1G-96型旋耕播种机的设计含开题及9张CAD图
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如何降低生产和管理成本，拖拉机和农业装备水平 汤匙小林季 承 译一、导言 自由贸易和市场营销跨越国界的农产品和食品已经减价格，并已因此被拉低价格的农业机械。 利用世界各地的工业基础设施，制造业，其中包括农业机械制造商，已扩大了在全球采购的材料和部件和遵守，如降低成本。 在高度工业化社会中，必不可少的条件，为农业机械变得更加多样化。要求，在过去主要是释放人类重体力劳动，但时至今日，使机器工作迅速，高效， 恰恰又轻松。此外，该规定涉及到越来越多地采取责任饲养经营者安全舒适，更环保的产品具有低排放噪声和气体，以及重要的是为保持粮食安全和可靠。农业机械制造商需要应对两个不同的市场需求，为规格及特征;一个特点是需要高档次产品，有具成本效益的性能外，其他的特点是需要简单规格产品特色，主要是价格低廉。 在目前这种情况下，为了满足需求的高档次产品，具有高高性能，高耐久性和低廉的价格，制造商必须努力，这不仅是为了减少制造成本，而且降低开发和营销成本。 通过俱乐部的博洛尼亚，我们被邀请提供我们的意见，关于如何减少 制造和管理的成本，拖拉机和农业设备之后 邀请后，我们打算解释，首先是农业和农业机械正盛行 在日本，其次是我们最近的做法可能会随着主题的本次会议。 二、如何农业机械化作出贡献的日本农业 1 、大规模的日本农业 在历史上，日本的主要农产品有水稻作为主食的，但辅以蔬菜和畜牧业。畜牧业已制订 引进管理和机械化技术，从欧洲和北美。该机械化的蔬菜生产，不包括栽培及病虫害控制是远远落后于在国际层面上，虽然有些政府已提供支助，在这些领域的合作。 近年来，稻米消费下降是由于该多样化的饮食习惯， 这导致了一种不断减少，在米价。因此，其重要性 机械与水稻减少了，导致在结构上的变化。 2 。水稻耕作机械化 工作时间每公顷稻米种植已下降到1 / 5 ，从1739小时在1960年至330小时， 2000年。它是人的现代化的农业机械从人的工作机器工作，从门市后面一骑式，从一个小马力向大 匹马力的机器。典型的机器拖拉机，头部喂给式联合收割机和大米transplanters 。 事实证明，农业机械化作出了贡献，以减少工时，在每一个阶段的稻米耕作。在同一时间内，肥料和农药技术制造业发达，在农业机械。这些技术也有助于减少工作时间，极大地。因此，机械化一致性系统的日本人是稻作农业已经确立。 3 。成本的农业机械及其实施 直到1990年左右比例的费用农业机械和实施中 总支出所需的稻米产量增加了。 1990年以后，这一上升趋势 消失了。 自1990年以来，农民的动力，以投资于农业机械和实施有下降。可能的原因包括; （ 1 ）饱和扩散的农业机械。需求主要是更换设备可以预计， （ 2 ）衰落的大米价格。日本政府在政治上控制了大米价格防止其反复无常的波动， 促进了还原acreages种植水稻生产由政府指导。 日本政府在政治上控制种植acreages ，以防止过量生产大米， （ 4 ）的数目减少了农户， （ 5 ）增加委托acreages的农业工作。 此外，服务年限一台拖拉机已增加至19年，从14年来，在上次十年。 三、减少生产和管理的成本，拖拉机和农业设备 1 、降低制造成本的拖拉机 下面是我们的一些降低成本的活动，其中涉及三个阶段进行： -减少购买原料成本， -降低成本通过模块化设计和共同性的单位， -降低成本，关系到整个企业的经营活动，利用C AE和它。 1-1 。减少购买原料成本 （ 1 ）减少成本的多样化，物资采购： -多样化和全球化的供应商， -多样化的采购制度; 综合采购由集团总部 换算从个别零件采购，以集中采购方式。 -配送成本降低，由集中收集和运送， -降低成本的包装（容器同时购买） 。 （ 2 ）降低采购成本，并行工程与合作厂商： -争取最佳的结构和最低的成本， -采购实行拖拉机在市场上。 （ 3 ）最佳位置的生产基地，同时考虑配送成本 -生产关键部件，如发动机，在主要基地，并装配成最终产品，在适当的市场或地区。 我们，洋马，制造日本式的头部喂养型联合收割机在中国和 走背后的拖拉机在印度尼西亚，再加上发动机的设施。一家合资公司，为拖拉机，装有一个横向水冷式发动机，开始了在中国。 1-2 、降低成本，通过模块化设计和共同单位相对于我们的竞争对手，拖拉机，我们的产品的特点如下： -相似性在一些基本型号， -太多的工厂选择， -少数衍生物出口型号由国内模型， -高生产成本，可能导致从生产太多的品种，在小号码。 然而，通过模块化的设计，能够满足大量的需求，退出市场的通道，并在同到时候就可以降低成本，通过使用共同的组件和群集部分。 我们的目标是减少投资总额和生产成本，采用共同零部件国内和出口模式 ，多项主要部件，如机械前轮驱动单元，传动装置，驾驶室将减为2 / 3 ，和有多少工厂安装的选项，将保存相结合的单位。相应我们可以降低总制造成本。 1-3 、降低成本与整个企业的经营活动，利用CAE和它 考试采用虚拟原型是有益的概念设计，实际的绘图，测试和制造业。它使; （ 1 ）缩短开发周期，并尽量减少不必要的retries ， （ 2 ）检查对数字的冲压模具和加工夹具， （ 3 ）检查装配过程中， （ 4 ）安排的销售文件（目录，操作手册，部分表，和车间手册等） ，从三维数据这将有利于提高业务的精确度，减少人力和因此降低成本。 2 、降低成本的开发和生产的联合收割机，由国家项目上述提及的是，该活动的每家公司可能执行。 在日本， 迫切的发展，农业机械工程已经启动，由政府，专题报道，在此几年前，我们想引进一个独特的机器，是开发和制造与少人力及成本较低。 2-1 、组织工程 （ 1 ）生物导向技术的研究进展研究所（脑） 该项目的目的： -发展机制市场有限，而私人公司能不能发展 本身 -发展机械，它有助于建立一贯机械化系统的用途，如蔬菜和果园耕作， -发展机械，它有助于环境减负，如酚醛。 （ 2 ）新的农业机械化，提高股份有限公司： -临时负荷投资为铸模，以支持少量生产， -促进共同使用的零部件和推广的O EM供应机械， （ 3 ）完成了研究和开发的项目表明，上述34只高效 农业机械2002年建成。 2-2 、开发和商业化的大型联合收割机有种种限制，在日本，如道路条件，野战条件，栽培 种等，这意味着联合收割机在欧洲或美国，不适合收割的水稻植株，主食的日本。另一方面，关于头喂养型联合收割机在日本发展有卓越的精确性，在收割水稻植株和小麦。但是，其结构复杂，难以扩大切割宽度和提高耐久性。 洋马的愿望是制定一个联合收割机具有优良的业务精度日本大米，也就是适用于其他植物，如小麦，大豆，油菜籽等对等，以减低成本，农场管理等问题。洋马成功，在商业化的媒介中型多功能联合收割机在1986年根据技术指导的大脑。 之后扩散的联合收割机，有需求的发展，较大规模类型。我们在洋马，不能将投资开发和制造这种附加的类型。发展成为一种可能被提名为这一项目。 此外，临时负担的投资额的名称减少了负担，就制造商在商业化进程。 相应地，洋马孔赎回的开发成本和生产准备牺牲，供应整个产品或主要组件给其他公司。 在另一方面，其他公司可能因此而节省了人力资源开发和设施。好处农民收到了来自开发多功能相结合收割机的得奖名单如下。如上所述，减少种植acreages大米产量接近40 的平均值。在北部的一部分，日本的情况，这种类型的联合收割机是很受欢迎，它是50 。他们成长的其他作物，如小麦， 大豆，荞麦等，再加上水稻。