Production Systems｜Marine Commercial

Production Network for Yanmar Marine Commercial Engines

Yanmar is one of only a few engine manufacturers to have implemented an integrated production system. At our Amagasaki and Tsukaguchi factories, we carry out each stage of engine production, from machining and assembly, through to outfitting, testing, and shipment. The factories are mechanized to promote automation and labor saving, and we have established an order entry system adapted to our product's characteristics and which allows us to manage the progress and history of each individual engine. With this system, we manufacture products of the highest quality. Furthermore, Amagasaki and Tsukaguchi take delivery of components manufactured at other Yanmar Group factories, such as cylinder blocks, fuel injection systems, gears, and clutches, meaning that our engines are produced almost entirely in-house.

Amagasaki Factory (Large Diesel Engine, Gas Engine, Gas Turbine)
Tsukaguchi Factory (Small and Medium Diesel Engine, Gas Engine)

Amagasaki factory

Automation and thorough quality control for absolute peace of mind

The Amagasaki factory opened in 1936, manufacturing the world's first commercially viable compact diesel engine. In time, the factory started mass-producing propulsion and auxiliary engines for marine vessels, and diesel engines for land-use and general applications. The factory also started producing gas turbines in 1983. Combining the in-situ "cell production method" together with line production, the factory also promotes automation and labor saving with the use of our own high-performance specialist equipment and state-of-the-art facilities. By establishing a traceability and quality control system, we can produce products of outstanding quality.

Marine Propulsion
Diesel Engine

Output: 374 - 4,500kW

Marine Auxiliary
Diesel Engine

Electrical Capacity:
180 - 4,800kWe

Marine
Dual Fuel Engine

Output: 1,533kW

Industrial
Diesel Engine

Electrical Capacity:
279 - 3,351kWe

Industrial
Gas Turbine

Electrical Capacity:
200 - 2,400kWe

Product Lineup

Certified under voluntary inspection by 11 shipping classification societies

Amagasaki Factory is an authorized factory by IACS members. We are the first to have been certified under the independent standards of each of the 11 classification societies.

Nippon Kaiji Kyokai (NK) - Japan
American Bureau of Shipping (ABS) - US
Lloyd's Register (LR) - UK
Det Norske Veritas and Germanischer Lloyd (DNV GL)
Registro Italiano Navale (RINA) - Italy
Bureau Veritas (BV) - France
Korean Register (KR) - South Korea
China Classification Society (CCS) - China
Indian Register of Shipping (IRS) - India
Russian Maritime Register of Shipping (RS) - Russia
China Corporation Register of Shipping (CR) - Taiwan

Advanced production system which has received global recognition

Amagasaki Factory acquired ISO9001 certification in July 1992 by the United Kingdom based certification provider, LRQA. Responding swiftly to environmental issues, in June 1997 our factory became one of the first land-use and marine diesel engine manufacturing facilities to be ISO14001 certified. Furthermore, Yanmar instantaneously attained the International Maritime Organization (IMO) Tier 2 and Tier 3 certification for the regulation of NO_X emission levels. Yanmar maintains an internationally acclaimed reputation for leading edge technology that has environmental conservation at its forefront.

ISO 9001(International Organization for Standardization)

Quality Management Systems Certification No:912208

ISO 14001(International Organization for Standardization)

Environmental Management Systems Certification No:770250

Integrated production system for high-performance engines

Production Processes for Diesel and Gas Engines

Machining

During the machining process, key components of the engine such as the cylinder block, cylinder liner, crankshaft, camshaft, and connecting rods etc. are all machined with high precision and efficiency.

Assembling

After machining, each part is properly assembled with the correct torque and sequence as instructed by our work navigation system.

Outfitting

The assembled engines are placed on a base plate and additional equipment such as generators, pumps, compressors, and clutches are installed, together with any necessary piping.The engines can also be fitted with an electro-hydraulic system, for automated and remote operations, according to the customer's specifications.

Testing

After outfitting, each engine is rigorously tested by a qualified engineer, run under conditions equivalent to actual operating conditions on-board a vessel. Further inspections are simultaneously conducted to determine compliance with the Ship Safety Act and the standards of the Fisheries Agency of Japan and also members of International Association of Classification Society(IACS).

Shipping

The engine is coated, treated to prevent rusting, inspected for shipping and then packaged for shipment to a location either within Japan or overseas.

Gas turbine Production

Parts such as the impeller, rotor, and nozzle are finished with ultra precision by the 5-axle control machine or the NC dedicated device, with the turbines assembled in a highly-controlled process. The turbines are then fitted with various generators and accessories and are shipped out after undergoing stringent testing and inspections.

Machining (impeller machining)

Assembling (clean room)

Outfitting

Testing

Quality control with traceability

During the machining process, a QR code is printed onto each part using a laser. In this way, all data generated during each stage of production is recorded. By conducting statistical and mathematical analysis using this recorded data, we work to achieve even higher levels of performance and quality.

Tsukaguchi Factory

Small and Medium Engines Developed with the Advanced Quality Control Systems

Tsukaguchi Factory took over the production of medium size diesel engines and compressors, from Showa Seiki Kogyo corporation in 2000. At Tsukaguchi Factory, we specialize in small and medium size diesel engines, employing cell production system to produce a diverse range of engines including marine propulsion and auxiliary engines alongside the full production of land-use and industrial engines. We undertake all operations from component machining through to assembling, outfitting and testing. Yanmar is advancing its long history of technological expertise and know-how at every turn, riding at the forefront of the industry in Japan and in markets across the world as a provider of highly reliable products.