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Mitsubishi automobile's new coating production line cuts costs by 30%

Mitsubishi automobile industry announced on August 10, 2011 that it has built a new coating production line at Nagoya production station in Okazaki City, Aichi county (Figure 1). By introducing new robots, improving the structure of buildings and changing the coating, the production cost, energy consumption and VOC (volatile organic compounds) production of the coating production line have been reduced by about 30%, 25% and 65% respectively. The code for the design of clean workshops gb50073 (2) 001 "takes into account both cost and environmental protection" (Mitsubishi automotive industry executive director, Nagoya Manufacturing Institute Takayama Anfu). The investment is about 15billion yen. Nagoya manufactures small SUV "RVR" and small car "colt", with a production capacity of 210000 vehicles per year

Mitsubishi Motors recently unveiled its new production line to the media. After being exposed to a large number of entrepreneurial projects, the implementation methods of this reduction include reducing the number of painting robots in the middle and upper painting processes; Introduce new coating guns to reduce waste paint; In the lower coating process, the "world's first" (Mitsubishi automobile) body handler is introduced, thereby shortening the length of the production line

in terms of reducing the number of robots, Mitsubishi Motors reduced the previous 18 robots in the middle coating process and the upper coating process to 14. The specific method is to import the robot produced by Yaskawa electric, which is about 40% lighter than the traditional model, and then install the robot originally set on the floor at a higher position on the wall to expand the coating range of each robot (Figure 2). The new coating gun for spraying paint on the car body is a cartridge product produced by ABB company in Switzerland. When in use, only the necessary amount of paint is put into the barrel, thereby reducing the waste of expensive paint by about 60%. The car body handling machine in the bottom coating process has been introduced into the dip (impregnation) process in which the car body is immersed in a large tank filled with aqueous epoxy solvent and electrodeposited to improve rust resistance. The characteristic of the carrier is that it can greatly change the angle of the front and rear direction of the vehicle body (Fig. 3). The length of the production line is shortened by changing the angle of the car body and increasing the angle of entering and leaving the groove (Fig. 4)

the measures taken to reduce energy consumption include: the factory adopts a three-layer structure to reduce the energy consumption of air conditioning; The lighting fixture is changed from the original fluorescent lamp (hot cathode tube) to cold cathode fluorescent lamp (CCFL). The factory adopts a three-layer structure, which means that the processes that use heat to improve productivity such as drying and painting are placed on the third floor of the factory, the mobile processes of high energy consuming devices such as robots are placed on the second floor, and the manual operation processes are placed on the first floor. Since the heat will naturally rise, if the process generating heat is configured on the upper floor of the plant, the temperature of the first floor where the operators are located can be reduced, thereby reducing the use of air conditioning. Masuki Takahashi, the coating production technology minister of Mitsubishi automotive production technology headquarters, said confidently, "although this idea is not difficult, there may be no precedent in the world that pistons and piston sleeves should be completely removed and ground to use this way of thinking."

voc reduction is achieved by changing the coating with organic solvent into water-based coating in the middle coating process and the upper coating process

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