以前他们收割水稻用头喂养联合收割机及其他作物用肥机器和threshers 重体力劳动的，或者由收割庄稼全部采用进口结合起来割机接受相当的粮食损失量的大米。 汤匙小林。 如何降低生产和管理成本，拖拉机和农业装备水平 。 不过，他们现在有一个方法，收获庄稼都用一个联合收割机。其初始投资成本购买，这是几乎一样，在其他两例以上，但无任何政府的援助。如果他们能够接受政府的援助，所花费用将一半。 此外，他们还经常收割别人的作物作为承包者，由于联合收割机收割机的耐用性和适用性，以庄稼。因此，他们可以摊还机器的成本迅速。工作时间假设为两倍以上，因为那样大 该负责人喂养联合收割机，与几乎相同的维修费用。 四、总结摘要 日本制造商已经尽了很大努力，在专业领域，以及制造商其他国家，具体情况如下： （ 1 ）减少开发成本，生产准备费用和制造成本已取得方式模块化设计。 （ 2 ）降低材料成本是实现多样化的采购方法。 （ 3 ）三维CAD系统已被用于缩短开发周期和降低 成本通过并行活动中的有关章节的开发，生产，销售和服务。 （ 4 ）在日本，汽车制造商可以分享产品和部件，其中一个或几个制造商参与开发和生产，按照紧急的发展农业机械工程。姓名的投资有助于减少总产品成本。 此外，日本制造商正在开发独特的产品本身。大数量的产品是共同对OEM的基础。 How to Reduce Manufacturing and Management Costs of Tractors andAgricultural EquipmentTomoo Kobayashi, DirectorResearch and Development DivisionYanmar Agricultural Equipment Co., Ltd.Maihara-cho, Sakata-gun, Shiga-pref.521-8521, Japantomoo_kobayashiyanmar.co.jpI. IntroductionThe free trade and marketing across borders of food and agricultural products have reduced theirprices, and have consequently been pushing down the prices of agricultural machinery.Utilizing the worldwide industrial infrastructure, the manufacturing industry, includingagricultural machinery manufacturers, has expanded the worldwide sourcing of materials andcomponents and complied with such cost reduction.In highly industrialized societies, essential requirements for agricultural machinery arebecoming more diversified. The requirements in the past were mainly to release humans fromheavy physical labor, but are nowadays to make the machinery work quickly, efficiently,precisely and easily. In addition, the requirements involve increasingly taking responsibilitiesfor keeping operators comfortable and safe, for making more environmentally friendly productsfeaturing lower emission noise and gases, and importantly for keeping food safe and reliable.Agricultural machinery manufacturers need to cope with two different market demands for thespecifications and features; one is characterized by need for high-grade products that havecost-effective performance, the other is characterized by the need for simple specificationproducts featuring mainly low price.In such present conditions, in order to meet the demands of high-grade products featuring highperformance, high durability and low price, manufacturers need to strive, not only to reducemanufacturing costs but also to reduce developing and marketing costs. Through the Club of Bologna we were invited to provide our comments about How to reducemanufacturing and management costs of tractors and agricultural equipment. Following theinvitation, we intend to explain firstly the agriculture and agricultural machinery being prevailedin Japan, and secondly our recent approach which may be along with the subject of this session.II. How agricultural mechanization contributed to Japanese agriculture1. Scale of Japanese agricultureHistorically, Japanese main agricultural products have been paddy rice as a staple food, butsupplemented by vegetable and stock farming. Stock farming has been developed byintroducing management and mechanization techniques from Europe and North America. Themechanization of vegetable farming excluding cultivation and pest control is far behind theinternational level, although some governmental support has been provided in these fields.In recent years, rice consumption has decreased as a result of the diversification in dietary habits,which has led to a continual decrease in the price of rice. Consequently, the importance ofmachinery related to paddy rice has reduced, resulting in a change in the structure of agriculturalas shown below.