PDS (Production of Daikin System)
Daikin Group has its own unique production system, which is referred to as PDS (Production of
Daikin System), whereby DIT has adopted such system as a foundation for its operations. The
system emphasizes on continuous improvement and employees’ participation in proposing ideas and
improving the production process, with the ultimate objective to minimize wastes through
flexibility of production and different production plans in order to effectively respond to
changes.
Conveyor System and Cell System
With the implementation of the conveyor system, cell system, and mixed production, the Company
is able to add value to the products and fulfill the needs of customers efficaciously. As a
result of such production system, Company was conferred with the Outstanding Industry Award on
Productivity in 2006. Nonetheless, we are still committed to develop and improve our production
process to attain the ultimate goal and thrive towards becoming the global leader in the aspect
of quality.
Development of Quality in Production Process (System)
We have integrated different technologies to support the production process, from the selection
of spare parts, production, and delivery of products, in order to reduce the burden on
employees, which subsequently leads to standardized products that are sufficient for customers’
needs. The comprehensive spectrum of technologies implemented in the production process include:
Milk Run System under the Concept of Just in Time
The Company and its suppliers are able to effectively reduce the number of trucks required in
the delivery of spare parts through the implementation of a milk run system. Moreover, the DO
(Delivery Order) system is also adopted to reduce the sorting time of spare parts.
DO System (Delivery Order system)
AGV (Automatic Guide Vehicle)
This technology was developed to transport equipment or spare parts to the production line in an
accurate and timely manner. The AGVs will navigate through the specified routes with high precision
and will stop automatically, which substantially reduces the production time.
Picking System
This is one of the most intelligent technologies that prevent employees in the Production
Department from picking wrong spare parts for product assembly. It also supports a variety of
production models. The system operates by using light as an indicator. The employee will have to
collect the spare parts according to the light installed in the corresponding shelf.
Quality Control System
This system inspects quality in the process of testing refrigerant leakages by using helium as a
refrigerant to minimize environmental impact.
Poka-yoke
This technology inspects the work process by scanning barcodes. If the barcode on the parts
matches with the barcode registered in the system, employees can continue with the next steps.
However, in the event of fault assembly, the system will immediately stop the production line to
detect errors and solve the problem. This system ensures that customers will receive the best
products from us.
Smart Tag E-Paper
This system is a part of Poka-Yoke technology that replaces printed barcodes with smart tag
e-paper to reduce the consumption of papers and minimize effects on environment.
(Parts Supply Division)
“...Excellent management system to optimize the production process...”
The import of raw materials is the upstream stage of our production process. Daikin has an
excellent management system that is fast and saves space, while facilitating the selection of
high-quality raw materials to be delivered to the production line efficiently. It ensures that
all of the raw materials that have been selected to be used in the production process will
deliver flawless air conditioners. In addition, we also have a quality control process that
meticulously inspects raw materials received from our suppliers. If a damage or flaw is
detected, the raw material will be immediately returned to the corresponding supplier. This is
in accordance with the standard of Daikin Quality: “No acceptance, emission, and delivery of
wastes to the next step”. Indeed, this “next step” refers to our customers wherein we have
instilled such concept in all of our employees.
(Process)
“...We invent a unique production system to fulfill the global demand...”
Our production process can be divided into two types, comprising of cell system and
conveyor system, in order to be appropriate to each type of products.
Cell Systemis the assembly of various parts of air conditioners,
one-by-one. The cell
system is performed by a small number of employees under the supervision of a skilled
foreman with expertise in the field. Each employee will assemble the parts by hand, a
single unit at a time from start to finish. This production method entails skilled
personnel with technical expertise to produce high-quality products.
Conveyor System is the assembly of parts using a conveyor to transport
the parts
continuously to each step of the production process. In addition, it can assemble
products with different models and configurations in the same production line, which is
referred to as ‘mix production’. It enables the production plan to be changed according
to the needs of customers. Each production line is different and can be adapted to suit
different types of products. The maximum production capacity is 1,300 units/shift, which
is equivalent to 650,000 units/year. Such capacity ensures that we can provide
sufficient and high-quality products to support the market demand.
Manufacturing of Parts is the Core Element of the Factory
The Company manufactures main parts and components with modern machinery through a quality
inspection in all steps of the production process, which subsequently results in standardized
parts for air conditioner assembly, such as:
1. Heat Exchanger process.
2. Sheet Metal process.
3. Paint Shop process.
4. Piping process.
5. Plastic Injection process.
6. Electric Box Component process.
