Solution Accompanying Solutions To Establish Continuous Improvement DENSO Factory IoT

Need to Improve Productivity, But No Idea Where to Start

Due to labor shortages and rising labor costs, improving productivity, including labor saving, has become an urgent issue. However, in many cases, productivity doesn’t improve as expected if improvements and the introduction of robots are made without a clear understanding of what is wasteful and where to start. It is important to use data to accurately identify the types of issues and the degree of loss, and to allocate management resources efficiently according to the degree of importance.

Can See the Issue, But No Idea Where to Start

Have you ever had the experience of promoting company-wide digitization, introducing tools in response to the DX policy, and visualizing electronic forms and equipment data, only to find that they were not used at the production site or that the data was only acquired? A typical trap in the promotion of digitalization is a situation where issues can now be visualized, but it is difficult to determine where to start, or the production site is too occupied with data analysis to take effective action. It is important not only to select effective tools, but also to extract appropriate issues from the data, identify root causes, and make appropriate improvements. Furthermore, it is important to establish the habit of doing them every day, and for workers to become proficient in using the data.

As They Leave Everything to the Vendor, They Can’t Make Full Use of the System

In many cases, only the policy of DX promotion and IoT implementation is leading the way and as a result of leaving everything to an IT department that doesn’t fully understand actual situations at production sites, a system that doesn’t match production sites is introduced and end up failing. The IT department claims that it is the production site side's fault for not being able to use the system, and the production site side claims that it is the IT department's fault for selecting a system that cannot be used. Without finding a solution to the problem, the vendor-dependent system continues, resulting in a high-cost structure. To avoid this, it is essential to develop human resources who understand the characteristics of the manufacturing site (OT) and who can properly utilize IT, which means who can correctly define requirements.

Once successful, But Neither Continued nor Developed.

“Succeeded in the model production line, but having trouble expanding to other departments.” “We’ve been trying to improve, but the workload has increased in response to the change.” “Understand the need for improvement, but do not have the manpower to take charge.” “No extra capacity at the production site.” We often hear about the challenges and concerns in continuing and developing improvements. Even if improvements are made successfully, they will not lead to significant results unless they are firmly established as part of the corporate culture and customs. To expand the process widely, rather than simply making improvements, it is important to standardize the process, including who implements the process and when.