What are productivity indicators? An explanation of types, calculation methods, and how to create effective production plans.
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 decrease productivity and strategies to address them! 【27 pages in total】
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 prone to tight deadlines, 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 Frequent issues with "specification changes" "Organizational structure" where the latest information is not shared "Shortage of skilled personnel" with technical knowledge and know-how Slow progress in "standardization" Frequent "setup changes" leading to long production stoppages Chapter 2 Six Initiatives to Increase Factory Productivity Record and utilize information related to manufacturing Flexibly respond to specification changes Visualize schedules to prevent delivery delays Pass on veteran skills to the next generation Reduce setup change times Shift to a "bill of materials-centered" manufacturing system Chapter 3 Methods to Systematize and Streamline Information Management and Sharing Functions and roles of production management systems Benefits of implementing production management systems How to implement production management systems without failure
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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: Implementing maintenance plans based on operational data to prevent line stoppages due to unexpected equipment troubles. Improvement of 5S and Flow in the Workplace: Digitizing the movement of people and objects to create a factory layout that eliminates waste in searching and moving. 【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. Reducing unexpected equipment stoppages by 80% and achieving stable production. Case 3 (Metal Processing): Transitioning from paper daily report management to a production management system. Real-time "visualization" in the workplace 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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