(Figure 1-1. Transition of gross agricultural output and rice, vegetables, and stock farmingproduction)(Figure 1-2. Transition of delivery of agricultural machinery)2. Rice farming mechanizationThe working hours per hectare in rice farming have decreased to 1/5, from 1739 hours in 1960to 330 hours in 2000. It is the modernization of the agricultural machinery from human workto machine work, from a walk-behind to a riding type, from a small horsepower to a largehorsepower machine. The typical machines are tractors, head feeding type combine harvestersand rice transplanters.(Figure 2. Transition of the number of agricultural machinery and working hours per hectare)It is proven that agricultural mechanization has contributed to reduction of working hours ateach stage of rice farming. At the same time, fertilizer and pesticides technologies havedeveloped manufacturing in the agricultural machinery. Those technologies have alsocontributed to reduction of working hours greatly. Thus, the mechanization consistencysystem of the Japanese rice farming has been established3. Costs of agricultural machinery and its implementsUntil around 1990 the proportion of the costs of agricultural machinery and implements in thetotal expense required for rice production had increased. After 1990 this upward trenddisappeared.(Figure 3. Transition of agricultural machinery and implements cost in the total rice productionexpense. Large decrease from 1995 is caused by the change of calculation method.)Since 1990 farmers motivation to invest in agricultural machinery and implements havedeclined. The possible reasons include;(1) Saturated diffusion of agricultural machinery. Demand for mainly replacement equipmentmay be expected,(2) Decline of rice price. The Japanese Government politically controls the rice price toprevent its erratic fluctuation,(Figure 4. Transition of the price of rice purchased by Japanese Government)(3) The promoted reduction of planted acreages for rice production by governmental guidance.The Japanese Government politically controls planted acreages to prevent excessive productionof rice,(Figure 5. Transition of paddy field of planted and reduced acreages)(4) Decrease in the number of farm households,(Figure 6. Transition of the number of farm households)(5) Increase in commissioned acreages of agricultural work.(Figure 7. Transition of the rate of commissioned acreage for rice planting work)Furthermore, the service life of a tractor has increased to 19 years from 14 years in the lastdecade.III. Reduction of manufacturing and management costs of tractors and agriculturalequipment1. Reduction of manufacturing cost of tractorsShown below are some of our cost reduction activities, which involve three phases:- Reduction of purchased materials cost,(Optimal location of production base by considering distribution cost)- Reduction of cost by modular design and commonality of units,- Cost reduction related to the entire corporate activity by utilizing CAE and IT.1-1. Reduction of purchased materials cost(1) Reduction of cost by diversification of material procurement:- Diversification and globalization of suppliers,- Diversification of procurement systems;Consolidated purchase by group headquarters,Conversion from individual parts purchase to clustered purchase.