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Support for the nature of the cause-and-effect diagram.

We will provide support for the characteristics and factors diagram!

When creating a cause-and-effect diagram, the following steps are taken: (1) Determine the issue (characteristic) and create the backbone. (In production technology, identify the details of defects, etc.) (2) Create the major bones. (It is easier to understand if you categorize the major bones according to the 5M1E.) (3) Create the middle bones (list the contents that could be factors of the major bones). (4) Create the minor bones (list the contents that could be factors of the middle bones). The characteristic of the cause-and-effect diagram is to organize the factors into major bones, middle bones, and minor bones, and visualize them to make it easier to grasp the overall picture. The cause-and-effect diagram is used for cause investigation, issue organization, information sharing, and more. The 5M1E of the major bone section refers to: 1. Machine (Technology) 2. Method (Process) 3. Material (Includes information on raw materials and consumables.) 4. Manpower (Physical labor) / Mind power (Brain function) 5. Measurement (Inspection) 6. Environment If this cause-and-effect diagram can be applied to various issues in production technology operations, it will contribute to improving operational efficiency.

  • Management consultant/Small business consultant

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Support for incident (concern) response in the manufacturing industry

We will support you in incident response methods and how to proceed with them.

The general content of incidents in the manufacturing industry is as follows: 1. Sales and profits 2. New product responses 3. Quality-related issues - Market complaints, delivery defects, internal defects (in-process, inspection) → Promotion of quality improvement meetings 4. Capital investment - Investment plans (new investments, rationalization investments, etc.) → Promotion at the equipment review committee → Implementation of investment plan progress management 5. Production responses - Personnel planning (production adjustments) - Productivity improvement (man-hour reduction) - Operating rate → Promotion of production adjustment meetings and productivity improvement meetings 6. Maintenance management - Equipment maintenance, mold maintenance → Major equipment stoppages, failures, etc., are addressed by the PM promotion committee, promoting improvements in equipment and mold maintenance 7. Safety environment, energy conservation, area - Safety environment status → Accidents, injuries, etc., are addressed by the safety environment and health committee - Energy conservation plans → Promotion by the energy conservation committee - Area plans → Promotion of area plan discussions Support will be provided for specific response methods and approaches for each of the incidents mentioned above.

  • Management consultant/Small business consultant

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Support for the approach to trial production considerations.

We will provide support on how to approach and proceed with trial production considerations.

The production technology prototype examination in the mass production support department is positioned as an important task within the front-loading activities of the production technology department, and the prototype examination demonstrates its effectiveness in the following ways: 1. Prototype information can be used as basic information for mass production equipment specifications and processing conditions. When establishing a new line to flow new products, it is necessary to create mass production equipment specifications and set processing conditions after equipment installation. However, if there is no existing line to reference, this setting can take time. In this case, prototype information becomes very valuable. 2. Failures and defects that occur during prototyping can also happen in mass production. Failures and defects that occur during prototyping can certainly occur in mass production as well. By effectively utilizing such prototype information, it becomes possible to take action before moving to mass production. Rather than thinking of it as a future issue, clarifying the causes and factors and incorporating them into equipment specifications can help minimize losses. 3. Participating in activities to address issues at the prototyping stage is also important. As a professional in mass production process design, participating in problem-solving activities during prototyping and proposing solutions to quality and cost issues at the prototyping stage, as well as conducting pre-improvement activities, is also effective.

  • Management consultant/Small business consultant

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Mass production feasibility support

We will assist in confirming the mass production capability of the technology and products.

Mass production refers to the ability to continuously produce items of a certain quality over a specified period. Generally, the term mass production is an abbreviation for large-scale production, which is defined in dictionaries as "producing a large quantity of the same standard products to reduce the cost of goods." However, in the context where the term mass production is used, it does not only refer to the quantity being large or small; it also implies that mass production equals market release, meaning it becomes a product used by consumers. In other words, mass production is based on the premise that "the finished product will be used by a third party," which distinguishes it from a "prototype." From this, when confirming the mass production capability of a certain technology or product, it is essential to determine whether it can maintain a certain quality as a product for consumers (ensuring process capability, etc.) and secure a certain supply volume (production capacity, etc.). Therefore, it is necessary to examine whether there are any issues regarding product design, process design (production processes, production equipment), and quality verification (acceptance, shipping, market, etc.) to confirm its mass production capability. The methods for confirming mass production capability and how to proceed with it will be the focus of our production technology consulting services.

  • Management consultant/Small business consultant

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Support for the next-generation rationalization project.

