ccc-1540 “challenge, change, completion” - kotra profile/07... · · 2013-08-14ccc-1540...

CCC-1540 “Challenge, Change, Completion”

Yushin Precision Industrial Co., Ltd.


Contents

1. Company Profile

10. Production Improvement

4. Production & Inspection Equipments

6. Customers & Turnover

8. Status of Certification & Patent

9. Application & Case Study for Cost Saving

2. Milestone

3. Organization

5. Major Products

7. Design System

11. Overseas plant profile


Incheon

Dangjin

- Head Office & Namdong Plant

- R&D CENTER

- Dangjin Plant(Hose Clamp)

인천 남동

Gunsan - Gunsan Plant(Wave Spring)

Ulsan

IncheonSongdo Namdong

Head Office PlantWarehouse

Company Yushin Precision Industrial Co., Ltd.

Chairman Dong Ah, Lee

CEO Kyung Shik, Song

Establishment Dec. 1975

Address

Head Office : 85, Gaetbeol-ro, Songdo, Yeonsu-gu, IncheonNamdong Plant : 125, Neungheodaero, 577beon-gil, NamdongDangjin Plant : 197, Galsan-gil, Sunseong-myeon, DangjinGunsan Plant : 110, Sandannambuk-ro, Gunsan

The number of employees 520

Sales US$ 204M(2012)

Main products

Disc Spring, Snap Ring, Drive Plate, Hose Clamp, Shim, Etc

Size of areaTotal 72,697㎡(Head Office 5,500㎡, Namdong Plant 11,047㎡,Dangjin Plant 21,500㎡, Gunsan Plant 34,650㎡)

Dangjin

Gunsan

1. Company Profile

Seosan


POLAND

WUXI

QINGDAO

INDIA

America(Sales Office)

Global Network4 Countries / 4 Plants / 1 Sales Office

→ 873 Employees

Year 2012

Sales Amount

7

Employees 87

Year 2012

Sales Amount

25

Employees 279

Year 2012

Sales Amount

15

Employees 157

Year 2012

Sales Amount

18

Employees 350

Description Sales Amount

Employees

Domestic 139 520

Overseas 65 873

TTL 204 1,393

Total

Unit : M. US$

Unit : M. US$

BEIJING(Sales Office)

Shanghai(Sales Office)

YENCHING


• 75.12 : Established

• 76.01 : Retainer Ring

• 78.02 : Registered as a HMC Supplier

• 89.07 : Manufacturing Snap-Ring, Drive Plate for A/T

• 94.06 : Manufacturing Hose Clamp

• 94.10 : Registered as a KIA Supplier

• 99.12 : ISO 9001, QS 9000 Certificate

• 01.12 : Export Anti-rattle clip (TRW US)

• 02.01 : Established Qingdao Factory in China

• 03.07 : Export Snap-Ring(Borgwarner US)

• 03.07 : Setup Batch Type Austempering

• 04.08 : ISO/TS 16949 Certificate

• 04.12 : Awarded the letter of Commendation fromPresidential Commission on SME

• 06.09 : BorgWarner Best Supplier Quality Award

• 07.01 : Established Dangjin Plant (Hose Clamp)

• 07.05 : Awarded the Prime Minister Prize (Single PPM Quality Innovation)

• 08.09 : Established Wuxi Plant in China

• 08.09 : Established Chennai Plant in India

• 09.01 : Established factory in Poland

• 09.10 : Manufacturing Single Flex Plate

• 10.12 : Established Gunsan Plant (Cushion Spring)

2. Milestone


6 Divisions & 17 Teams

3. Organization

Office Worker Production Worker TOTAL

180 340 520

30% 70% 100%

会長

Accounting

Material Purchasing

社長

Sales & Marketing

Development

R & D

Plant RenovationOverseas Support

Cost Analyzing

Production

Production Administration

Quality Control

Quality Assurance

Chairman

Administration ProductionSales & Development Quality

General Affair

CEO

Planning

Production Engineering

R&D

Business Planning

I.T Tooling


4-1 Production Equipment

Production Equipment (Incheon Plant)

NO Equipment Qty Remarks

1 Press 15 80 ~ 650ton

2 Coiling M/C 17

3 Double Disc Grinding M/C 5 Ø300~Ø760

4 CNC Lathe 10 Ø860

5 Austempering Furnace 2

6 Barrel 9 20L ~ 200L

7 Fine-Blanking M/C 3 630ton, 800ton

8 Batch Tempering Furnace 1

9 Welding Line 2 (CO2, SPOT)

10 Single Flex Plate Line 1 P/F, Hb, Chp, & Etc.

TOTAL 65

Production Capacity (Incheon Plant)

NO ITEMS Annual Capacity(Mil.)

