Yushin Precision Industrial Co., Ltd.
CCC-1540 “Challenge, Change, Completion”
Contents
1. Company Profile
2. Milestone
3. Organization
4. Production & Inspection Equipments
5. Major Products
6. Customers & Turnover
7. Design System
8. Status of Certification & Patent
9. Application & Case Study for Cost Saving
10. Production Improvement
11. Overseas plant profile
CCC-1540 “Challenge, Change, Completion”
1. Company Profile
Company
Chairman
CEO
Establishment
Address
The number
of employees
Sales
Main
products
Size of area
Yushin Precision Industrial Co., Ltd.
Dong Ah, Lee
Incheon 인천 남동
Namdong
Songdo
Kyung Shik, Song
Dec. 1975
Dangjin
Seosan
Head Office : 85, Gaetbeol-ro, Songdo, Yeonsu-gu, Incheon
Namdong Plant : 125, Neungheodaero, 577beon-gil, Namdong
Dangjin Plant : 197, Galsan-gil, Sunseong-myeon, Dangjin
Gunsan Plant : 110, Sandannambuk-ro, Gunsan
520
Gunsan
Head Office
US$ 204M(2012)
Disc Spring, Snap Ring, Drive Plate, Hose Clamp, Shim,
Etc
Ulsan
Warehouse
Plant
Incheon
- Head Office & Namdong Plant
- R&D CENTER
Dangjin
- Dangjin Plant(Hose Clamp)
Gunsan
- Gunsan Plant(Wave Spring)
Total 72,697㎡
(Head Office 5,500㎡, Namdong Plant 11,047㎡,
Dangjin Plant 21,500㎡, Gunsan Plant 34,650㎡)
CCC-1540 “Challenge, Change, Completion”
Unit : M. US$
Year
2012
Sales
Amount
7
Employees
87
POLAND
BEIJING
(Sales Office)
YENCHING
America
(Sales Office)
Total
Description
Sales
Amount
Employees
Domestic
139
520
Overseas
65
873
TTL
INDIA
Unit : M. US$
204
Year
2012
Sales
Amount
18
Employees
350
Year
2012
Sales
Amount
25
Employees
279
QINGDAO
Shanghai
(Sales Office)
WUXI
Year
2012
Sales
Amount
15
Employees
157
1,393
Global Network
4 Countries / 4 Plants / 1 Sales Office
→ 873 Employees
CCC-1540 “Challenge, Change, Completion”
2. Milestone
• 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 from
Presidential 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)
• 75.12 : Established
• 08.09 : Established Wuxi Plant in China
• 76.01 : Retainer Ring
• 08.09 : Established Chennai Plant in India
• 78.02 : Registered as a HMC Supplier
• 09.01 : Established factory in Poland
• 89.07 : Manufacturing Snap-Ring, Drive Plate for A/T
• 09.10 : Manufacturing Single Flex Plate
• 10.12 : Established Gunsan Plant (Cushion Spring)
CCC-1540 “Challenge, Change, Completion”
3. Organization
Chairman
会長
CEO
社長
Administration
Sales &
Development
Planning
Production
R&D
Quality
General Affair
Sales & Marketing
Business Planning
Production
R&D
Quality Control
Accounting
Development
Cost Analyzing
Production Administration
Production Engineering
Quality Assurance
Overseas Support
Plant Renovation
Material Purchasing
I.T
Tooling
6 Divisions & 17 Teams
Office Worker
Production Worker
TOTAL
180
340
520
30%
70%
100%
CCC-1540 “Challenge, Change, Completion”
4-1 Production Equipment
Production Equipment (Incheon Plant)
NO
Equipment
Production Equipment (Dangjin Plant)
Qty
Remarks
NO
80 ~ 650ton
1
Equipment
Qty
Remarks
Muti Slides Lines
17
(Ø200~Ø560)
2
Austempering Furnaces
2
1
Press
15
2
Coiling M/C
17
3
Double Disc Grinding M/C
5
Ø300~Ø760
3
Shot Peening Machines
2
4
CNC Lathe
10
Ø860
4
Geomet Coating Lines
2
5
Austempering Furnace
2
5
Auto Assembler for D/W Clamp
4
6
Barrel
9
20L ~ 200L
6
Clipper for Clipless Clamp
2
7
Fine-Blanking M/C
3
630ton, 800ton
7
Vision System for 100% Inspection
5
8
Batch Tempering Furnace
1
8
Auto Packing Equipment
1
9
Welding Line
2
(CO2, SPOT)
9
Return Spring
7
10
Single Flex Plate Line
1
P/F, Hb, Chp, & Etc.
