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Support for promoting PFMEA to address human error prevention.

Support for promoting PFMEA to address human error prevention.

All measures against human errors in the manufacturing industry hinge on the execution of PFMEA. We will support your company's PFMEA promotion!

In the manufacturing industry, there are various countermeasures for quality issues such as internal defects, supplier defects, and external complaints. (See below) 1. Concurrent engineering involving related departments, including design quality (front-loading activities). 2. As it is said that quality is built into the process, ensuring process quality through improved precision in condition management and outcome management. 3. Regarding human error countermeasures, which are said to inevitably occur probabilistically, measures should be taken such as thorough PFMEA implementation, setting FP, and promoting manualization. Among these, PFMEA is a must-have requirement for the manufacturing industry, so I would like to support this content. PFMEA: Process Failure Mode and Effects Analysis.

  • Management consultant/Small business consultant

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Support for the examination of various construction methods.

Support for the examination of various construction methods.

We will provide support for your company's construction method review!!

As a manufacturing industry, we regularly consider optimal methods for the purpose of product development discussions, new product responses, new construction methods, and improvements to current processes. The subjects of method consideration include various aspects such as parts processing, assembly methods, and inspection methods. We provide support regarding the thinking, approach, and summarization needed to identify the optimal methods.

  • Management consultant/Small business consultant

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Support for store closure activities (measures for suspension lines, equipment, etc.)

Support for store closure activities (measures for suspension lines, equipment, etc.)

We will support your company's store closure activities (measures for suspension lines, equipment, etc.)!!

In the manufacturing industry, we provide support for the management and direction of idle equipment, idle lines, and idle molds that exist in any sector. Just as humans have a lifespan, so do lines (equipment). From the birth of a line, through initial flow activities, peak periods, stable periods, responses to production reductions, and minimal production responses, to the end of its life, which means smoothly entering the end-of-life phase of that line, is what we refer to as the "closing activities" of lines and equipment. Factories often perceive lines in the minimal production phase as lacking vitality and having a dark image (both spatially and in terms of area, they are seen as burdensome for the factory). Overcoming this image and positively moving forward to the next step is the main objective of closing activities. On the other hand, it can also be seen as an effort to efficiently retain assets (equipment, molds, jigs, etc.) and space (area) for the company to engage in new activities.

  • Management consultant/Small business consultant

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Support for reducing man-hours activities

Support for reducing man-hours activities

We will support your company's efforts to reduce man-hours!!

In improvement activities on the production line, there are often demands for reducing production costs, and I believe that activities to promote improvement goals as part of the annual policy are conducted regularly. One of the targets for improvement is the reduction of labor hours within production costs, which is directly linked to tangible effects. Smaller initiatives may include reducing work items, simplifying work procedures, and improving jigs, while larger initiatives could involve reducing personnel through the introduction of rationalization equipment that automates the work itself. However, to connect these efforts to substantial effects, it is necessary to consider possibilities, make prior adjustments, conduct internal discussions, and prepare accordingly. Support and guidance related to the advancement and execution of these labor hour reduction activities will be the focus of consulting.

  • Management consultant/Small business consultant

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Support for new product response activities

Support for new product response activities

We will assist with your company's new product support activities!!

Among the new products, there are important and challenging new products that will become new businesses for the company, as well as similar new products that are extensions of existing ones. In either case, the role of production technology, which should collaborate with product design and development design, is crucial. Production technology is considered to be in a central position to control cost, quality, and delivery as the executing force for mass production flow of products. Once the procedures for handling the most important new products are mastered, for similar new products, it generally involves implementing part of those procedures. In responding to important new products, it begins with thorough participation in upstream activities through front-loading, and from an early stage, it is necessary to consider processing methods that affect cost and quality, investment equipment, and installation locations (layout, environment), while undergoing discussions related to investment and quality. The way to proceed with this work (implementation procedures, summarization, schedule management), how to solve issues, how to control related departments and stakeholders, and how to present will significantly influence the efficiency of the response. Support and guidance regarding this approach to handling new products (including new and similar ones) will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for promoting FMEA of equipment

Support for promoting FMEA of equipment

We will support the FMEA promotion activities of equipment manufacturers!

