How FUJIFILM's new X-PRO2 is made. A visit to FUJIFILM's Taiwa factory

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I actually posted this in the blog section, but then recalled that the blog posts are not viewable via the mobile app. So I decided to share it here as well.


Links to the blog posts are provided below, but it is no different from this thread.
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The Taiwa factory visit followed the official announcement of the Fujifilm X-Pro2, X70, XF100-400mmF4.5-5.6 R LM OIS WR, X-E2S, EF-X500 (development announcement), and the FinePix XP90. As well as the new ACROS film simulation found together with the latest 24.3MP X-Trans CMOS III sensor and X Processor Pro image processing engine.

Read more on the announcements here - Fujifilm's X 5th Anniversary Announcements - X-Pro2, X70, and more.
Read keithwee's review of the X-Pro 2 here - [Keithwee] Preview of The Fujifilm X-Pro 2 : The ‘Pro’ returns
Read keithwee's review of the X70 here - [keithwee] Preview of the Fujifilm Fujion XF35mm F2 R WR lens

 

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[Jan.2016] ClubSNAP was invited to FUJIFILM’s Taiwa factory in Sendai (Japan) earlier this year. This is currently FUJIFILM’s only factory that assembles the recently launched new flagship X mirrorless camera, the X-Pro2. The Taiwa factory also assembles a number of XF lenses and X cameras (not limited to the list below). We were brought down to view the assembly lines of the new XF 100-400mmf/4.5-5.6 R LM OIS WR and the XF 35mmf/2 R WR, as well as the X-Pro2 and the X-T1.


Fujifilm X-Pro2 + XF 35mmf/2 R WR

Fujifilm has a long history in optics, starting back in 1940’s. People will be familiar with Cristar (50mmf/2 and 35mmf/3.5), Fujinon’s Speed Trio (35mmf/2, 50mmf/1.2, and 100mmf/2), Large Format lenses (W135f/5.6, W90mmf/5.6, and W300mmf/8), Fujica (ST801, ST605II), Medium Format (GX645, GF670), and now the line-up of 21 XF lenses. We saw first-hand the efficiency and meticulous attention that we have some to expect from something that bares the “Made in Japan” label.

The lenses were assembled in a clean room environment. We were dawned in clean room suits, given handouts were printed on clean paper to reduce the risk of particle contamination, and even camera straps were to be removed for the same purpose.


XF 56mmf/1.2, Fujinon L 50mmf/2, Fujinon L 35mmf/2, XF 23mmf/1.4, Fujinon L 50mmf/2.8


It was a 45mins Shinkansen ride up to Sendai, and then another 45mins up to the Taiwa factory


Media partners decked out in space (cleanroom) suits


Taiwa factory production lines

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The assembly of the lenses were almost entirely by hand, with some assistance from machine aided adjustment (calibration & testing) and automated UV cementing. It takes 80mins to assemble a XF 35mmf/2 R WR, and 220mins to put together the more complex XF 100-400mmf/4.5-5.6 R LM OIS WR.


Assembly line checks made on the XF 35mmf/2 R WR

Once the lenses were assembled, they were put through a number of adjustments and checks before they are sent off to be serialised and packed.

SFR (Spatial Frequency Response) Adjustment - this measures the sharpness of the lens. It may be more commonly known as the Modulation Transfer Function (MTF). After which, the UV bonding is applied to fix all parts.
Resolution Check 1 – After the SFR adjustments.
Drive Test – Checking drive mechanism and zoom are working properly.
Vignetting Test – Evaluating the performance of the vibration control and vignetting.
Lens Hood Assembly
AF / Aperture Test – Checking on AF and aperture controls.
Resolution Check 2 – Evaluating if CIPA standards are met.
Appearance Test – Mounting and external check.






Manually inspection, cleaning, and mounting of the lens elements

 

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Automated UV bonding

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For cameras, they go through 4 key sections - Assembly, Adjustment, Inspection, and Leather Assembly. The assembly of the bodies were all done by hand, combining circuitry from the front plate (with the sensor) together with the rear plate (with the LCD), top plate, and the bottom plate. While this may sound like a trivial process, just consider that just the top dial of the X-Pro2 comprises of 23 different pieces!



Once assembled, the firmware is loaded into the cameras before putting them through the integrated performance test and image quality check. These checks evaluate more than 20 characteristics of the camera, including the resolution, image quality, image processing, dust detection, angle of view, etc.

The last step of the assembly was the affixing of the leather, where workers place the leather on the cameras manually, and a press mechanism was used to complete the process.

It takes about 30mins to assemble each unit. The Taiwa factory uses 2 assembly lines to produce about 300 units of the X-Pro2 per day, and also has other dedicated assembly lines for the X-T1 and X100T.


Soldering the circuitry on a X-Pro2






Affixing of the leather on the X-Pro2, manually and use a press mechanism

 

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A "naked" X-T1

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Before the cameras and lenses were ready to be packed and shipped out, they have to go through the packaging and shipping process. This includes the capturing of the serial numbers of each unit, the laser engraving of the serial number and “Made in Japan” marking, and the final inspection.



If the above is not enough to convince you that your new Fujifilm X camera or XF lens will arrive in excellent working order, you may also want to know that Fujifilm carries out a 100% check on lenses during the final inspection. They even used gravimetric determination in the packaging, meaning every box is weighed to with +/- 5 grammes to ensure that all contents are included in the box. Further to all of that, even after all the boxes are already placed in cartons, 1 in 10 cameras (10%) are pulled out at random for a spot check, to go through a check list of 76 items, including resolution check, operation check, and box contents.

With that, you can be assured that your "Made in Japan" Fujifilm X camera and your XF lenses will be pristine, fully operational, and ready to capture your precious moments.

ClubSNAP would like to thank FUJIFILM Singapore for the invitation to their Taiwa factory to understand and share more about how FUJIFILM X cameras and XF lenses are made.


Assignment of the serial numbers of the X cameras and capture into the system


100% checks on the the XF 35mmf/2 R WR

 

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All packed into cartons, and ready to be shipped to Singapore!

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