ref. # C16-033
Honda Develops World’s First, Unprecedented Mass-production Automobile
Assembly Line, Called ARC Line
-- ARC Line has been introduced to new automobile plant in Thailand -TOKYO, Japan, April 21 2016 – Honda Motor Co., Ltd. has developed the world’s first*1 cell
production-style ARC*2 Line, as a fluid line to be incorporated into a main line of a conventional
mass-production automobile assembly line. Honda introduced the ARC Line to Honda’s new
Prachinburi Plant in Thailand that became operational in March 2016. The plant is part of Honda
Automobile (Thailand) Co., Ltd. (HATC), Honda's automobile production and sales subsidiary in
Thailand, and is located within the Rojana Industrial Park in Prachinburi Province.
The newly-developed ARC Line is a world’s first innovative and unique assembly line that is different
from a conventional line production system and was developed by incorporating flowing cell
production-style production units in the main line. In production on a conventional line, which has
been broadly adopted for automobile production to date, each production associate takes charge of a
single process and installs parts to vehicle bodies flowing on a conveyor. In cell production, on the
other hand, one production associate takes charge of a broader range of production processes and
installs multiple parts.
In ARC Line production, four production associates get on board an ARC Unit, a unit of a conveyor
that carries one vehicle body and a complete set of parts to be installed to the vehicle body, and
assemble the vehicle while moving along the production line together with the vehicle. This system
reduces any incidental movements by production associates – such as selecting the proper parts for the
specifications of the next vehicle body coming down the line and installing them while walking along
with the vehicle body. These are not considered essential assembly movements but are inevitable in
conventional production processes. The ARC Line production achieves a significant improvement in
production efficiency through the reduction of such process loss.
Moreover, with ARC Line production, each production associate takes charge of a broader range of
production processes, which makes it possible for associates to gain a broader range of production
knowledge and skills. This is expected to have a positive effect on the development of proficient
production associates who will be capable of providing feedback from the production team to the
development team in the future.
Honda will continue its efforts to increase the efficiency of production processes for the purpose of
delivering attractive and high-quality products to its customers in a timely manner and at reasonable
prices.
*1 Honda internal research
*2 ARC: Assembly Revolution Cell
The ARC Line installed to HATC’s new Prachinburi Plant
Image of production associates working on connected ARC Unit
<Key technologies adopted for the ARC Line>

ARC Unit:
An ARC Unit constitutes the function of a conveyor that moves with the fixed layout of a
vehicle body, with assembly parts and a workspace for each production associate onboard.
Traffic lines of production associates do not cross, therefore four associates can work on one
vehicle simultaneously with a reduced amount of unnecessary incidental movements, which
increased ARC Line work efficiency by approximately 10% compared to that of a conventional
line. In the area of logistics, because of the loop-shape of the conveyor, supplying full boxes of
assembly parts at the start of assembly and retrieving empty boxes at the end of assembly can
be done at the same spot. As a result, the number of spots where assembly parts are brought to
the line was minimized, which reduces the workload related to parts handling within the plant
by approximately 10%.
The ARC Unit can be added to the production line unit by unit, which enables the plant to
change the layout of a production line flexibly to accommodate future changes in production
volume as well as the additions of production models. Moreover, the ARC Line has a structure
that is less likely to be affected by spatial restrictions of an installation site, therefore reduction
of investment cost can be expected when structurally identical ARC production lines are
installed to Honda production plants around the world.

PLUTO*3 System:
The PLUTO System is a quality maintenance/management support system designed to equalize
both the skill level of ARC Line production associates and the quality of finished products at a
high level. Using tablet-type devices placed in the work space on each ARC Unit, the system
provides visual and audio instructions such as the sequence of parts assembly and points for
quality management so that human errors such as misassembly of parts by less proficient
associates will be prevented.
Moreover, inspection associates will immediately inspect each vehicle at the Q-GATE, the
quality inspection area which follows the ARC Line, which makes it possible to immediately
address any assembly errors. After addressing identified error(s), the system feeds inspection
results back to the responsible production associate. When any error is found, the system
displays an alert message on the screen when the associate turns on the system to work on the
next vehicle. With these functions, the PLUTO System will ensure high quality maintenance
during the assembly process.

DiSC*4 System:
The DiSC System works in conjunction with production planning and helps to supply the
proper parts to each production associate. When associates in charge of the parts storage area
adjacent to the ARC Line prepare assembly parts for upcoming vehicles, indicator lights on
parts shelves will illuminate to notify the location of necessary parts. This system enables the
accurate supply of parts even for a production line where multiple models are being assembled
simultaneously.
*3 PLUTO: Proficiency Learning and Ushering Target for Operator
*4 DiSC: Distribution Set-pack Control