1 Snap Ring 113

2 Washer/Spacer 78

3 Drive Plate 3

4

TOTAL 194

Production Equipment (Dangjin Plant)


1 Muti Slides Lines 17 (Ø200~Ø560)

2 Austempering Furnaces 2

3 Shot Peening Machines 2

4 Geomet Coating Lines 2

5 Auto Assembler for D/W Clamp 4

6 Clipper for Clipless Clamp 2

7 Vision System for 100% Inspection 5

8 Auto Packing Equipment 1

9 Return Spring 7

10

TOTAL 32

Production Capacity (Dangjin Plant)


1 Hose Clamp 150

2 Double Wrap Clamps 50

3 Clip 16

4 Return Spring 2

TOTAL 218


Production Equipment (Gunsan Plant)


1 Press 3 450, 600 ton

2 Deburring M/C 2

3 Induction HeatingDie-Quenching M/C

25 Tempering Furnace(3)

4 Shot Peening M/C 24

5 Vision Tester 1

6 Washing & Load Tester 33

7 Mark’g M/C 2

TOTAL 89

Production Capacity (Gunsan Plant)


1 Disc Spring (D/Q Items) 25

TOTAL 25


Inspection Equipments (Incheon, Dangjin, Gunsan)

NO TYPES Namdong Dangjin Gunsan

1 3D CMM 1 1

2 Hardness Tester (Rockwell & Vickers)

3 3 3

3 Metallographic Microscopes 1 1 1

4 Surface Roughness Tester 1

5 Clamp Force Tester 1 1

6 Contour Measuring M/C 1 2

7 Inductive Coating Thickness Tester

1 1

8 Leakage Tester (Air pressure) 1 1

9 Leakage Tester (Hydraulic pressure)

3 1

10 Profile Projector 1 1

11 Eddy Current Test Instrument 1

12 Cycle Impulse Tester 1

Inspection Equipments (Incheon, Dangjin, Gunsan)

NO TYPES Namdong Dangjin Gunsan

13 Load Tester for Disc spring 1 1

14 Pulse Tester 1

15 Cutting M/C 1 1 1

16 Polishing M/C 1 1 1

17 Mounting Press M/C 1 1 1

18 Complex Durability Test M/C 1 1

19 Salt Spray Test M/C 1 1

20 Cyclic Corrosion Test 1 1 1

21 Cleanness Tester 1 1

22 Universal Tensile Tester 1

23 Disc Spring durability Tester 1 3

TOTAL 27 15 16

4-2 Inspection Equipment


5. Products


5. Products – Transmission Parts 1

Snap Ring

Material High Carbon Steel (SAE 1065~1085 / SK5M)Steel Wire(SWRH72B)

Customer HMC, HPT, GM, Borg Warner, JATCO, TRW

Core Manufacturing Process Stamping / Coiling

Remark- Standard/Customized design available- Various notch profile- Rolling for raw material capable in house



Disc Spring / Return Spring

Material High Carbon Steel (SAE 6150 / 50CrV4)

Customer HMC, HPT, GM, Borg Warner, JATCO, TRW

Core Manufacturing Process Stamping - Induction Heating - Shot Peening

Remark

- Blackbox design capability for High/Low load disc spring - 100% load test for high load spring in the production line



Shim & Washers

Material High Carbon Steel (SAE 1065~1085/ SK5M)

Customer HMC, HPT, Scheffler, NSK, Borg Warner

Core Manufacturing Process Stamping - Heat Treatment – (Grinding)

Remark- In-house capability for all process include heat treatment- Can control various selective parts


5. Products – Engine Parts

Drive Plate /One Piece Flex Plate

Material Medium Carbon Steel (SAE1035 / S35C) High Strength Steel (SPFH590)

Customer HMC, KIA, Chrysler

Core Manufacturing Process

Pre Forming – Hobbing - Induction Heating – (Shot Peening) – Balancing – Run out

Remark


5. Products – Hose Clamp

Hose Clamp

Material High Carbon Steel (SK5M, 50CrV4)

Customer HMC, KMC, RSM, GM, Ford, Nissan, IDEAL/Tomkins, TRW

Core Manufacturing Process

Multi Forming - Austempering - Coating

Remark

- In-house capability for heat treatment and coating - Various design per applications (Standard, Stoptab, POPP, Sus Band)


5. Products- Others (Fine Press parts Etc.)

Multi Forming

Fine Press

Others


6. Customers & Turnover

Domestic Overseas

1)Customer


Korea (Domestic)110

Korea (Export)29

Qingdao25

India18

Wuxi15

Poland7

2012 Korea & Overseas Plants Turnover

2012 Sales Share (Customers) 2012 Sales Share (Items)

2) Turnover

FY’13 : 245 FY’12 : 204

Unit : M. US$

HPT 22%

HYUNDAI 21%

GM GLOBAL 14%

MOBIS14%

KIA 6%

ETC18%

Snap Ring,

27%

Disc Spring,

17%Hose Clamp,

10%

Drive Plate,

15%

Washer /

Shim, 15%

Etc., 16%


8. Design System

Design Flow for ProtoDesign Tool

FEMFAT

Finite Element Method FAT

Product Design Tool Design Pre-Production TOTAL

5 10 7 22

Academic Background Ph.D 1 / Master 3 / Bachelor 15 / College Degree 3


Design Boundary Concept Design 3D Modeling

4.75INSTALLED HEIGHT

0.8

0.74MIN HEIGHT STROKED

[ Lay

Out]

