease has improved" after implementation. - Designing for processes that retain manual work, including flow, jigs, HMI, and safety, ensuring stable operation with low burden.
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- Industries served: We specialize in large and heavy work such as automotive, aircraft, trucks, and construction machinery, and we cater to factories in various industries considering labor-saving measures, including home appliances. - Scale/Work supported: We excel in lines involving the transportation, handling, and positioning of large and heavy work. We can accommodate everything from partial labor-saving to the comprehensive construction of multi-process lines. - Processes supported: Transportation, supply, positioning, processing, inspection, discharge, and recording. We design by separating manual work, automation, transportation, and inspection. - Forms of support: We achieve feasible labor-saving not only through full automation but also through semi-automation, work assistance, and optimal distribution of manual tasks. - Scope of services: We provide comprehensive support from work breakdown and conceptualization to line design, manufacturing, startup, and maintenance after mass production. - Customization: Completely tailor-made. Instead of fitting standard machines, we design individually from work breakdown and also accommodate line modifications utilizing existing equipment. - Implementation purposes: Addressing labor shortages, improving productivity, stabilizing quality, reducing workload, enhancing maintainability and operational stability, and labor-saving modifications of existing lines. - Consultation examples: We accept inquiries on a process basis, such as "I want to automate the inspection process," "I want to shorten the changeover time for multiple varieties," "I want to automate heavy load handling," and "I want to partially modify an existing line."
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We, Thermix, a top-tier production line builder with proven expertise, handles automation and line construction for production equipment across diverse fields including automobiles and automotive parts, aircraft bodies, and industrial machinery. We provide full turnkey solutions from concept and specification review through design, manufacturing, installation, commissioning, and maintenance, ensuring reliable mass production launch. Leveraging our production technology expertise, we organize and visualize the current state, including process feasibility, integration with existing equipment, and safety. Utilizing industrial robots, image processing, conveyance/inter-process transfer, and material handling, we propose realistic automation roadmaps without unnecessary strain. We address challenges like “We want to reduce staffing on lines that can't be stopped” or “Equipment investment decisions are difficult,” accompanying you from small-scale PoCs to full-scale deployment with our project management expertise. Leveraging our domestic and international launch experience, we collaborate to create the optimal production line.
