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The Integrated Scheduled Production System


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Introduction of the New Painting Technology Drastically Reduced VOC Emissions as Well

Aqua-Tech Paint System Enables painting with respect to each vehicle in the different desired color of the customer, without wasting paint due to rinsing.
Aqua-Tech Paint System Enables painting with respect to each vehicle in the different desired color of the customer, without wasting paint due to rinsing.

In 2010, the new challenge was started to replace the Three Layer Wet Paint System*1 with Aqua-Tech Paint System*2, which generates less VOC emissions. The old and new paint System technologies, differing in materials, methods and process, were used simultaneously, during which the Integrated Scheduled Production System was continued. "Regression is out of the question." With such determination, Ondo and other members of Painting Group No. 1 made it possible to maintain the Integrated Scheduled Production System while incorporating the new technology. This was another addition of great value to Mazda.

The adoption of Aqua-Tech Paint System is expected to drastically reduce the environmental impact of the painting process.

The Integrated Scheduled Production System is 10 years old and now it is the norm for Mazda's production lines.

Many changes occurred at the startup of production for the new CX-5, fully equipped with SKYACTIV technology, but the system was maintained, and Mazda continued to deliver "fresher vehicles" to its customers.

The production line will continue its improvement efforts for higher-level, zeroloss straight production.

  • *1Three Layer Wet Paint System is a method where the primer color, base and clear coatings are layered while still wet, and finished with one drying process, eliminating the conventional drying process after the primer. Compared to the conventional painting method, CO2 emissions are reduced by 15% and VOC emissions by 45%. It is used as the standard method in domestic and overseas Mazda Group manufacturing plants.
  • *2Aqua-Tech Paint System is a water-based painting technology of world's best class method with the lowest CO2 and VOC emissions. This method reduces a remarkable 57% of VOC emissions, while keeping the world's best class of low CO2 emissions which was already realized by Three-Layer Wet Paint System.

VOICE

The Key to the Integrated Scheduled Production System is People Training.

Shinsou Morikawa,
Shinsou MorikawaStaff Manager of Hiroshima Plant, Mazda Motor Corporation (current Senior Managing Director of Malox Co., Ltd.)

The Integrated Scheduled Production System is made possible by the "human capital" who run it. The power of people is infinite, and if each and every one of the 6,000 operators of the Hiroshima Plant becomes a human resource that can independently use, maintain and improve the facilities, we can achieve better-quality vehicles and prevent any and all losses. Production and product development related members will continue to work together in order to achieve a zero-loss production system.

World-Best-Class Painting Plant with Ultimate Reduction of Losses

Painting Group No.1, Vehicle Production Department No. 1, Hiroshima Plant, Mazda Motor Corporation
(From left)
Seiji Kouchi Assistant Manager Hirofumi Ondo Manager Nobufumi Tanaka Assistant Manager

As a result of persistent and diligent efforts to solve problems, we have reduced losses such as re-painting, which also led to reduction of material and energy use. Another significant benefit was that the quality improvement awareness and problem-solving skills of each and every member were increased. We will continue our efforts to become a world-best-class painting plant with ultimate reduction of losses.

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