Y.K：Yes, this state-of-the-art plant was established based on a group company that had been manufacturing products mainly for automobiles for about 25 years.

Y.K：The AGS is the product used in automobiles that Roechling Automotive, our business partner located in Germany, and Starlite are providing worldwide. The AGS is mounted behind the radiator grille, controls the inflow of outside air into the engine compartment, and reduces energy loss during ambient temperature warm-up... Well, to put it in simple terms, it is a popular unit because the AGS controls air flow, reduces air resistance, and even improves fuel efficiency.

Y.K：Yes, that would be the 1,850-ton double injection molding machine, which is one of the largest in Japan.

Y.K：Yes, that is right. It is much more efficient and effective than making two parts separately and then putting them together later. In the three years since mass production for AGS began, there has not been a single defective product on the market. I think we might be the only company in Japan that can stably manufacture large molded products with such complex structures in multi-cavity mold.

Y.K：But there are more. We have injection molding technology that improves appearance defects, use the in-line production method, and also incorporate collaborative robots for automation.

Y.K：First loosely fasten the mold. Then, gradually fasten the mold at high pressure to prevent it from opening, as resin is poured into the mold. If the gas generated while resin melts remains in the mold, they can cause a poor appearance on the product surface. This is the injection molding technology that creates a slight gap to allow gas to escape, but does not generate burrs from the resin that subsequently flows in. In addition to controlling the injection molding machine, there is also expertise required for the mold. If resin burrs remain in the mold, continuous molding may be halted. Click here for the article about moldmaking technology.

Y.K：The Yamaguchi Plant is also promoting manufacturing with an emphasis on efficiency. For example, in-line production method.

Y.K：The molding area and assembly area are connected on one floor, and the flow of production from the injection molding machine is in a single line. We also do simultaneous production, and the assembly process can complete next to the molding machine.

Y.K：An AGF (Automated Guided Forklift) brings finished products assembled by people and collaborative robots to the shipping area. What we are trying now is to have a collaborative robot pick up the injection molded products directly from the automatic extractor. If the grabbing position shifts even slightly, the product will be dropped. But if this works, we are very close to full automation.

We also started using an AGV (Automatic Guided Vehicle) that moves the wagon to transport containers for large products as wide as the width of a car called cowl grille. We are trying to move raw materials in paper bags from the raw material storage area to the molding machine area by AGV too. In addition, we try to let a well-known serving robot seen in some family-style restaurants move secondary materials to the assembly and processing line (working table).

Y.K：I would like to engage in high value-added work while taking advantage of the abilities people possess, and to go forward toward a "manufacturing plant with attractive, state-of-the-art technology" which is the concept behind the establishment of the Yamaguchi Plant. Simply adding more people to night shifts due to shortage in labor will only increase fixed costs and worsen profitability. It is getting more difficult to recruit people now, which is another reason why we want to avoid increase in fixed costs.

We would like to advance our plant with the wisdom of people for better manufacturing.

Y.K：We have started DX initiatives not only on the production floor, but also in the production management, the heart of the plant. For example, in the shipment verification, scanning the bar-code on a product automatically checks the required checklist. It would be nice if we can install monitors near each molding machine to show the status of all molding machines in the plant as well as the operational status or any issues at a glance.

U.M：That would be great.

Y.K：The progress can also be viewed through a tablet, which will allow us to see any updates anywhere.

U.M：That is nice. We do not have to walk around the plant then.

Y.K：If we scan a bar-code to confirm the completion of assembly and the status is shared on the monitors, all progress will be visible anywhere in the plant to make sure that there are no delays.

U.M：Yes, that sounds good too. I usually go to the production floor every one or two hours, but I will be able to see all the production progress even from my desk in the office. That would make our job a lot easier, and we can focus on our daily work at our desk.

Y.K：But it is not good to just sit at your desk all day. Because if you go and look around the production floor, you often notice things that need improvement.

Y.K：Yes, we also plan to build a second plant. We have already made concept drawings and researched construction and estimated costs so that we can start anytime. We would like to incorporate water circulation systems.

Y.K：Whenever we switch injection molds, we have to remove all the coolant that has accumulated in the mold, which amounts to about 40 to 60 liters per side of the mold. We would like to create a system where water can be collected and reused, rather than being used once and then drained.

U.M：Yes, I agree. It is of course better not to dispose of the water after a single use. We should be able to come up with more ideas for the second plant!

Y.M：It would be nice to have a system that allows us to instantly talk to people in different locations at the push of a button. When the second plant is built, going back and forth between the plants will cause time loss, so it will be very convenient to be able to see each other and communicate with each other anytime, anywhere. When you want to ask for something or have a message, it is better to be able to see facial expressions and gestures so that the message can be conveyed clearly and tasks can be performed more quickly too. It would be interesting to have a system where we can talk face to face not only with people at the Yamaguchi Plant, but also with people at other locations, or even with people overseas.

Y.K：Yes. It may be nice if we could talk to people at each location on the screen right away when we talk to the large monitor. I will feel comfortable if I know exactly who I am talking to, and I am sure we will be able to exchange more information and increase communication that way.

U.M：I think it would be interesting if we could manufacture our own brand car from scratch at the Yamaguchi Plant. It seems that vehicles at speeds of 19 km/h or less can be built relatively freely, and it would be convenient and fun to use it as a mobility vehicle that can travel between the first and second plants.

U.M：It would be entertaining to make the brand car in the shape of an anime or manga character. I would like to see and ride in such a car, because I love the manga character "Opanchu Usagi". It would be fun to see a variety of characters or to be able to redecorate the inside of the car with a different character.

Y.M：We will be even more motivated if we can customize our uniforms. If I could choose a design while using the same logo, it would lift my spirits because I get to wear the uniform of my choice. I like wearing black or a little bit tight. And we will wear something more formal when meeting with customers.

U.M：If we can incorporate a bit of playfulness into our daily work, we may find easier to propose free ideas. We would like to create an environment that encourages people to come up with a lot more interesting ideas.

Y.K：My dream is that someday people would say that the Yamaguchi Plant is the mother plant of Starlite Group as a manufacturing plant with attractive, state-of-the-art technology that proposes new ways of working, in addition to manufacturing.

Y.K：Yes, we would like to manufacture products using super engineering plastics, which have already been done at the Ritto Plant. Super engineering plastics are the materials with excellent heat resistance and strength, but they are very difficult to mold. However, we should take on challenges, and become the plant that exceeds the Ritto Plant.

U.M：We should steal new businesses from them! We would like to continue providing the world with products that will make everyone happy!