Yaskawa Electric : Presentation material “Sustainable and Productive Manufacturing”

June 05, 2024 at 10:10 pm

Sustainable and Productive

Manufacturing

June 6, 2024

Masahiko Okura

Executive Officer, General Manager, Production Management Div.

1. History of Manufacturing

Unmanned Factory Concept - Ideal Motor Factory -

Pursuit of Cutting-Edge Manufacturing at the Mother Factories

Unmanned Factory Concept - Ideal Motor Factory -

Unmanned Factory: A term coined by Yaskawa meaning a human-centeredautomation factory while moving away from manpower dependence. We differentiate it from "no-man," which marginalizes human intervention.

				Automatic	Automatic
Automatic	Automatic mid-	Automatic	Automatic
processing line	process warehouse	assembly line	inspection line	parts warehouse	products warehouse

Shaft warehouse

Product

warehouse

Cutting

Grinding

Frame bracket

warehouse

Image of Unmanned Factory

proposed in 1970

© 2024 YASKAWA Electric Corporation	2

Pursuit of Cutting-Edge Manufacturing at the Mother Factories - Challenges to Realize Unmanned Factories -

1990	2006	2014
Moteman Center	Flexible automatic assembly line	Space-saving automatic assembly method
"A factory where robots assemble robots"	utilizing IC tag	(Compact line)

2018	2022	2024
Yaskawa Solution Factory	Robot production line utilizing human	Robot component plant for internal
An i3-Mechatronics demonstration plant	collaborative robots	production realizing 24 hour unmanned
		operation

© 2024 YASKAWA Electric Corporation	3

2. Global Production Strategy

Demand Area Production

Targets and Progress in the "Realize 25" Mid-Term Plan Challenges for Realizing Sustainable and Productive Manufacturing

AC Drive Factory Robot Factory

In-houseparts manufacturing factory

YASKAWA AMERICA, INC.

Drives & Motion Division

USA

Demand Area Production

・Based on the demand area production policy, we have established a system that is resilient to demand fluctuations and environment changes (forex fluctuations and geopolitical risks).

・Global horizontal deployment of cutting-edgemanufacturing demonstrated at the mother

factoriesAC Servo Factory

YASKAWA EUROPE YASKAWA ELECTRIC UK ROBOTICS D.O.O. LTD.

ScotlandSlovenia

YASKAWA Electric (Shenyang)

Co., Ltd. China

YASKAWA (China) Robotics CO., LTD.

China

Iruma city, Saitama Prefecture

Yaskawa Electric (mother factory)

YASKAWA (Changzhou) Mechatronics

System CO., LTD. China

Local Procurement Rate at Major Business Sites	SHANGHAI YASKAWA DRIVE
(Based on FY2023 results and in value terms)	CO., LTD. China

Yaskawa Electric	82%
Yaskawa America	87%
Yaskawa Electric UK	68%
Shanghai Yaskawa Drive	90%
Yaskawa Electric (Shenyang)	98%
Yaskawa (China) Robotics	96%
Yaskawa India	34%

YASKAWA INDIA PRIVATE LIMITED

India

Yukuhashi city,	Kitakyushu city,
Fukuoka Prefecture	Fukuoka Prefecture
	Regional breakdown of production capacity by product
		(FY2023 results, one shift, unit basis)
0%	10%	20%	30%	40%	50%	60%	70%	80%	90%	100%
AC Servo			68%					32%		1%
							2%

AC Drive		57%				23%	6% 10% 4%
Robot		43%					50%			7%
	Japan	China	Americas	Europe		Asia excluding China

© 2024 YASKAWA Electric Corporation	5

Targets and Progress in the "Realize 25" Mid-Term Plan

In the mid-term plan "Realize 25," we set the following as the pillars of our policy, and carry out activities to achieve the KPIs.

・Evolution of our own "manufacturing" through i3-Mechatronics

・Building a global optimized production system and resilient supply chain

KPIs (FY2023 Results)	KPIs (FY2025 Targets)	Purpose

Improvement of direct			Promote automation through
productivity (no. of units	10% improvement	46% improvement	i3-Mechatronics solutions at our own
produced per direct	production sites, and improve product
(Compared to FY2022)	(Compared to FY2022)
personnel at factories in	competitiveness by pursuing higher

Japan and China)			productivity and production management.

