Streamlining the inspection process | Key points for solving labor shortages through capital investment
Manufacturing Industry Labor-Saving Series | Inspection Process
Are you facing challenges like having people taken for inspections and not being able to allocate them to the production process?
Are you facing such challenges as being unable to allocate sufficient personnel to the production process because people are tied up in the inspection process? In fact, the issue is not just that 'there are not enough inspectors.' What needs to be reconsidered is the system that binds people to the inspection process itself. When personnel are taken away for inspection, it leads to stopping processing equipment, disrupting the flow to the next process, and even if production is increased, inspections cannot keep up. In other words, problems in the inspection process may be limiting the overall productivity of the factory. So, where is there room for labor-saving improvements? We have compiled a document outlining the labor-saving points hidden in the inspection process and how to identify them.
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【Tasks involving human intervention in the inspection process】 * Transporting the workpiece to the inspection location * Leaving the processing machine for inspection * Setting the workpiece on the measuring device * Visually checking the appearance * Measuring dimensions * Making judgments on quality by a person * Handwriting and transcribing measurement results * Sorting good and defective products * Re-inspecting in case of defects
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If this is the case, the inspection process may be the bottleneck. * While processing equipment can be operated, inspection cannot keep up. * Processing personnel are leaving their posts for inspection. * If production is increased, there will be a shortage of manpower in the inspection process first. * Work-in-progress waiting for inspection is piling up. * The absence of veterans reduces inspection capacity. * Even if the number of inspectors is increased, the busyness does not resolve. * I want to streamline, but I don't know where to start. If any of these points apply, there is room to break down the inspection process before 'increasing personnel'.
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In manufacturing equipment investment, decisions may be made based solely on manufacturers' estimates and the possibility of subsidies. However, when introducing high-cost equipment, it is necessary to confirm the "total investment amount," which includes not only the main price but also transportation, installation, construction, tools, jigs, and maintenance costs. Additionally, one must consider the funds until the subsidy is received, cash reserves after the investment, monthly repayment amounts, investment recovery periods, order forecasts, production plans, and gross profit estimates, as neglecting these can strain cash flow after implementation. Our company organizes the figures that should be confirmed before equipment investment based on experience in manufacturing and financial analysis. Before ordering high-cost equipment such as machining centers, CNC lathes, 5-axis machining machines, and 3D measuring instruments, we provide materials for the manufacturing industry that highlight often-overlooked aspects such as cash flow, repayment sources, and investment recovery. Equipment investment is not merely a machine purchase; it is a management decision that changes the way a company competes. We will provide insights to confirm subsidies, loans, self-funding, repayment plans, and order forecasts before placing an equipment order. Supervised by Toshirou Ooyama, a former successor of a machining company and tax accountant.
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