2020.1

Mirror SystemManufacturing

Process

Evaluationand Analysis

Developmentand Design

The body painting process supports small production runs of a large range of products.The same single line can paint products for many models and in many colors.

Plastic is injected into the mold to the form of the body.

The metal mold for the body shell is designed and manufactured by our in-house tooling department.

In overseas markets, as in Japan, even those who have a long

history of supplying to automakers no longer enjoy vested

rights. The ability to study and anticipate market trends and

automakers’ demands and the ability to propose solutions

anticipating customers’ demands, are more important

than ever. At Murakami we conduct preliminary research

anticipating each automaker’s model change timing and

propose our products, which include self-developed

technologies. Working together closely with automakers,

Murakami has realized many world’s firsts in functional mirrors,

such as power folding mirrors. Seeking not only basic

performance, but also aesthetic design that enhances the

overall impression of the vehicle, Murakami proposes

cutting-edge products.

Thinking globally, it is also vital for us to expand into markets

that give priority to cost over advanced functions. From this

viewpoint, Murakami is focusing on the development of

lower-cost products while maintaining Murakami’s high

standards for quality. Murakami is developing production

systems and sales strategies adapted to local markets, while

enhancing a global network around development bases in

Japan. Murakami is also enhancing cooperation with the

overseas production bases of domestic automakers, while

building trustworthy relationships with overseas automakers.

Also in the areas of evaluation and analysis that are vital for the improvement of product quality, Murakami has developed know-how and increased its levels of expertise in development and manufacturing. To conduct performance tests before mass production and check the validity of product design and production systems, the company has developed many testers deemed necessary for analysis, making it possible to evaluate samples from more directions and more accurately. Further, after mass production, an independent quality control section rigorously checks products on more than 20 criteria and analyzes the causes of any failures. Meanwhile, with the globalization of production, the quality control section is promoting standardization adapted to local regulations and user environments so as to support our global manufacturing system.

Units and parts manufactured on different lines are assembled into a mirror assembly. A mirror assembly, depending on design specification, may be comprised of as many as 20-50 material items.

Large sheets of glass are automatically cut into the appropriate sizes for rear-view mirrors.

Various electrical parts are efficiently mounted on a self-designed substrate.

In a furnace, heat is applied to allow precise bending of the glass around the mold.

Multiple PCBs are fixed at the same time on the line.

The sputtering machine coats the glass with a mirror surface and further coats it with multiple layers of thin-films.

Each unit, such as actuator and power folding unit, is assembled on fully automated lines.

The body shell is completed, along with other sub-assembly components.

The mirror part is completed when the mirror holder and anti-fogging heater are attached.

The power unit is completed after noise check, operation and other function checks.

Mirror

Power Unit

Body Shell

Cutting Forming

Assembly

Coating with thin-films

Mounting parts Soldering Assembly

Mold fabrication Injection molding Painting

Adding development to the three performance indicators quality/cost/delivery

(QCD), we are committed to achieving a QCDD balance of our own.

Development and proposalOur development/sales proposal approach allows us to work with customers from

the very start of the development phase, propose a variety of solutions defying

the boundaries of existing technologies and offer optimal products.

Development and manufacturingOur integrated system from development to production allows us to respond to

large-lot production on large-sized machines, producing products efficiently and

delivering them at low cost and in short time.

Quality assurance systemThrough a rigorous quality control system we have developed in the automotive

industry, we seek high qualities in every aspect of product manufacturing.

The top market share in Japan through development ability and superior quality - Gaining trust in more countries

Supported by Japanese automakers, whose quality

standards are some of the highest in the world,

Murakami's Mirror Systems enjoy the top market

share in Japan today. As automakers globalize their

operations, we are also expanding our bases and

exploring markets overseas. There, too, we have

proved our in-house development abilities in meeting

high-level demands for safety, cost, delivery, etc.,

while developing human resources in these fields.

In a unique QCDD balance, seeking to offer something better than what’s demanded

■ Wind tunnel testerThis tests noise, vibration, air resistance, etc. caused by exterior mirrors when the vehicle is in motion by simulating air flow. This allows us to test mirrors in changing weather and environmental conditions and to study optimal designs on the spot.

■ Thermo hydrostat testerEnables reliability tests supposing extreme conditions such as high-temperature, high-humidity, or cold temperature. When combined with other testers, the tester can simulate even severer environments.

■ Vibration testerEnables tests under every possible condition of vibration, such as vibration for long periods of time or at high temperatures. With more and more automotive parts being made out of plastics and lighter in weight, higher rigidity of mirror assembly is required.

■ Mirror vibration angle meterSelf-developed to measure the wobbling of the mirror that might be caused while the vehicle is in motion. Using laser, the meter detects micro-wobbling, enabling an objective analysis.

■ X-ray photoelectron spectrometer (XPS)Used for a variety of purposes, including test analysis of structure components and observing internal skin structure.