Future factory concept that goes beyond mere relocation | Redesign of Thermix's production line
Simply arranging the equipment neatly does not provide a reason to invest.
This is a production line redesign service that organizes the conditions for transferring production functions to a new factory, including building constraints, production capacity, and the continued operation during phased relocation, while conceptualizing everything from factory layout, automation and versatility, production equipment investment, return on investment, to the implementation roadmap. The layout is the most significant variable, determining not just equipment placement but also logistics flow, transportation methods, buffers, and future expansion possibilities. Multiple proposals with different concepts are created, and their advantages and disadvantages are visualized. The challenging part is understanding the current situation. We verify production volume, equipment capacity, processes, work methods, transportation routes, losses, and equipment layout through on-site surveys and interviews. The foundation is the perspective of production technology that has handled everything from the concept of automated lines to construction. "I want to determine if just moving is sufficient" → Consideration from understanding the current situation to future concepts as a whole. "I want to objectively compare layout proposals" → Score multiple proposals using a common evaluation axis. "Where would automation be most effective?" → Judged from production volume, product mix, process capacity, and operating rates. "I have no materials to explain the investment to management" → Organize investment amounts and return on investment at the conceptual stage. "The definition of a good factory differs by department" → Establish a common yardstick among stakeholders. Please consult us on what should be analyzed.
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【Scope of Consideration】 - Factory layout concept: Creation and comparison of multiple proposals with different concepts - Automation concept: Process selection based on production volume, product variety, process capacity, equipment utilization rate, and personnel allocation - Equipment generalization: Response to future changes in product composition - Buffer design: Absorption of capacity differences between processes and suppression of stoppage propagation - Review of logistics and transportation routes and organization of necessary personnel considerations - Estimation of production equipment investment and investment effectiveness - Implementation roadmap: Balancing phased relocation and continuous operation 【Evaluation Criteria】 Cost reduction effects, necessary investment amount, ease of automation, ease of equipment generalization, logistics and transportation efficiency, workability, maintainability, and adaptability to future production increases and product changes. 【Features】 - We start by defining what should be clarified, rather than analyzing data provided to us. - A larger buffer is not necessarily better. Decisions are made considering both the increase in work-in-progress and space, as well as the propagation of stoppages. - There are reasons for long-standing practices. We engage in dialogue with the site, unravel the reasons, and then implement changes. - We confirm the feasibility of the entire production line, including upstream and downstream processes, transportation, and logistics, rather than focusing solely on individual equipment. - We align different definitions of a "good factory" from the production department, maintenance department, and management using the same yardstick.
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- Response Phase: Understanding the current situation, organizing conditions for establishment, layout concept, automation concept, investment estimation, roadmap formulation - Technical Areas: Mechanics, electronics, robotics, automation, transportation, equipment design, construction - Scope of Services: From individual production lines to entire factories, providing a consistent approach from concept, design, manufacturing, to construction - Target Departments: Production department, maintenance department, management level - Implementation Uses: New factory transfer, factory renewal, response to increased production - Approach: Hypothesis formulation, on-site investigation, interviews, iterative verification - Deliverables: Comparison of multiple layout proposals, investment amounts and return on investment, implementation roadmap - Case Study: Domestic manufacturing industry. Triggered by the transfer of production functions to a new factory, considerations included reviewing logistics flow while maintaining production capacity, automation and equipment generalization, and cost reduction. Room for future increases in production and changes in product composition was also preserved. The scope of consideration has expanded from transfer planning to future production systems. - Consultation Examples: "I want to relocate gradually without stopping current production." "I want to connect the renewal of aging equipment to a comprehensive review of the entire factory."
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We, Thermix, a top-tier production line builder with proven expertise, handles automation and line construction for production equipment across diverse fields including automobiles and automotive parts, aircraft bodies, and industrial machinery. We provide full turnkey solutions from concept and specification review through design, manufacturing, installation, commissioning, and maintenance, ensuring reliable mass production launch. Leveraging our production technology expertise, we organize and visualize the current state, including process feasibility, integration with existing equipment, and safety. Utilizing industrial robots, image processing, conveyance/inter-process transfer, and material handling, we propose realistic automation roadmaps without unnecessary strain. We address challenges like “We want to reduce staffing on lines that can't be stopped” or “Equipment investment decisions are difficult,” accompanying you from small-scale PoCs to full-scale deployment with our project management expertise. Leveraging our domestic and international launch experience, we collaborate to create the optimal production line.