Our products are produced at approx. 80 sites in 15 countries around the world. The role of production engineering is to achieve high product quality regardless of where in the world our products are produced, and to design the most efficient production methods. We are proud of our cutting edge Monozukuri, and we contribute to society through the evolution of technology in our pursuit of excellence.
of Calsonic Kansei
Various techniques to achieve robust Monozukuri
Plastic processing techniques
Plastic processing is a technique to form materials into the required shapes using various methods. This is a core technology because plastic processing is used to shape important functional components in Calsonic Kansei’s products. At Calsonic Kansei, we use our own unique outside-the-box thinking in our challenge to develop high value-added methods.
We use CAE techniques to improve product quality and design highly efficient production processes. In addition, we also conduct R&D into new CAE techniques to improve our core technology and contribute towards developing new technologies.
Machine molding techniques
For machine molding, we carry out high precision processing and control at the sub-micro level of aluminum alloys, ferrous components, etc. In addition, we constantly look at next-generation processes when putting effort into R&D.
By developing a special material with high fluidity and an injection molding technique that controls pressure within the mold, we are able to achieve molding of our injection skin for instrument panels, which is an ultra-thin skin of approximately 1.0 mm in thickness, and supply this product with its excellent feel at a low price.
This technique seamlessly wraps a 3D-sewn leather skin over the full instrument panel providing an exceptional sense of quality. We are able to deliver decorative variations of the interior cockpit assembly by changing the skin material, color, and texture.
We are automating our assembly & inspection processes, which were dependent on human labor, so as to move towards developing smart factories driven by IoT, and use machine learning based on different types of inspection data to optimize maintenance and control of processes. The picture shows an example of cooperative robots being developed for application in the assembly process. Cooperative robots can work together with people. They also contribute towards reducing the footprint of the overall production line because they are not required by law to have safety barriers installed.
Welding is one of our core technologies. Besides improving on traditional methods such as arc welding and resistance welding, we also improve the value we add through R&D into new welding methods.