Manufacturing of Rolling Stock in Kawasaki Heavy Industries (KHI) Kobe, Japan 9 th of June 2009 1
Agenda 1. KHI Rolling Stock Company 2. Domestic Rolling Stock Circumstance 3. Feature of each phase in the Project 4. For the future 2
Agenda 1. KHI Rolling Stock Company 2. Domestic Rolling Stock Circumstance 3. Feature of each phase in the Project 4. For the future 3
Overview of KHI Hyogo Works Hyogo Works (Rolling Stock) in Kobe city Sapporo Hokkaido Kyushu Fukuoka Shikoku Kobe Nagoya Osaka Honshu Tokyo Area;223,000m 2 Employees;Approx.1,000 Number of Engineers;360 Output; Coaches 80cars/month Locomotives 8cars/month 4
Market of KHI Rolling Stock Company Bullet Train (Shinkansen) Automatic controlled vehicle LRT Maglev Electric Cars Metro Exportation Locomotives 5
KHI Rolling Stock Portfolio Domestic Product JR Shinkansen Commuter Private railroad Company Oversea Product High Speed Metro Locomotive Coach Truck of London underground is also KHI products 6
Agenda 1. KHI Rolling Stock Company 2. Domestic Rolling Stock Circumstance 3. Feature of each phase in the Project 4. For the future 7
Production Trend (Domestic) 8
Customer, Competitor, Vender (Domestic) Customer: In Japan, there are 7 major railroad companies (JR Central, West, East, Kyushu, Shikoku ) In Urban Area, there are many private railroad companies. (16 huge and 5 middle and other small companies) Competitor: 4 major companies (Hitachi, Tokyu Sharyo, Nippon Sharyo, Kinki Sharyo) Vender: Many companies 9
Route map In 1933, Underground in London Made by Harry Beck (Electrical Engineer) Thames River? 10
Sales (International) 11 Big 3 No.1 Sales in Japan
Agenda 1. KHI Rolling Stock Company 2. Domestic Rolling Stock Circumstance 3. Feature of each phase in the Project 4. For the future 12
Contract Phase >Scope of Contract (between customer and us) [Basic planning, Basic design, Detail design, Procurement, Fabrication & Assembly, Inspection, and Hand over ] >Before: Nomination + Cost plus fee contract Now: Competitive bidding + Lump sum fixed contract Before completing the detail design, we have to estimate the cost of cars and decide the bidding price. (Problem!) 13
Engineering Phase >For a long time, Rolling Stock was basically Order-made product like a high-quality suit. (one by one) >Customers have their standards and strong policy. >Shape, length, number of doors, color are quite different company by company. Because of the new design every time, We need big man power for engineering. (Problem!) 14
Manufacturing Phase >Rolling stock is not always a mass production product. >The number of the production is not constant. For example, a big customer request more than 200 cars, however a small customer request only 1 car. >Our factory stands in the limited area. Therefore the latest arrangement of factory is not most suitable. >Commuter and Shinkansen are assembled in the same line. (Structure of Commuter is different from Shinkansen) >Manufacturing Phase can be divided into 2 stages. Bodyshell Frame stage and Interior & Equipment stage Special techniques are still required for workers. (Problem!) 15
Manufacturing Phase A >It is difficult to invest for the new machinery. >The quality is not steady. Schedule Image B Atype Btype Ctype Dtype C D Different type and different number of production >Workers need much time for preparation of production every time. >Workers need special techniques to meet the requirements of each cars. 16
Manufacturing Phase (Body-shell Frame) >Sub-assembled 6 parts are connected by automatic welding machine. >However many workers are still welding and using the grinder in some part. Assembly 17
Overview of Manufacturing(Interior and Equipments) Many hand-work done by experienced worker. (Similar to carpenters or artists) 18
Agenda 1. KHI Rolling Stock Company 2. Domestic Rolling Stock Circumstance 3. Feature of each phase in the Project 4. For the future 19
For the future We are now proceeding to 1) develop KAWASAKI standard train 2) inherit the special techniques TAKUMI for manufacturing. 20
KAWASAKI standard train 1) We are now proceeding to develop KAWASAKI standard train >What is standard train? to specify the changeable part and the fixation part >changeable part = visible part to meet the requirements from each customer >fixation part = non-visible part - standardization >It is also very important for us to assemble easily! >From order type business to proposal type business! 21
KAWASAKI standard train A proposal request Standard A B C D request proposal request proposal request proposal Standard B Standard C + Standard D + It is difficult to propose KAWASAKI standard train to every customer. However we can propose standard + to many customers. =changeable part E proposal request Standard E + 22
KAWASAKI standard train A >It will be easy to invest for the new machinery. >The quality will be steady. Schedule Image B Same Production way A B C D C D >Workers will not need much time for preparation of production every time. >Worker will not need special techniques to meet the requirements of each cars. 23
TAKUMI 2) We are proceeding to inherit the special techniques TAKUMI for manufacturing. >If we will develop KAWASAKI standard train, we still need the special techniques for manufacturing. >For example, front shape of shinkansen is made by special technique of experienced worker. >It is important to inherit the special techniques TAKUMI of experienced worker to next generation. >video, manual, education, apprenticeship 24
Conclusion We have to change! 25