DENSO Corporation
Development of a flexible, fully automated production system that can respond to changing markets
The automotive industry is facing an uncertain demand for EVs and must respond to fluctuations in production numbers. It is also facing the challenge of dealing with a decline in the working population due to a declining birthrate and aging population, and is in need of a once-in-a-century transformation.
In this situation, DENSO is working on developing a flexible fully automated production system.In order to achieve both safety and productivity, which have always been important, even in the new production system,We have been working with Macnica to develop a safety monitoring system.
USER PROFILE
■Company information: DENSO Corporation
■Business Description:
DENSO is a global automotive parts manufacturer that provides cutting-edge automotive technologies, systems and products. We will fulfill our corporate social responsibility by providing world-first products and technologies.
Macnica members (top photo)/Lee, Aoki, Asakura
DENSO Corporation members (bottom photo)/Mr. Noro, Mr. Arai, Mr. Kodama, and Mr. Hoshino
Aiming for a production system where people and machines can coexist and where everyone can work with peace of mind
-Please tell us what prompted you to startthis initiative.
Mr. Hoshino:
The automotive industry is facing a once-in-a-century transformation. Flexible production systems are required at manufacturing sites, and we are adopting collaborative robots that can be used without safety fences and perform a variety of tasks, using them in various locations in the factory according to production plans, without limiting their use. However, existing 2D safety sensors react only when an object is present in a set area, slowing down the robot's movements, so there is a need to distinguish between AGVs that do not need to react and workers who must be detected.
--Could you tell us why you decided to work with Macnica on this development?
Mr. Hoshino:
We felt that Macnica 's high level of comprehensive technological capabilities could solve this difficult problem. Initially, we were thinking of using AI for identification, but in an ever-changing factory environment, it is not yet recognized under global rules that it is necessary to not only issue warnings to workers but also control the operation of equipment to ensure safety. So we looked for a partner who could handle everything from selecting sensing equipment to software development. We were fascinated not only by the content of Macnica 's proposals, but also by their speed of response and ability to execute through the PoC development, and we decided that we definitely wanted to work with them on mass production development.
MAC Aoki:
Macnica 's sensor consulting is a service that provides consistent support from the selection to the introduction of sensors used in autonomous driving, etc. We make proposals with an eye toward commercialization, from hearing from users, selecting sensors, developing PoC, and mass production.
Identify workers and AGVs to ensure both safety and productivity.
Can you tell us about this project and its flow?
Mr. Kodama:
As this was our first attempt, we started from scratch, feeling our way through everything.
So the first thing we did was to install the 3D sensor suggested by Macnica at the work site and check the actual data that was acquired.
Based on that data, we discussed and decided one by one with Macnica on the installation position of the 3D sensor, the image processing method, and the judgment logic.
At the implementation stage, we requested that Macnica create a highly reliable system, as this system affects the safety of workers. We exchanged specifications through close communication, and in the final testing evaluation, they evaluated and confirmed over 100 items that we requested.
MAC Li:
We proposed not only3D sensors but also software and hardware, and although it was a long journey of two years, we were able to successfully complete the system.
-Aiming for peace of mind and safety with fully automated operation by 2030What is your vision for the future of your manufacturing plant and what is the most important thing to you?
Mr. Arai:
In Japan, the birthrate is declining and the population is aging, so there is an urgent need to automate and unmanned manufacturing sites. However, there is still a possibility that humans may enter the manufacturing site. Therefore, we have developed a safety system that allows humans and machines to coexist.
DENSO's long-term policy is to "maximize the value of the environment and safety and create empathy" through its business activities. Safety is also our number one priority at our factories, and we are working to create a workplace where employees can work with peace of mind.
How it will be done in the future
--Could you tell us about your future plans?
Mr. Kodama:
Over the next few years, we will add a demonstration line and evaluate the performance of this system.I plan to do so.
--What are your requests and expectations for Macnica?
Mr. Kodama:
Although the system was completed, there were issues with actual operation and the need to add more lines.Although we believe there will be many issues to come, we hope to continue working together on various developments in the future.
MAC Asakura:
We hope to continue our relationship for a long time to come.
Inquiry
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