We will assist in promoting the next-generation rationalization project.

Next-Generation Rationalization Project ● Purpose It is common to introduce next-generation products to significantly improve Q (quality) and C (cost) in order to surpass competitors in relation to mass-produced products that are currently in circulation. To support this, the Production Technology, as manufacturing professionals, participates from the product development stage in a project known as the Next-Generation Rationalization Project. This project is positioned as a task to promote production preparation. ● Project Promotion Unit The basic unit is by product. ● Duration, Frequency, Location - Duration: Typically around 3-5 years; the duration may vary depending on the product development period and investment scale. - Frequency: Generally once a month. - Location: The meeting location changes according to the phase. ● Approach - Members, Promotion Leader: Production Technology (minutes taken by Production Technology) MUST participate: Design, Production Technology WANT to participate: Quality Assurance, Planning, Production Management, Inspection (parts inspection, product inspection), and others. - Meeting Method: Respond according to the phase; primarily in-person meetings (Web meetings as necessary). - Meeting Themes: Progress confirmation of each department, progress checks on homework for reporting various issues, etc. Support and guidance regarding the structure and approach of the "Next-Generation Rationalization Project" will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for the promotion of the QMS construction project

We will assist in promoting the QMS construction project.

【QMS Construction Project】 ●Purpose When the QMS (Quality Management System) is not well established, this project is often implemented with the aim of improving the QMS. To address this, there is a QMS Promotion Project (Manufacturing) driven by production technology, which is comprised of manufacturing professionals. ●Project Promotion Unit The basic unit is the factory. ●Duration, Frequency, Location - Duration: Typically around 3-5 years; the duration may vary depending on the level of QMS construction. - Frequency: Generally once a month. - Location: Factory side. ●Approach - Members, Promotion Leader: Production Technology (Minutes: Production Technology) MUST participate: Quality Assurance, Production Technology, Production WANT to participate: Design, Planning, Production Control, Inspection (Parts Inspection, Product Inspection), etc. - Meeting Method: Primarily in-person meetings (Web meetings held as necessary). - Meeting Themes: Progress confirmation of each department, progress confirmation of homework for reporting various issues, etc. (Issues: Inventory of operations, standardization considerations, consistency considerations, creation of standards, etc.) Support and guidance regarding the above "QMS Construction Project (Manufacturing)" approach and implementation are the subjects of consulting.

  • Management consultant/Small business consultant

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Support for the format of equipment specifications.

We will provide support for the specifications of the equipment document.

【Basic Items of Equipment Specification Document】 1. Equipment Quotation Request Document (Overview); - Target Equipment Name; A concise name that represents the equipment, including process name, machining name, purpose, etc. - Purpose of Use; Clearly state the target products/parts, target processes, machining content, purpose of equipment use, etc. - Request Details; Include the using department, equipment installation deadline, quantity requested, estimated cost, etc. - Operating Conditions; Fully automatic, semi-automatic, manual, number of operators, number of units held, - Equipment; Size, weight, method of delivery - Quotation Conditions; Descriptions aimed at estimating costs for ordering - Others; Design scope, relevant laws, etc. 2. Machining Capability Instruction Document; - Cycle time, production capacity (monthly), operating rate, setup time, compatible models, material supply, handling of defective products, etc., related to the equipment's machining capability. 3. Machining Conditions Document; - For each process, detail the machining procedures, machining standards, machining methods, machining conditions (pressure, time, temperature, etc.), specific machining parts, necessary dimensions, etc. (including illustrations). 4. Process Capability Instruction Document; - Instruction on evaluation items for the quality of the processed products (evaluation content, sampling number, measurement methods, evaluation standards (Cp, Cpk, defect rate), etc.). 5. Others; Related Information; - Attach notes regarding safety, workability, etc., product/part drawings, layout drawings, etc.

  • Management consultant/Small business consultant

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Support for AI visual inspection process

We will provide support for the approach to AI visual inspection processes!

The disadvantages and advantages of AI visual inspection are as follows: 【Disadvantages of AI Visual Inspection】 1. Cannot make qualitative judgments 2. Cannot detect conditions outside of what it has been trained on 【Advantages of AI Visual Inspection】 1. Can detect foreign objects that may be overlooked by the human eye 2. Does not complicate the setting of inspection rules Although AI has its weaknesses, its greatest advantage is the ability to "correctly judge quantified criteria at a consistent speed." To effectively utilize this advantage and automate visual inspections, it is essential to meticulously quantify the qualitative judgments that have traditionally been made visually and to carefully adjust the judgment criteria during the training phase for the AI. This allows for automation while ensuring the quality demanded by the company. In summary, the disadvantages and advantages of AI visual inspection indicate that fine quantification of judgment criteria and meticulous threshold adjustments are indispensable. By implementing these, it is possible to significantly improve inspection challenges through the construction of custom-made AI.

