Daifuku Automotive America is a leading provider of automated material handling systems for automotive manufacturing plants. This guide explains what Daifuku Automotive America does, how their systems work, and what you need to know if you’re considering their solutions for your facility. We’ll break down their key products, services, and practical considerations in a clear, step-by-step format.
Ingredients
- 1 understanding of Daifuku’s core business (automated guided vehicles, conveyor systems, and storage/retrieval systems)
- 1 familiarity with automotive manufacturing processes (body-in-white, paint, assembly, and parts distribution)
- 1 knowledge of your facility’s layout and material flow requirements
- 1 budget for capital equipment and ongoing maintenance
- 1 team of engineers and operators to implement and manage the systems
Instructions
- Understand Daifuku’s role: Daifuku Automotive America designs, manufactures, installs, and services automated material handling equipment. Their systems move car bodies, parts, and assemblies through the plant efficiently, reducing manual labor and improving safety.
- Identify your material handling needs: Determine where you have bottlenecks, high labor costs, or safety risks. Common areas include the body shop (moving body panels), paint shop (conveying bodies through ovens), and final assembly (delivering parts to the line).
- Research Daifuku’s product lines: Key products include Automated Guided Vehicles (AGVs) that follow floor magnets or laser guides, overhead conveyor systems for paint lines, and automated storage and retrieval systems (AS/RS) for parts warehouses. Each solves a different problem.
- Request a site assessment: Daifuku’s engineering team will visit your plant, analyze your current process, and propose a system design. This is a no-cost first step.
- Evaluate the proposal: The proposal will include system layout, equipment specifications, installation timeline, and cost estimate. Compare it against your internal ROI model.
- Plan for installation: Installation typically takes weeks to months, depending on the system’s complexity. Schedule it during plant shutdowns or off-peak production to minimize disruption.
- Train your staff: Daifuku provides training for operators and maintenance personnel. Ensure you have at least one dedicated technician per shift who understands the system’s control software.
- Implement and monitor: After go-live, track key performance indicators like throughput, downtime, and safety incidents. Daifuku offers ongoing support and preventive maintenance contracts.
Tips
- Start small: If you’re new to automation, consider piloting one AGV or a single conveyor zone before committing to a full plant-wide system. This reduces risk and helps your team learn.
- Understand the software: Daifuku’s systems are controlled by proprietary software that integrates with your existing ERP or MES. Make sure your IT team is involved early to ensure compatibility.
- Budget for maintenance: Automated systems require regular parts replacement (e.g., wheels, sensors, batteries). Include a 5-year maintenance budget in your financial planning.
- Safety first: AGVs and conveyors have safety features like light curtains and emergency stops. Train all employees to respect these systems and never bypass safety interlocks.
Serving Suggestions
Daifuku systems are best “served” in high-volume automotive plants where consistent throughput is critical. They are particularly effective in:
- Body-in-white welding lines, where AGVs transport car bodies between stations.
- Paint shops, where overhead conveyors move bodies through cleaning, coating, and baking ovens.
- Final assembly, where parts are delivered to the line just-in-time, reducing worker walking time.
- Parts distribution centers, where AS/RS systems store and retrieve components automatically.
Variations
Daifuku offers several system types, each suited to different applications:
- AGVs (Automated Guided Vehicles): Flexible, battery-powered carts that follow magnetic tape or laser targets. Ideal for dynamic paths and reconfigurable layouts.
- Overhead Conveyors: Continuous chains or power-and-free systems that move parts overhead, saving floor space. Best for paint lines and assembly.
- AS/RS (Automated Storage and Retrieval Systems): High-bay warehouses with robotic cranes that fetch pallets or totes. Perfect for high-density parts storage.
- EMS (Electrified Monorail Systems): Individually powered carriers that run on overhead rails, offering precise control and flexibility for mixed-model production.
Storage and Reheating
Unlike food, Daifuku systems don’t need reheating, but they do need proper maintenance to keep performing:
- Daily checks: Inspect AGV wheels, sensors, and batteries each shift. Clean conveyor chains and lubricate as per the manual.
- Weekly: Verify safety systems (emergency stops, light curtains) and check for loose bolts or worn parts.
- Monthly: Test the control software’s backup and recovery procedures. Update firmware as recommended by Daifuku.
- Annual: Schedule a full system audit with Daifuku’s service team to identify wear and plan replacements.
Frequently Asked Questions
Q: Is Daifuku Automotive America the same as Daifuku Co., Ltd.?
A: Yes, Daifuku Automotive America is the North American subsidiary of Daifuku Co., Ltd., a Japanese company that is one of the world’s largest material handling system suppliers. The American branch serves automotive plants in the US, Canada, and Mexico.
Q: How much does a Daifuku system cost?
A: Costs vary widely based on system type and scale. A single AGV might cost $50,000–$100,000, while a full conveyor system for a paint shop can run into the millions. You’ll need a custom quote from Daifuku for your specific project.
Q: Can Daifuku systems be retrofitted into an existing plant?
A: Yes, Daifuku specializes in retrofitting. They can integrate new AGVs or conveyors into existing buildings, but you may need to modify floor surfaces, ceiling heights, or electrical systems. Their engineers will assess feasibility during the site visit.
Q: What is the lead time for a new system?
A: Typical lead times are 6–12 months from order to installation, depending on complexity and current demand. Custom-engineered systems can take longer. Plan ahead for production cycles.
Q: Does Daifuku offer training and support?
A: Yes, they provide operator and maintenance training at your facility or at their training center. They also offer 24/7 support and preventive maintenance contracts. Many customers opt for a full-service agreement to maximize uptime.
Q: Are Daifuku systems safe?
A: Yes, they comply with OSHA and ANSI standards. AGVs have sensors to detect obstacles, and conveyors have emergency stops. However, safety depends on proper installation and employee training. Always follow the safety guidelines in the operator’s manual.
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