In the case of equipment FMEA, there are two meanings of FMEA. One is the FMEA for designing equipment (referred to as Design FMEA (DFMEA) in product design), and the other is the FMEA for equipment manufacturing (referred to as Process FMEA (PFMEA) in product manufacturing). The focus this time is on the latter, the FMEA in equipment manufacturing. The FMEA for equipment (FMEA for equipment manufacturing) requires a similar approach to the PFMEA for regular production products, as mentioned above. However, the criteria for evaluating impact, occurrence, and detection need to be set according to the actual conditions of each company. Additionally, to ensure that no failure modes are overlooked and to establish the settings, it should be conducted as a team effort. (In this case, the team refers to a cross-functional team, including the equipment design department, equipment manufacturing department, equipment inspection department, sales, etc.) Based on the above, supporting the FMEA for equipment and promoting its establishment will be the focus of consulting.

  • Management consultant/Small business consultant

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Support for creating QC engineering documents

Support for creating QC engineering documents

We will support the creation of your company's product QC process chart!

A QC process chart is essentially a table that describes the management methods (condition management items, quality management items) for all manufacturing processes where products are processed (machined, inspected, etc.) in an orderly manner. The QC process chart (process management chart, process management details, etc.) that should be created by the production technology department should contain all the basic information that needs to be managed in the production process. It should not just be a list of management items, but should also include information regarding the tools (equipment, jigs, tools) used in processing, product, part, and auxiliary material information, points of caution during work, checks, inspection contents, and even details down to the fine points. This serves as the foundation for the work standard documents (work procedures) created and managed by on-site workers, and it is important to incorporate all the process design information intended by the production technology (process designer). (Depending on the company, there may be cases where the process management chart (process management details) and work standard documents (work procedures) are combined due to organizational and role divisions, but in any case, it is necessary to have a centralized collection of information in terms of content.) Guidance and support for the ideal form of such QC process charts will be the subject of consulting.

  • Management consultant/Small business consultant

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Thorough support for limited sample management

Thorough support for limited sample management

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

I will comment on the nature of criteria samples (limit samples). Although we refer to them as limit samples, since they are subject to visual judgment, they do not represent strict limits. Generally, the contents that are referred to as good product samples and defective product samples also fall under the category of limit samples. Given the recent improvements in the precision of visual devices and the enhanced analysis and judgment capabilities of AI, it seems that reforms regarding the setting of limit samples are being undertaken. However, even when advancing these reforms, I believe that the experiential knowledge related to traditional limit sample settings will be very useful for the technical basis of the data and information used to establish AI judgment criteria. Support and guidance regarding the nature of limit samples (including good product samples and defective product samples), the approach to their setting, and the considerations for establishing new judgment criteria through AI will be the focus of production technology consulting.

  • Management consultant/Small business consultant

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FP (foolproof; Poka-yoke) installation support

FP (foolproof; Poka-yoke) installation support

We will support the installation of FP (foolproof; poka-yoke) that can serve as an effective measure!

The FP (Poka-Yoke) that has been considered through activities such as PFMEA is particularly effective as a means of addressing human error. It is important to create a system that addresses issues such as wrong parts, missing parts, reverse assembly, and skipping processes without incurring costs. An excellent FP is one that does not affect the work hours, meaning it does not hinder the work process, and it is also important to establish a system for maintaining and managing it so that it does not become obsolete. As a practical implementation of the action items from PFMEA, it is the consulting objective to ensure that effective FP (Poka-Yoke) can be rooted in the field for use.

  • Management consultant/Small business consultant

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Traceability support assistance

Traceability support assistance

We support traceability measures that can become effective means!

Traceability refers to a term currently used in various industries, indicating the ability to track the processing details and distribution routes of a product from its raw materials and components to its current state, or the system for tracking such information. The quality of traceability can sometimes determine the survival of a company (for example, significantly impacting the financial losses related to market complaints). In the manufacturing sector, traceability involves many departments, but the part that concerns production technology and factory managers, which is the focus of our consulting services, is to ensure that the processing details of products and parts can be traced in detail. To build excellent traceability, it is crucial to create a system that allows for quick and accurate tracing, narrowing down to the minimum necessary scope when the need arises. The introduction of traceability measures (including IoT) can dramatically improve the accuracy, reliability, and response speed of quality control for processed products, and it also holds potential for reducing quality costs. Guidance and support related to the adaptation of traceability measures in quality management will be the focus of our consulting services.

  • Management consultant/Small business consultant

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Support for improving the ability to utilize business plans.

Support for improving the ability to utilize business plans.

We will support the improvement of business planning utilization and operational capabilities for biotechnology industry professionals!