Just given the two things from the customer YSP’s Spring Design

Sheet


FE Modeling Stress Analysis Fatigue Analysis

Spring height 1.84 mm

Max Stress 1182 MPa

Max. Damage5.289E-1

Life = 983,172 cycles


Tooling Proto Production Validation Test


R&D Facility

NO Proto Line Equipment Q’ty Test Equipment Q’ty

1 Induction Heating M/C

1 Disc Spring durability Tester 3

2 Shot peening M/C 1 RAD Hose clamp durability Tester

1

3 Milling M/C 1 Wave-plate Assembly durability Tester

1

4 Radial M/C 1 Vibration Test 1

5 Surface Plate 1 Hydraulic Stroke Tester 1

6 Flat Grinder 1 Hydraulic Leak Tester 1

7 Form Grinder 1 D/P Ignition Test M/C 1

8 Lathe M/C 1 D/P Vertical-load Tester 1

9 Grinding M/C 1 D/P Horizontal-load Tester 1

10 Bench Drill 2 D/P Torque Tester 1

11 Hose Clamp Proto M/C

1 Profile Projector 1

12 Lab Austempering Furnace

1

Total 13 Total 13

Test Equipment

Proto Line


◎ ISO / TS 16949:2009 Certificate Acquisition – 2004(Revised - July.2010)◎Awarded the letter of Commendation from Presidential Commission on SME – December.2004◎ ISO 14001 : 2009 Certificate Acquisition – November.2011◎Awarded the letter of Commendation on Single PPM Innovation from the Prime Minister – May.2007◎ Patent Status – 9 Patents, 3 Utility Models, 3 Registered Designs (Total 15 registered Applications)

8. Status of Certification & Patent


* Various Design of YSP’s Spring

Cushion Spring Return Spring Coil Spring Pack

Wave Spring Dished Spring 2 Turn Spring

• Function ： Piston Control by Hydraulic, and prevent vibration & Judder• Tech. Point ： Durability and load• Cost Saving : 40%

9．Application & Case Study for Cost Saving


• Process Improvement : Grade(Selection) Improvement of the identification of goods

(Temper Color → Laser Marking)

• Cost Saving : 20%

Special : Ellipse RingPerfect circle at install state

[Snap Rings (Selection Parts)]

[Thrust Washer]

• Material Change

: Copper → Steel (SK5M)

• Cost Saving : 40%

NC CoilingLaser Marking

for identification


[Differential Washer]

• Surface Treatment Change

: Electroless Nickel Plating

→ Nitriding

• Cost Saving : 30%[Locking Nut]

• Process Change

: Forging & Machining

→ Fine Blanking

• Cost Saving ： 40％


1st Generation Single Hot Press

2nd Generation6 Hot Press

3rd GenerationAutomatic Hot Press

1) Jig Tempering

10. Production Improvement

Through this Improvement, Productivity increased more than 100%

1. Cycle Time ↓2. Labor ↓

3. Quality Improved

UPH : 30Labor : 5

UPH : 120Labor : 0.5

UPH : 150Labor : 0.5

※ 4th GenerationDuel Hot Press is in test.


Blank’g & Deburr’g

Bending Heat Treatment Jig Temper’g

Die-Quenching Temper’g

Shot Ball

Conveyer Belt

Parts

Parts Rotation

Shot Peen’g

NEW

Cost Saving and Improve Quality by Manufacturing Change

2) Improvement for Disc Spring

OLD

Cost Saving : 20%


Company Qingdao Yushin Co., Ltd

Establishment Jan. 2002

Address Tonghe Town, Pingdu City, Qingdao, Shangdong,, China

Turnover 2012 US$ 25 M.

Employee 279

Main Item T/M Support Plate, Airbag Door Ass’y

Main Customers HMC, KMC, TOYOTA, NIDEC, DELPHI

Main Item

11. Overseas plants profile


Main Item

Company Wuxi Yuzhong Co.,Ltd

Establishment Sep. 2008

Address ＃B-16、Koshin development district, Wuxi, China


Employee 157

Main Item Back Plate, Booster Shell

Main Customers MOBIS, KMC


Main Item

Company YSI Automotive Private Ltd

Establishment Sep. 2008

Address Chennai Tamil Nadu, India


Employee 350

Main Item T/M Brackets, Seat Belt

Main CustomersHMC, KMC, TATA, UNIPRESTOKAI RIKA, TAKATA


Company YSP &C Poland sp z.o.o

Establishment Jul. 2009

Address ul, Poznanska 4, Pyskowice,Poland


Employee 87

Main Item Back Plate, Booster Shell

Main CustomersHMC, KMC, MOBIS, FUJI KOYONEXTEER

BACK PLATE ASSEMBLY LH and RH

START OF PRODUCTION : Feb. 2011

SHELL&STUD ASSEMBLY(ED/FD, EL/SL)

START OF PRODUCTION

Main Item


Thank you.

ccc-1540 “challenge, change, completion” - kotra profile/07... · · 2013-08-14ccc-1540...

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