Here is some info about the Onkyo's Kurayoshi factory, near the Japan Sea coast of Tottori prefecture, where the company builds its TX-SR805, TX-SR875 and TX-NR905 receivers, as well as the audio computer. Although thepicture states the below image is a TX-NR905, the power supplies indicate its probably a 875...
An amazing 4935 parts go into a TX-SR805, with pre-assembly of circuitboards handled down on the ground floor by an array of board-populating and soldering machines. As well as conventional board-stuffers there's at least one super-fast 'gatling-gun' insertion machine, while components for boards are loaded onto carts which can be slotted into the machine with hardly any break in production. The board assembly section runs 24 hours a day, servicing the production lines upstairs with items such as the video processing board below.
At the moment the factory is producing some 200 TX-SR805s a day, with a total of 192 staff. And yet the efficiency of the plant is shown by the fact that labour costs only account for some 20% of the cost of the finished product - not bad when 30-40% of your total staff are involved in inspection and quality control.
We followed the progress of a receiver from the manual loading (above) of boards with components too large to be handled by the machines downstairs, through the assembly of the large power amplifier sections, and uploading of firmware into the processors before final inspection. it was clear that there's a lot of quality control going on - every single product is tested and examined, and the stringent controls were clear in the number of products being pulled off the line for checking and rectification (below) at this very early stage of production.
> an array of board-populating and soldering machines. As well as conventional
> board-stuffers there's at least one super-fast 'gatling-gun' insertion machine
The company I work for makes those machines. I don't know if Onkyo uses our equipment or our competitor's, which is chiefly Panasonic in the thru-hole side. The gatling gun machine is called a "Chip Shooter". This sounds like one that we market that is made by Sanyo.
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