Not limited to the biotechnology industry, creating an appropriate business plan and executing operations can serve as a means to promote various business initiatives and achieve goals. Business plans can vary from annual plans to monthly, weekly, and daily plans; here, I will discuss monthly plans, which encompass weekly and daily plans, rather than long-term plans like annual plans. (Of course, monthly plans are closely related to annual plans in the sense that they are based on them.) The purpose of creating and operating a business plan is to maximize the efficiency of each responsible party's work and to use it as a tool for reporting, communication, and consultation, which also enhances the overall operational efficiency of the department. It is important to create frequent plans and record the status of implementation, as these records will serve as materials for considering the next actions. While it can be challenging until one gets used to it, once accustomed, it allows for an accurate assessment of business conditions that tend to fall into qualitative judgments. (Recently, these tasks have significantly advanced as they can be implemented using databases and other tools.) Guidance and support regarding the creation and operation of business plans related to production technology will be the subject of consulting.

  • Management consultant/Small business consultant

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Why-Why Analysis Support

Why-Why Analysis Support

We will provide support for your company's why-why analysis.

I often see companies implementing the "5 Whys" analysis as a method for addressing quality defects. Here, I will explain this "5 Whys" analysis. The "5 Whys" analysis is a method that stops hasty solutions and leads to more reliable solutions. The number five is not fixed and can vary depending on the situation, but by repeating the process about five times, the underlying causes that were not initially visible usually become apparent. Additionally, as we go about our daily work, problems tend to multiply endlessly, so if we increase the number of times we think through each issue, it will consume too much time. Therefore, a minimum and moderate number of thought repetitions is set at five. This makes around five repetitions optimal as a framework for thinking that can be easily used daily. Guidance and support regarding points of caution in implementing such "5 Whys" analysis will be the subject of consulting.

  • Management consultant/Small business consultant

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Support for predictive maintenance in the mainstream promotion of IoT in the manufacturing industry.

Support for predictive maintenance in the mainstream promotion of IoT in the manufacturing industry.

We will support the approach to predictive maintenance using IoT.

The utilization of IoT for maintenance can be summarized as follows: 1. Equipment Operation Management The goal is to record and collect actual data as a history of the operating status of equipment and lines, linking it to the necessity for general periodic maintenance and the replenishment of consumables. 2. Equipment Maintenance Support To carry out maintenance activities, it is essential to record information about the environment and the processes or operations that have taken place. IoT is utilized for data collection during the preparatory phase of such maintenance activities and for monitoring critical parameters, which are then reflected in the management of regular maintenance (daily maintenance conducted by production departments and periodic maintenance conducted by equipment maintenance departments). 3. Equipment Failure Monitoring (Detection) It detects any troubles such as delays in production processing, equipment stoppages, power outages, or delays in materials and consumables, and communicates this to the monitoring center to initiate repair instructions. At that time, a preliminary diagnosis is summarized and communicated before maintenance personnel arrive, thereby reducing the time required for the diagnostic process. 4. Equipment Failure Prediction It detects precursor data from past troubles (such as vibrations, unusual noises, temperature anomalies, etc.) and evaluates the likelihood of future troubles occurring (automatically assessed by IoT), sending alert information to the monitoring center.

  • Management consultant/Small business consultant

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Support for extracting failure modes in PFMEA.

Support for extracting failure modes in PFMEA.

I will assist you with the extraction of failure modes for PFMEA.

Regarding the extraction of failure modes in PFMEA, taking examples from the assembly process, common failure modes include incorrect parts or materials assembly, missing parts, reverse assembly, misalignment, double assembly, foreign object contamination, excessive or insufficient processing, skipping processes, forgetting tasks, packaging errors, and so on. Since the focus of PFMEA analysis is heavily weighted towards addressing human errors, it is important to identify potential failure modes from the elemental tasks of each process as accurately and in as much detail as possible. Based on this information, we will support you in the extraction of failure modes for PFMEA.

  • Management consultant/Small business consultant

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Support for the nature of meetings in the manufacturing industry.

Support for the nature of meetings in the manufacturing industry.

We will support you regarding the nature of meetings in the manufacturing industry.

In the context of meetings in the manufacturing industry, it is essential to constantly seek solutions to challenges, prepare in advance for meetings (setting meeting materials, requesting report preparations), and conduct efficient meeting progress (setting members, informing meeting objectives, time management, setting locations, etc.). Additionally, creating meeting minutes (sharing within the meeting, reaching consensus on direction, agreeing on assignments (action items) and deadlines, etc.) and issuing them on the same day are crucial practices that significantly influence the speed of problem-solving. In production technology operations, there are often opportunities that require coordination and agreement with related departments (and sometimes external manufacturers), making this ability extremely important. Based on the above, I will support you regarding the conduct of meetings in the manufacturing industry.

  • Management consultant/Small business consultant

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