10
TOTAL
TOTAL
65
Production Capacity (Incheon Plant)
NO
ITEMS
32
Production Capacity (Dangjin Plant)
Annual Capacity(Mil.)
NO
ITEMS
Annual Capacity(Mil.)
1
Snap Ring
113
1
Hose Clamp
150
2
Washer/Spacer
78
2
Double Wrap Clamps
50
3
Drive Plate
3
3
Clip
16
4
Return Spring
2
4
TOTAL
194
TOTAL
218
CCC-1540 “Challenge, Change, Completion”
Production Equipment (Gunsan Plant)
NO
Equipment
Qty
1
Press
3
2
Deburring M/C
2
3
Induction Heating
Die-Quenching M/C
25
4
Shot Peening M/C
24
5
Vision Tester
1
6
Washing & Load Tester
33
7
Mark’g M/C
2
TOTAL
Remarks
450, 600 ton
Tempering
Furnace(3)
89
Production Capacity (Gunsan Plant)
NO
1
ITEMS
Disc Spring (D/Q Items)
TOTAL
Annual Capacity(Mil.)
25
25
CCC-1540 “Challenge, Change, Completion”
4-2 Inspection Equipment
Inspection Equipments (Incheon, Dangjin, Gunsan)
NO
TYPES
Namdong
Dangjin
Inspection Equipments (Incheon, Dangjin, Gunsan)
Gunsan
NO
1
13
Load Tester for Disc spring
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
21
Cleanness Tester
1
22
Universal Tensile Tester
1
23
Disc Spring durability Tester
1
1
3D CMM
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
6
Contour Measuring M/C
1
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
1
2
TYPES
TOTAL
Namdong
27
Dangjin
Gunsan
1
1
1
3
15
16
CCC-1540 “Challenge, Change, Completion”
5. Products
CCC-1540 “Challenge, Change, Completion”
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
Remark
Stamping / Coiling
- Standard/Customized design available
- Various notch profile
- Rolling for raw material capable in house
CCC-1540 “Challenge, Change, Completion”
5. Products – Transmission Parts 2
Disc Spring
/ Return Spring
Material
High Carbon Steel (SAE 6150 / 50CrV4)
Customer
HMC, HPT, GM, Borg Warner, JATCO, TRW
Core Manufacturing
Process
Remark
Stamping - Induction Heating - Shot Peening
- Blackbox design capability for High/Low load disc
spring
- 100% load test for high load spring in the
production line
CCC-1540 “Challenge, Change, Completion”
5. Products – Transmission Parts 3
Shim & Washers
Material
High Carbon Steel (SAE 1065~1085/ SK5M)
Customer
HMC, HPT, Scheffler, NSK, Borg Warner
Core Manufacturing
Process
Remark
Stamping - Heat Treatment – (Grinding)
- In-house capability for all process include heat
treatment
- Can control various selective parts
CCC-1540 “Challenge, Change, Completion”
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
CCC-1540 “Challenge, Change, Completion”
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)
CCC-1540 “Challenge, Change, Completion”
