A Study on Administration in Robot Reliability for Body Assembly Line

In Toyota body assembly line we introduced the Flexible Body Line since 1985. This line has the character that consists of 300 robots, and the robot breakdown causes the enormous damage for the product line. As the result the line availability depends upon the robot reliability in particular. Therefore in order to improve the robot reliability, we tried to apply the statistical method and proved the effectiveness. At first we investigated the failure field data and clarified the failure mode. After that we designed reliability line model for the requirement of Robot MTBF. In addition we developed the estimation method for the mechanical parts life according to the each robot's motion. Consequently we standarized the overhall specification and reduced the life cost of the robot. Owing to these activity, we attached the high reliability of robot and introduced many robots into the line.