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Support×PEC-KUMATA　生産技術コンサルタント - List of Manufacturers, Suppliers, Companies and Products

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Support for the way of Tier 1 companies.

Support for the way of Tier 1 companies.

We will provide support for the way Tier 1 companies operate.

I will comment on the ideal state of Tier 1 by each point. 1. To gain high trust from OEMs (car manufacturers). As a Tier 1 supplier, it is essential to satisfy OEMs in all aspects of Q (quality), C (cost), and D (delivery time), and to maintain high production technology capabilities in the relevant products within the field of production technology. 2. To appropriately manage companies below Tier 2. As a Tier 1 supplier, there is a management responsibility for parts (including materials) produced by Tier 2 and below, making quality management across the supply chain crucial. In the field of production technology, it goes without saying that one should respond to process audits of suppliers (Tier 2) and provide solid guidance and feedback as a manufacturing professional. 3. To have an excellent management system and operational capability as a Tier 1 supplier. It is important to have a high-level management system and operational capability for initial flow management of new products, troubleshooting of flow items, daily management, and various improvements. Based on the above, we will provide support for the ideal state of Tier 1 companies!

  • Management consultant/Small business consultant

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Processing condition setting support

Processing condition setting support

We will provide support for setting your company's processing conditions!!

There are likely various processing steps at our manufacturing plant. For example, there are different types of assembly processing, cutting processing, molding processing, pressing processing, die casting processing, and so on, where each type of processing is carried out under certain predetermined conditions. However, it is questionable whether there are many processes that can clearly demonstrate that these processing conditions are indeed optimal and that proper records of the setting process are well maintained. We will provide support regarding the approach and methodology for setting processing conditions that can address the above concerns.

  • Management consultant/Small business consultant

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Area creation activity support

Area creation activity support

We will support your company's factory area creation activities!!

A company always has elements of activity and fluctuation, and the location (area) is an important asset for the company in everything it does. Smoothly managing that asset is a crucial task for the company. Particularly, being mindful of creating the area that will be needed in the future and controlling it is the essence of "area creation activities." We will provide support that includes specific methods and means to promote this activity.

  • Management consultant/Small business consultant

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Support for Defect Reduction Activities

Support for Defect Reduction Activities

We will support your company's efforts to reduce defects!!

In the manufacturing industry, I believe that for each processing stage, management values for conditions and quality are set, and daily production activities are carried out with the goal of achieving 100% good products. However, due to various circumstances, unintended defective products can occur. These can arise from a lack of process capability relative to the standard values, or they may occur unexpectedly even when there is supposed to be sufficient process capability, among other reasons. Defective products not only incur costs as waste disposal but also affect costs when reworked into good products due to the labor involved in the rework. We will provide support to promote various initiatives aimed at resolving these issues.

  • Management consultant/Small business consultant

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Initial flow management support

Initial flow management support

We will support your company's initial liquidity management!!

Generally, activities aimed at achieving QCD (Quality, Cost, Delivery) targets for new products (including new and similar ones) involve "initial flow management." However, it seems that there are few examples where initial flow management is firmly established. Initial flow management involves all related departments (design, quality assurance, production management, production, and production technology, etc.), but here, as a response to the production activities of a manufacturing-based company, we will focus on supporting activities from the perspective of production technology.

  • Management consultant/Small business consultant

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Support for various automation considerations

Support for various automation considerations

We will assist you with your automation considerations!!

One of the tasks in production technology is the consideration of automation. The opposite of automation is the term "manual operation," which refers to work done primarily by humans. Automation involves replacing human tasks (including those performed by robots) with machines that carry out all operations. If there is a completed line based on exemplary human work (that is, a line with a 100% good product rate), it becomes relatively easy to progress to the first stage by considering replacing each work element (such as work input, work posture changes, processing, checking, inspection, transfer, etc.) with machines. However, for processes that cannot be easily replaced (such as those relying on human intuition or visual judgment, or processes that originally have a high defect rate but are expected to stabilize through automation), thorough preliminary research, testing, and consideration are necessary. Additionally, it is important to consider the number of units and takt time for each work element to ensure efficient investment in automation. (Sometimes, significant changes to the method may be required for automation, which can lead to even more challenges to consider.)

  • Management consultant/Small business consultant

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Support for improving operational efficiency

Support for improving operational efficiency

We will assist you in improving your company's operational efficiency!

The operational status of production lines and production equipment is a daily concern for manufacturing companies, and I believe that activities to maintain and improve their operational rates are always being carried out. Therefore, support and guidance related to the approach and execution of activities aimed at improving operational rates will be the subject of consulting. (For reference, there is a term called "availability" in relation to operational rates, so I will briefly explain the difference. Operational rate refers to the ratio of hours spent producing goods with the equipment during a standard day, while availability refers to the ratio of the equipment being in a state to operate normally when desired. The operational rate can vary depending on sales, meaning it does not always have to be 100%, and it can sometimes exceed 100%, whereas availability always aims for 100%. In any case, improvement activities to enhance equipment productivity are important, and here it is explained as activities to improve operational rates.)

  • Management consultant/Small business consultant

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Line transfer promotion support

Line transfer promotion support

We will support the promotion of your company's line and product transfer!

It is common for companies to transfer production lines and products due to various circumstances. The transfer of production lines has two aspects: one is the need to minimize changes due to the transfer, particularly from a quality perspective, to avoid any quality issues; the other is that for the production line, this is a valuable opportunity for change and a chance to significantly improve, so improvements in quality and cost should be pursued simultaneously. From the standpoint of production technology, it is essential to seize this opportunity and implement everything possible before and after the transfer, aiming for significant improvements in quality control as well. To achieve this, it is important to firmly grasp the changes in the 5Ms and 1E and take action based on that understanding, planning for quality improvements (with a comprehensive understanding of past quality issues) and cost improvements (planning for logistics reviews and labor hour adjustments through layout improvements). The direction, support, and guidance regarding this line transfer will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for Promoting Production Technology Benchmarking

Support for Promoting Production Technology Benchmarking

We will support the promotion of your company's production technology benchmarking!