5. Products- Others (Fine Press parts Etc.)
Multi Forming
Fine Press
Others
CCC-1540 “Challenge, Change, Completion”
6. Customers & Turnover
1)Customer
Domestic
Overseas
CCC-1540 “Challenge, Change, Completion”
2) Turnover
2012 Korea & Overseas Plants Turnover
India
18
Wuxi
15
Poland
7
Qingdao
25
Unit : M. US$
FY’12 : 204
FY’13 : 245
Korea (Domestic)
110
Korea (Export)
29
2012 Sales Share (Items)
2012 Sales Share (Customers)
Etc., 16%
ETC
18%
Snap Ring,
HPT 22%
27%
Washer /
Shim, 15%
KIA 6%
HYUNDAI
21%
MOBIS
14%
GM GLOBAL
14%
Disc Spring,
Drive Plate,
15%
17%
Hose Clamp,
10%
CCC-1540 “Challenge, Change, Completion”
8. Design System
Design Tool
Design Flow for Proto
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
CCC-1540 “Challenge, Change, Completion”
Design Boundary
Concept Design
3D Modeling
0.74
MIN HEIGHT STROKED
4.75
0.8
INSTALLED HEIGHT
[ Lay
Out]
Just given the two things
from the customer
YSP’s Spring Design
Sheet
CCC-1540 “Challenge, Change, Completion”
FE Modeling
Stress Analysis
Fatigue Analysis
Max Stress
1182 MPa
Spring height
1.84 mm
Life = 983,172 cycles
Max. Damage
5.289E-1
CCC-1540 “Challenge, Change, Completion”
Tooling
Proto Production
Validation Test
CCC-1540 “Challenge, Change, Completion”
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
Proto Line
Test Equipment
CCC-1540 “Challenge, Change, Completion”
8. Status of Certification & Patent
◎ 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)
CCC-1540 “Challenge, Change, Completion”
9．Application & Case Study for Cost Saving
* 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%
CCC-1540 “Challenge, Change, Completion”
[Snap Rings (Selection Parts)]
Special : Ellipse Ring
Perfect circle at install state
Laser Marking
NC Coiling
for identification
• Process Improvement : Grade(Selection) Improvement of the identification of goods
(Temper Color → Laser Marking)
• Cost Saving : 20%
[Thrust Washer]
• Material Change
: Copper → Steel (SK5M)
• Cost Saving : 40%
CCC-1540 “Challenge, Change, Completion”
[Differential Washer]
• Surface Treatment Change
: Electroless Nickel Plating
→ Nitriding
• Cost Saving : 30%
[Locking Nut]
• Process Change
: Forging & Machining
→ Fine Blanking
• Cost Saving ： 40％
CCC-1540 “Challenge, Change, Completion”
10. Production Improvement
1) Jig Tempering
UPH : 30
Labor : 5
1st Generation
Single Hot Press
UPH : 120
Labor : 0.5
2nd Generation
6 Hot Press
UPH : 150
Labor : 0.5
3. Quality Improved
3rd Generation
Automatic Hot Press
※ 4th Generation
Duel Hot Press is in test.
2. Labor ↓
1. Cycle Time
↓
Through this Improvement, Productivity increased more than 100%
CCC-1540 “Challenge, Change, Completion”
2) Improvement for Disc Spring
OLD
Bending
Heat Treatment
Jig Temper’g
Shot Peen’g
Blank’g & Deburr’g
Shot Ball
Parts
Conveyer Belt
Die-Quenching
NEW
Temper’g
Parts Rotation
Cost Saving : 20%
Cost Saving and Improve Quality by Manufacturing Change
CCC-1540 “Challenge, Change, Completion”
11. Overseas plants profile
Main Item
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
CCC-1540 “Challenge, Change, Completion”
Main Item
Company
Wuxi Yuzhong Co.,Ltd
Establishment
Sep. 2008
Address
＃B-16、Koshin development district, W
uxi, China
Turnover 2012
US$ 15 M.
Employee
157
Main Item
Back Plate, Booster Shell
Main Customers
MOBIS, KMC
CCC-1540 “Challenge, Change, Completion”
Main Item
Company
YSI Automotive Private Ltd
Establishment
Sep. 2008
Address
Chennai Tamil Nadu, India
Turnover 2012
US$ 18 M.
Employee
350
Main Item
T/M Brackets, Seat Belt
Main Customers
HMC, KMC, TATA, UNIPRES
TOKAI RIKA, TAKATA
CCC-1540 “Challenge, Change, Completion”
Main Item
Company
YSP &C Poland sp z.o.o
Establishment
Jul. 2009
Address
ul, Poznanska 4, Pyskowice,Poland
Turnover 2012
US$ 7 M.
Employee
87
Main Item
Back Plate, Booster Shell
Main Customers
HMC, KMC, MOBIS, FUJI KOYO
NEXTEER
BACK PLATE ASSEMBLY
LH and RH
START OF
PRODUCTION : Feb.
2011
SHELL&STUD
ASSEMBLY(ED/FD, EL/SL)
START OF PRODUCTION
CCC-1540 “Challenge, Change, Completion”
Thank you.
CCC-1540 “Challenge, Change, Completion”