Increase in global production	6% improvement	36% improvement	Improve production capacity and
capacity
(Compared to FY2022)	(Compared to FY2022)
(no. of units we can produce)	productivity in response to expanding

			demand and build a global production

Implementation of	Japan: 45%	Japan: 57%	system that is resilient to environmental
in-house substrate	China: 42%	China: 62%	changes and risks.
manufacturing plans	(FY2021: 19%・ Global)	(FY2021: 19%・ Global)

Reduction of environmental
impact through products and	Achieved CCE100	Achieve CCE100*	Contribute to a sustainable society
reduction of CO2 emissions in
(125.9 times)	through sustainable manufacturing.
in-house production

processes

*Contribution to Cool Earth 100: Our goal to make reduction of the CO2 emissions through our products 100 times or more
of the amount emitted by the Group by 2025

© 2024 YASKAWA Electric Corporation		6

Challenges for Realizing Sustainable and Productive Manufacturing

Establishment of robust productivity that can cope with variable-mixvariable-volume production for sustainable manufacturing

① Production system with minimum manpower dependence

・In response to the rapid increase in orders between FY2021 and FY2022, securing a production system under the impact of the COVID-19 became an issue.

・We need to further automate to minimize our dependence on manpower.

Supply chain optimization

・Based on the basic policy to reduce procurement costs, we traditionally selected suppliers individually.

・We selected candidate components for internal production from the perspective of overall efficiency beyond costs, technology inheritance and procurement risk.

① Total	Added value of parts, difficulty of in-house production,
efficiency	reduction of procurement lead time, and quality cost

② Sustained	Necessity of retaining and improving product
improvement of
development and production technologies
product QCD*
③ procurement	Dependence on specific suppliers (Region/Country,
risk (BCP)	Company) and whether there are alternatives

*Quality, Cost and Delivery

Evolution of manufacturing independent of manpower

Board mounting

Machining
(Shaft, robot parts)	Resin molding

Promotion of in-house

manufacturing with automation

3. Way Forward

Strengthening the Global Optimal Production System Based on

the Promotion of Demand Area Production and In-House Manufacturing

Transformation of Robot Production in Japan

- Initiatives for Integrated Production of Robots and Motors -

Strengthening Production Systems to Provide Further Value to Customers in Europe

Investment to Strengthen Response to Growth Markets in North America

Strengthening the Global Optimal Production System Based on

the Promotion of Demand Area Production and In-House Manufacturing

Implementation of plans to realize global optimum production in Japan and overseas

	Region	Location	Main measures			Purpose
						Enhancement	Enhancement	Enhancement

						of mother	of demand	of internal
					Start of operation	plant functions	area	production
							production

Japan	Kitakyushu,	・New robot machining factory	Mar. 2024	●		●


			Fukuoka	・New robot factory (integrated production of motors)	Mar. 2026	●


				・South-Yukuhashi business site	FY2026	●
				(Yaskawa Automation Drive)

			Yukuhashi,

			Fukuoka	・New AC drive factory	FY2028	●		●

				・New resin molding parts factory	FY2028			●

				・Expansion of substrate line	FY2023		●	●
		China	Changzhou	- 2025


				・New machine controller production line	FY2024		●

		Asia	Vietnam	・New factory (production of substrates for production	FY2026		●	●
Overseas		in Europe, the U.S. and India)


	Europe	Slovenia	・Robot factory No.2 (engineering and systems)	FY2025 2Q		●


		・Consolidation of European logistic functions	FY2025 2Q		●


				・Expansion of the robot system plant	Jul. 2024		●

		Americas	United	・Consideration of production of robots	FY2027		●
		States
			・New manufacturing base for motion solutions for
				FY2026		●
				semiconductor industry



				© 2024 YASKAWA Electric Corporation				9

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Yaskawa Electric Corporation published this content on 06 June 2024 and is solely responsible for the information contained therein. Distributed by Public, unedited and unaltered, on 06 June 2024 02:09:02 UTC.

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YASKAWA ELECTRIC CORPORATION	-5.43%	9.34B
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SCHNEIDER ELECTRIC SE	+25.37%	141B
EATON CORPORATION PLC	+29.35%	133B
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AMETEK, INC.	+6.15%	40.74B
WEG S.A.	+27.47%	36.11B
VERTIV HOLDINGS CO	+70.27%	33.59B
ROCKWELL AUTOMATION, INC.	-7.29%	33.56B
DELTA ELECTRONICS, INC.	+31.10%	32.81B

1st Jan change

Capi.

YASKAWA ELECTRIC CORPORATION

-5.43%

9.34B

SIEMENS AG

+4.99%

154B

SCHNEIDER ELECTRIC SE

+25.37%

141B

EATON CORPORATION PLC

+29.35%

133B

EMERSON ELECTRIC CO.

+21.49%

68.01B

AMETEK, INC.

+6.15%

40.74B

WEG S.A.

+27.47%

36.11B

VERTIV HOLDINGS CO

+70.27%

33.59B

ROCKWELL AUTOMATION, INC.

-7.29%

33.56B

DELTA ELECTRONICS, INC.

+31.10%

32.81B

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