Benchmarking refers to the activity where countries, companies, etc., continuously measure their products, services, processes, and practices, and compare and analyze their performance against that of superior competitors and other excellent companies. This benchmarking is effective as a strategy for new product development and technological innovation, and it can also be considered a very effective means for continuous improvement of production technology, cost reduction, and quality enhancement. (It has a meaning almost identical to Tear Down and is synonymous with reverse engineering mentioned earlier.) The support and guidance for examining the procedures and methods related to the significant improvement of one's own production technology, cost reduction, and quality enhancement through the utilization of this benchmarking will be the subject of consulting.

  • Management consultant/Small business consultant

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Concurrent Engineering Execution Support

Concurrent Engineering Execution Support

We will support the establishment of your company's concurrent engineering!

Generally, the method of progressing work with upstream and downstream departments working simultaneously and cooperating can be referred to as Concurrent Engineering. In other words, Concurrent Engineering refers to a technique that advances multiple processes in product development concurrently, aiming to shorten development time and reduce costs. Concurrent Engineering involves sharing information and collaborating between departments, allowing tasks to proceed in parallel without waiting for the completion of previous processes, and providing feedback from later processes to earlier ones. For example, this includes feeding back information from manufacturing to design to create structures that are easier to mass-produce. As mentioned above, the methods and concepts of Concurrent Engineering demonstrate their effectiveness in various aspects of production technology and factory management. Providing support and guidance on this approach and methodology falls under the scope of production technology consulting.

  • Management consultant/Small business consultant

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Support for promoting the flow of first-class liquidization.

Support for promoting the flow of first-class liquidization.

We will support the promotion of your company's first-class fluid activities!

Generally, the advantages of one-piece flow compared to lot flow include the minimization of lead time, reduction of work-in-progress, prevention of large-scale defects, ease of line balancing, and potential improvements in productivity. Therefore, it is considered important to create standard work sheets, continuously consider improvements, and ensure efficient operations in the production site. As a production technology department, we believe it is crucial for process designers to incorporate these elements into the line configuration and equipment specifications during the design phase to create a well-structured line. The considerations for process design that take into account one-piece flow will be the subject of consulting.

  • Management consultant/Small business consultant

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Skill management promotion support

Skill management promotion support

We will support the promotion of your company's skill management!

Regarding skill management, I will comment primarily on skill management for workers in the manufacturing industry. Skill management generally refers to the process of visualizing the skills that workers possess and making them available as shared information within the company. Once skill management is established, it can be utilized in various ways, such as considering personnel allocation in each department, assigning tasks (referring to the distribution of work to individuals, where managers assign tasks or duties to their subordinates), and for the purpose of performance evaluations. On the other hand, when promoting skill improvement through skill management, it becomes possible to enhance visual management levels, correct skill variations, and promote multi-skilled workers. Furthermore, in manufacturing processes that are primarily centered around human labor, it can significantly influence the quality of manufactured products and the productivity of the production line. Here, I will specifically mention the key points for implementing skill management aimed at promoting various benefits from improving the proficiency of manufacturing process workers. Support and guidance regarding the approach to skill management, including its structure, item setting, evaluation criteria, and educational methods, will be the focus of production technology consulting.

  • Management consultant/Small business consultant

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Support for the establishment of the seven tools of QC.

Support for the establishment of the seven tools of QC.

We will support the establishment of your company's seven QC tools!

In the manufacturing industry, there are seven tools of QC (Quality Control) used for education and guidance. These tools are primarily utilized on the production floor to confirm quality and identify opportunities for quality improvement, and they are employed by analyzing numerical data such as statistical information. The seven tools are: 1. Pareto chart, 2. Histogram, 3. Control chart, 4. Scatter diagram, 5. Cause-and-effect diagram, 6. Check sheet, 7. Graph. We support the basic usage, application, and establishment of these tools.

  • Management consultant/Small business consultant

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Support for the creation of engineering design plans.

Support for the creation of engineering design plans.

We support the improvement of the level of process design planning in production technology!

It is important to systematize the approach to production technology-related work and to clarify the tasks that should be implemented. The process design plan document serves as a format for establishing an overall plan at the start of process design for new products, rationalization, etc. Whether it is a new business, a new product, or a response to rationalization, anything planned as a point of change in the flow (above a certain level) requires goal setting to execute that plan. The goals for process design work include clarifying the investment amount, allowable flow quantity (such as MT), processing costs (man-hours), layout (required area, logistics), and target quality (target defect rate), as well as determining when these will be executed. The purpose of establishing the "Process Design Plan Guidelines" is to formalize these goal-setting contents as operational rules. Support related to such goal setting will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for factory layout management

Support for factory layout management

We support the improvement of factory layout management levels in production technology!

There are various types of layouts, but here we will focus specifically on the overall factory layout (excluding individual line layouts, office layouts, etc.). One aspect being considered is the optimization of logistics, ensuring a smooth flow from the delivery of materials and components to the shipment of products and parts. Another aspect is the proper arrangement of each component, intermediate product, finished product, and stagnant inventory to maintain appropriate stock levels. Additionally, the area efficiency of each section is confirmed and optimized. Other considerations include environmental concerns and the securing of necessary space. It is important to establish a comprehensive layout management system that allows top management to continuously monitor and manage these aspects, and the examination of these factors and the establishment of maintenance management methods will be the focus of consulting.

  • Management consultant/Small business consultant

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