An in-vehicle device manufacturer was planning to introduce a new mounter and asked us to help them create a database of the components used. We created a work routine for efficiently inputting the mass data between their business activities. As the work for creating components data was simplified from the initial stage of introduction, the client was very happy to be able to start using the mounter promptly.
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- Trouble：
- We need to create mass components data when introducing new facilities.
- Solution：
- MASS helped to create a components database.
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- Trouble：
- We want to build boards using a non-standard process…
- Solution：
- MASS proposed the optimal line by combining the facilities of several manufacturers.
A medical equipment manufacturer wanted to install a line which included a special process. They wanted to shorten the tact time and reduce the number of facilities used. Accordingly, we proposed the best production line for their needs which consisted of the equipment of several manufacturers. As the line differed from their normal process, we repeatedly checked that quality is maintained. The customer was able to achieve the quality they were looking for, limit the tact time to within their target, and is currently rolling the system out to their plants around the world.
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- Trouble：
- We want to reduce the data creation time and misinformation rate.
- Solution：
- Cut the data creation time from 1.5H→0.5H and improved the percentage of defect-free products from 80% to 99.5%
An in-vehicle manufacturer was taking 1.5 hours to create the inspection data for one model. They wanted to reduce this data creation time and raise their percentage of defect-free products.
Through discussions with the manufacturer, they were able to reduce their data creation time to 0.5 hours by adding new functions. They also succeeded in reassessing their inspection data and conditions, and in raising the percentage of defect-free products from 80% to 99.5%. -
- Trouble：
- We want to enhance efficiency by dual lane operation.
- Solution：
- Improved the efficiency of their planned maximum production volume up to 120%.
An EMS manufacturer decided to install a dual lane system.
They were facing many problems as they were also using conveyors made overseas. Therefore, we arranged for engineers from the different manufacturers to grasp the present situation in the respective countries and resolve the issues thoroughly. As a result, the customer was able to improve the efficiency of their planned maximum production volume by 120%.
They complimented us with the remark, “We have never had a manufacturer or trading company that supported us to this extent.” -
- Trouble：
- Mounting personnel costs are a source of concern even at our overseas production sites.
- Solution：
- Achieved stable production by shifting from “people” to “automation”
A Japanese in-vehicle manufacturer installed a mounter for automating the process of manually inserting large components with different shapes at their Thai plant. Because this was the latest model, we visited the plant repeatedly with the manufacturer to check the mounter, grasp the situation, and clarify problems, to ensure that the customer’s needs were being met. Currently, the customer is carrying out production stably, and has been able to cut personnel costs. They are also presently rolling out the machine.
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- Trouble：
- Don’t know what t o do with frequent defects
- Solution：
- Contributing to improving quality and productivity
A home appliance manufacturer had been localizing production in China.
Due to the many inconsistencies in machine settings and conditions, quality defects were frequent.
MASS investigated the actual situation and proposed specific goals for improving the operation rate and defect rate.
The customer was able to prevent defects through intensive machine repairs and regular maintenance, which is now contributing to quality and productivity improvements.