Consultation for Improving Inspection Operations for Color Variations and Quality Defects in the Toy Industry

Although the work standard documents are established, is there a difference in work quality and work time depending on the person in charge? In manufacturing sites, even if work standard documents and manuals are in place, actual work may depend on the experience and intuition of veteran employees. For example, are there any issues like the following? There are work standard documents, but they are not sufficiently utilized on-site. Even for the same task, the quality and work time vary depending on the person in charge. The judgment criteria and tips of veteran employees are not documented. Training new employees takes time, and the content of instruction varies by person in charge. Even if work procedures are changed, the updates to the standard documents lag behind. Variability in work leads to quality defects and rework. What is important in addressing these issues is not simply increasing the number of manuals, but understanding the differences between actual work and the standard documents, and creating a state where the judgment criteria and know-how of veteran employees can be shared within the organization. Gemco Co-operations supports the organization of challenges such as the visualization of technology and skills, standardization of operations, and human resource development in the manufacturing industry.

We are currently accepting free consultations to think together with experts about the inheritance of technology in the manufacturing industry, eliminating reliance on specific individuals, and developing young talent! "Only that person can do this task." Is there such a situation in your manufacturing site? As experienced employees retire and labor shortages increase, there is a risk that the skills, techniques, and judgment based on years of experience and intuition may be lost without being adequately passed on. For example, do you have any of these concerns? - We cannot respond to equipment troubles without veteran employees. - There are work manuals, but actual decisions are left to individuals. - We want to develop young employees, but we lack people and time to teach them. - There are variations in quality depending on the person in charge, even for the same task. - We feel the need for technology inheritance, but we don't know where to start. The problem is not just the lack of manuals. It is important to make the tacit knowledge that experienced workers have—such as "why we perform this task," "how to judge abnormalities," and "where to pay attention"—shareable within the organization. Gemco Co-operations supports initiatives such as visualizing skills and techniques, standardizing work processes, improving on-the-job training (OJT), and developing young talent, tailored to the challenges faced in the manufacturing industry.