(Figure 9. Promotion of clustered purchase)- Distribution cost reduction by concentrated collection and delivery,- Cost reduction of packing (container simultaneous purchase).(2) Reduction of purchasing cost by concurrent engineering with cooperative manufacturers:- Pursuit of the best structure and the lowest cost,- Procurement of tractor implements in the market.(3) Optimal location of production base by considering distribution cost- To produce key components such as engines in the main base, and to assemble them intofinal product in the appropriate market or region.We, Yanmar, manufacture Japanese style head feeding type combine harvesters in China andwalk behind tractors in Indonesia, together with engine facilities. A joint venture company fortractors, equipped with a horizontal water-cooled engine, was started up in China.(See Figure 10. Optimization of production, procurement and distribution)1-2. Reduction of cost by modular design and common unitCompared with our competitors tractors, our products are characterized as follows:- Similarity in the number of basic models available,- Too many factory options,- A few derivative export models from domestic models,- High manufacturing cost that may result from production of too many varieties in smallnumber.However, by modular design, we can satisfy a lot of demand from the market, and at the sametime we can reduce the cost by using common components and clustered parts.Our goal is Reduction of the total investment and the manufacturing cost by using commonparts for both domestic and export models. The number of major components such asmechanical front wheel drive units, transmissions, and cabs will be reduced to 2/3, and thenumber of factory installed options will be kept by the combination of units. Consequentiallywe can reduce the total manufacturing cost.1-3. Cost reduction related to whole corporate activity utilizing CAE and ITExamination using virtual prototypes is useful for conceptual design, actual drawing, testing andmanufacturing. It enables;(1) Shortened development period and minimized unnecessary retries,(2) Examination on figure of stamping die and machining fixture,(3) Examination of assembly process,(4) Arrangement of sales documents (catalog, operators manual, part table, and workshopmanual, etc.) from 3D data which will improve the operational accuracy, reduce manpower andconsequently reduce cost.2. Cost reduction of development and manufacturing of combine harvester by nationalprojectThe above mentioned is the activity that each company may execute respectively.In Japan, “Urgent Development of Agricultural Machinery project” has been initiated by thegovernment, the feature was reported here several years ago by Mr. Yotsumoto of Kubota. Wewould like