What is small-batch production of multiple varieties? A complete explanation of the background, benefits, and challenges.
Six Initiatives to Increase Factory Productivity: Towards a Factory that Continues to Grow with the Times
This is a guidebook for the manufacturing industry focused on custom order production, detailing factors that reduce productivity and measures to address them! [Total of 27 pages]
In make-to-order production, while it is possible to flexibly change production items in response to consumer needs, it is necessary to be cautious of increased costs and decreased production efficiency. However, at the same time, make-to-order production often involves many changes in specifications and is frequently pressured by short delivery times, leading not to improved productivity but rather to exhaustion on the production floor in many cases. What exactly is lowering productivity, and how can we expect to improve it...? This book addresses the challenges in make-to-order production and introduces effective countermeasures.
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Chapter 1 Factors Contributing to Decreased Productivity in Custom Order Production Factories Chapter 2 Six Initiatives to Increase Factory Productivity Chapter 3 Methods for Systematizing Information Management and Sharing to Improve Efficiency
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【Purpose and Benefits of Implementation】 Improvement of Productivity and Resolution of Bottlenecks: Visualizing the progress and operational status of processes to reduce waiting times and setup losses. Elimination of Dependency on Individuals and Technology Succession: Standardizing and digitizing the know-how of veterans to establish a system where even less experienced workers can perform uniform tasks. Realization of Preventive Maintenance: Operating maintenance plans based on operational data to prevent line stoppages due to unexpected equipment troubles. Improvement of 5S and Workflow on the Shop Floor: Digitizing the movement of people and objects to create a factory layout that eliminates waste in searching and unnecessary movement. 【Examples of Improvements and Achievements】 Case 1 (Automotive Parts): Digital standardization of assembly process work procedures. Smooth technology succession to younger employees, reducing setup time by 35%. Case 2 (Precision Machining): Thorough implementation of preventive maintenance through visualization of equipment operation. Achieved an 80% reduction in unexpected equipment stoppages, leading to stable production. Case 3 (Metal Processing): Transitioned from paper-based daily report management to a production management system. Real-time "visualization" on the shop floor reduced indirect work hours by 40 hours per month.
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Continuing to stay close to our customers, we have built up business knowledge and empathy to understand their challenges. By handling a wide range of operations in a one-stop manner, including system design, development, operation, hardware and software proposals and sales, and network construction, we remain a partner that supports the creation of "valuable systems," sometimes in a collaborative manner and sometimes in a leading role. Our company changed its name on April 1, 2025. (Former company name: Daiko Electronic Communication Co., Ltd.) The data and presentation materials published are from the time of the announcement.
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