DX in a factory (Smart Factory) means a system to improve Q (Quality improvement), C (Cost reduction), and D (Delivery capability) by IT.
For each manufacturing industry, it is very important if you can realize a smart factory or not because it greatly affects productivity and profitability.
Solve these issues
with IoT
ISSUE
3 points
for IoT
FEATURES
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1
Building a foundation for system introduction
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Introduce the system after preparing an environment where the flows of materials and information are normal.
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2
System introduction and analysis
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Introduce the system that suits your company, and analyze the databased (visualized) information.
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3
Improvement activity
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Implement the improvement activity to improve Q (Quality improvement), C (Cost reduction), and D (Delivery capability).
Building a foundation for system introduction
If you introduce IoT to the shop floor where many issues remain, the issues will not be solved. In order to use IT to solve the issues in the shop floor, it is important to first prepare an environment where the flows of materials and information are normal.
System introduction and analysis
In the environment where the flows of materials and information are normal, it becomes clear what kind of system should be introduced for the first time. If it becomes clear, cost for system introduction can be reduced. You can introduce the system that suits your company, analyze the databased (visualized) information, and decide the target values for improvement activities.
Improvement activity
We decide management indicators, standards, and targets for improvement activities and consider how to collect those indicators by IoT.
There are some methods such as taking signals from equipment and collecting from S/W or various sensors installed.
Then, we visualize the data, identify the gap between the standards and targets as problems, and run a cycle of daily improvement. The cycle of improvement is finding problems + investigating causes + solving problems. By repeating this process, we can improve Q (Quality improvement), C (Cost reduction), and D (Delivery capability).
Consultants from major companies
with experience in over 40 countries will respond.
Please feel free to contact us.
If you are in a hurry, please call us.
（Japan time）
Except for Saturday, Sunday, holidays, Year-End and New-Year holidays
Iot specialist
ITO, Akihiro
Process improvement consultant
Akihiro Ito is active on the front line as a shop floor improvement consultant. He has improved a wide variety of large and medium-sized shop floors of over 300 companies in more than 12 countries in Japan and overseas, and has solved the problems of each shop floor every time. Based on his experience working on the production control system, he implements improvement activities in all processes of a factory such as sales, materials, production control, manufacturing, and outsourcing. In addition, he implements the improvement activities together with the people at the shop floor, make the culture of shop floor improvement rooted in the company, and realize quality improvement, productivity improvement and lead time reduction.
Case example of Genba Kaizen Consulting RESULTS
Acquired orders from two new customers
by improving quality.
We reduced most work-in-progress inventories and defective inventories, which were found throughout the factory, and reduced manpower, and now we almost no longer receive customer complaints that we had every month before. (Automobile industry / Plant manager)
Turn the factory into a showroom
in order to improve profitability
We improved 250 cases out of 300 cases pointed out by the 5S patrol conducted for one year. The factory was realized to be the showroom and also achieved cost reduction of 30 million yen per year. (Metal processing / Director)
Productivity Up to 169.6%
by 6 months of improvement activities
the Japanese president decided to outsource a shop floor improvement consulting to have their shop floor checked, and asked us, Hirayama Consulting.（Auto parts manufacturer/Managing director）
3 reasons why we are chosen REASON
REASON 1
Improvement experience of
more than 1,500 companies in 40 countries
There must be the shop floor issues that cannot be solved by your own company alone. Improvements and reforms for manufacturing industry to survive, regardless of country or industry, need development of your human resources through practical experiences of improvement, and strengthening of your production system base.
REASON 2
Consulting that shop floor workers
acknowledge our superiority and be pleased
In conventional consulting styles, there was a distance between consultant and the shop floor because it was promoted mainly consultant and management executives. Our consultant can provide a guidance without a distance between consultant and the shop floor through the guidance based on the "seeds of improvement" in a concrete way, instead of "finding fault" like a critic.
REASON 3
Continuous improvement will continue
even after the end of guidance
While strengthening "human resource development", we focus on the "overall flow" from design to purchasing, manufacturing, logistics, and production control, and provide guidance that matches the actual situation of your company. Continuous improvement will continue even after the end of guidance through the guidance that is acceptable to the shop floor workers.