to introduce a unique machine which was developed and manufactured with lessmanpower and less cost.2-1. Organizations of the project(Figure 11. Urgent development of Agricultural Machinery project)(1) Bio-oriented Technology Research Advancement Institute (BRAIN)Purpose of the project:- Development of machinery for limited markets where private companies could not developby themselves,- Development of machinery which contributes to the establishment of consistent mechanizedsystems for uses such as vegetables and orchards farming,- Development of machinery which contributes to environmental burden reduction such as PF.(2) New Agricultural Mechanization Enhancement Co., Ltd. (NAME):- Temporary load investment for molds to support small amount production,- Promotion of common usage of the parts and components and promotion of OEM suppliesof machinery, (3) Accomplishment of research and development of the project shown above are 34 efficientagricultural machines by 2002. 2-2. Development and commercialization of large-scaled combine harvester(Figure 12. Structure of YANMAR combine harvester)There are various restrictions in Japan, such as road conditions, field conditions, cultivationkinds, etc., which means that combine harvesters made in Europe or USA are not suitable forthe harvesting of the rice plant, the staple food of Japan. On the other hand, head feeding typecombine harvesters developed in Japan have superior accuracy in harvesting the rice plant andwheat. However, their structures are complicated, and it is difficult to widen cutting width andimprove durability.Yanmars desire was to develop a combine harvester with excellent operational accuracy forJapanese rice, which is also applicable for other plants such as wheat, soybean, rapeseed and soon, to reduce the cost of farm management. Yanmar succeeded in commercializing a mediumsized multipurpose combine harvester in 1986 under the technical guidance of BRAIN.After the diffusion of the combine harvester, there was demand for development of larger-scaledtypes. We, at Yanmar, could not afford to invest in the development and the manufacture ofsuch additional types. The development became possible to be nominated for this project.Moreover, temporary burden of the investment borne by NAME reduced the burden on themanufacturer in the commercialization process.(Figure 13. Supply of machines and components)Consequentially, Yanmar bore the redemption of the development cost and the productionpreparation expense, supplying the whole products or major components to other companies.On the other hand, other companies could consequently save development manpower andfacilities.The benefits farmers received from the development of the “Multi purpose combineharvester” are as follows. As mentioned above, the reduced planted acreages for riceproduction is almost 40% on average. In the northern part of Japan, where this type ofcombine harvester is very popular, it is 50%. They have to grow other crops such as wheat,soybean, buckwheat and etc., together with rice. Previously they harvested rice by using thehead feeding combine harvester and other crops by using the
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