  • Management consultant/Small business consultant

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Support for creating equipment safety specifications.

We will assist you in creating safety specifications for the equipment.

In companies where a Quality Management System (QMS) is established, there are safety specifications for equipment, and I believe there are no particular issues. However, considering a situation where such systems are not in place, I will provide references on what should be considered for safety. There are fundamental principles for ensuring the safety of machinery to effectively prevent mechanical hazards. These are the three principles: 1. Principle of inherent safety: Eliminate hazardous areas (hazard sources) of the machinery or reduce them to a level that does not cause harm to people. For example, rounding off corners or reducing operational energy. 2. Preventing human access or contact with hazardous sources of machinery. For example, installing guards such as fences or enclosures. 3. Principle of stopping: Generally, if the machinery is stopped, it poses no danger. Therefore, if a person needs to enter the operational range of the machinery, it should be stopped using interlocks or permission should be granted only after stopping. In creating safety specifications for equipment, it is necessary to adhere to the above three fundamental principles and to consider the specific content of the equipment in question, developing and documenting the specifications in a more concrete manner.

  • Management consultant/Small business consultant

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Support for creating equipment maintenance specifications.

We will assist you in creating equipment maintenance specifications!

Equipment maintenance involves the regular inspection and repair of various factory equipment that is operational in the factory. It is ideal for the equipment specifications to include the following three types of maintenance: 1. Preventive Maintenance: This requires establishing a maintenance plan to ensure that factory equipment and machinery do not break down, involving inspections, repairs, and parts replacements. The goal is to prevent equipment failures in advance through regular inspections and ensure stable operation. → One aspect is to clearly define the items that should undergo daily inspections. Additionally, it is important to list the parts that should be replaced regularly. 2. Corrective Maintenance: This refers to maintenance performed in response to issues such as functional decline, malfunctions, or breakdowns that occur in factory equipment. → This includes the development of manuals for troubleshooting, ease of conducting emergency maintenance work, and securing maintenance and workspaces. 3. Predictive Maintenance: In contrast to preventive maintenance, which involves regular inspections, predictive maintenance monitors the condition of factory equipment and machinery. It is conducted when signs of functional decline, breakdowns, or malfunctions are detected. → This involves clarifying methods for sensing precursors to equipment failures based on past failure histories and accumulated data from the specification creation company and equipment manufacturers, enabling predictive maintenance for the targeted equipment.

  • Management consultant/Small business consultant

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Support for the mass production line preparation project.

We will assist in promoting the mass production line preparation project.

【Mass Production Line Production Preparation Project】 ●Purpose As an investment in mass production lines, there are various aspects such as responding to newly developed products, next-generation products, similar new products, increased production, and rationalization. However, depending on the importance of quality and the size of the investment, project activities are necessary for its business viability. This is positioned as the task of promoting production preparation for that project. ●Project Promotion Unit Fundamentally implemented on a product basis. ●Duration, Frequency, Location - Duration: For newly developed products, approximately 3-5 years before mass production and about 1 year after; the duration may vary depending on the importance of quality and the size of the investment. - Frequency: Generally once a month (may also be every 2-3 months depending on the situation). - Location: The main location will be aligned with the production preparation phase. ●Approach - Members, Promotion Leader: Production Technology (Minutes: Production Technology) MUST participate: Production Technology, Design, Quality Assurance, Production Management, Production WANT to participate: Maintenance, Inspection (Parts Inspection, Product Inspection), Planning, etc. - Meeting Method: Primarily in-person meetings - Meeting Themes: Progress confirmation of issues related to mass production preparation by each department, etc. The above-mentioned support and guidance regarding the structure and approach of the "Mass Production Line Production Preparation Project" will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for area creation projects

We will assist in promoting the area creation project.

【Factory Space Creation Project】 ●Purpose In the manufacturing industry, factory space is an important asset. In addition to space, the efficiency of logistics is also crucial. The "Factory Space Creation Project" aims to smoothly respond to the constantly changing production numbers, line configurations, and the need for future space allocation in an optimal manner. Production technology is positioned as a central element of this project, taking on the role of the driving leader. ●Project Promotion Unit Company-wide (as it involves optimization of logistics and management of space, it is a company-wide initiative) ●Duration and Frequency - Duration: Ongoing - Frequency: Generally once a month (set according to the size of fluctuations as a company) ●Approach - Members, Driving Leader: Production Technology (Minutes: Production Technology) MUST participate: Production Technology, Planning, Production, Production Management, relevant departments (specifically those involved in relocations, etc.) WANT to participate: Maintenance, Quality Assurance, Inspection (parts inspection, product inspection), and others - Meeting Method: Real meetings at each location (or online as necessary) - Meeting Themes: Progress confirmation of issues related to relocations and other departments, etc. Support and guidance regarding the structure and approach of this "Space Creation Project" will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for procurement projects

We will assist in promoting the procurement project.

【Procurement Project】 ●Purpose As a production technology initiative, this is somewhat of a special undertaking, but it is generally understood that 20-40% of product costs come from purchased goods from suppliers. The "Procurement Project" was initiated to address the need to tackle these costs. The production technology team, as experts in manufacturing, will primarily focus on developing suppliers through factory inspections, especially for companies that have no prior purchasing experience. ●Project Promotion Unit The basic unit is by factory, but it may be implemented by product group or line group as needed. ●Duration, Frequency, Location - Duration: Typically around 3-5 years; the duration may vary depending on the situation. - Frequency: Generally once a month. - Location: At the relevant factory (also applicable at candidate supplier companies). ●Approach - Members, Promotion Leader: Production Technology (Minutes: Production Technology) MUST participate: Production Technology, Procurement (Purchasing), Production Management, Planning, Quality Assurance WANT to participate: Design, Inspection (Parts Inspection, Product Inspection), Production, etc. - Meeting Method: Real meetings at the relevant factory or at the investigation sites of new candidate suppliers (for on-site verification). - Meeting Themes: Progress confirmation of each department involved in procurement project activities, progress confirmation of homework to report various settlement issues (such as account opening), etc.

  • Management consultant/Small business consultant

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Support for the line transfer project.

I will assist with the promotion of the line transfer project.

【Line Transfer Project】 ●Purpose There is always a reorganization aimed at expanding the company's scale, and as part of this, there is the transfer of manufacturing lines. The activities promoting this transfer are carried out with the aim of leveling up both Q (Quality) and C (Cost) as an opportunity presented by the transfer itself. ●Project Promotion Unit The basic unit is by line, but it may be implemented by product groups or line groups as necessary. ●Duration and Frequency - Duration: Approximately two years before the line transfer to about one year after the line transfer. This assumes there is no new investment; if there is new investment, the duration will be extended accordingly. - Frequency: Basic is once a month. ●Approach - Members, Promotion Leader: Production Technology (Minutes: Production Technology) MUST participate: Production Technology, Production, Quality Assurance, Production Management, Maintenance, Inspection (Parts Inspection, Product Inspection) WANT to participate: Design, Planning, Others - Meeting Method: Real meetings at each location - Meeting Themes: Progress confirmation of each department related to the transfer (using the transfer checklist), progress confirmation of homework to solve issues for leveling up Q (Quality) and C (Cost) as an opportunity presented by the transfer, etc. Support and guidance regarding the nature and approach of the "Line Transfer Project" are the subjects of consulting.

  • Management consultant/Small business consultant

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Support for the store closure activity project

We will assist in promoting the store closing activities project.

【Store Closure Activity Project】 ●Purpose Products have a lifespan, and of course, the production lines that handle them will eventually become low-load lines and ultimately face the fate of being discarded. On the other hand, for factories, these low-load lines become a burden due to the need to free up space for new lines. In response to this, there is the "Store Closure Activity Project." Production technology can play a central role in this project, positioning it as the driving leader of the initiative. ●Project Promotion Unit The basic unit is the factory, but it may be implemented at the product group or line group level as needed. ●Duration, Frequency, Location - Duration: Typically around 2 years; the duration may vary depending on the flow years of the target line and the response years for bulk production, etc. - Frequency: Basic is once a month. - Location: The relevant factory. ●Approach - Members, Promotion Leader: Production Technology (Minutes: Production Technology) MUST participate: Production Technology, Production Management, Production, Quality Assurance WANT to participate: Maintenance, Inspection (Parts Inspection, Product Inspection), Planning, etc. - Meeting Method: Real meetings at the factory. - Meeting Themes: Progress confirmation of each department related to store closure activities, bulk production, equipment disposal, and various decision-making issues to be submitted as homework for progress confirmation, etc.

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