SCREEN SPE is promoting the development of a smart factory centred on its Hikone site and driven by shop-floor needs. Through the development of 3D digital work instructions and the introduction of a manufacturing execution system (MES), the company is advancing standardisation and visualisation of bottlenecks in its high-mix, low-volume production operations, while reducing the labour required to search for parts and check work progress.
The Hikone site meets the needs of high-mix, low-volume production as a main production base for cleaning equipment. The company's in-house manufacturing engineering division is responsible for factory automation and digitalisation, and is proceeding with system implementation and the design of dedicated machines in response to issues identified on the shop floor.
The shop floor has begun using 3D digital work instructions and dividing processes into cellular manufacturing operations. This is advancing process standardisation while creating a cycle in which MES converts work times into data and visualises bottlenecks.
Reported results include a 50% reduction in parts-search time, a 50% reduction in the labour required to check work progress, and a reduction in simple tasks such as press-fitting. At the same time, the company is addressing issues including the suitability of introducing robots and the space and cost-effectiveness involved.
Opportunities for shop-floor employees to propose and discuss improvements have increased. K.K. designed a compact piping connection device aimed at improving the safety of assembly work. The company will strengthen a system in which production engineering is involved from the design stage, with horizontal deployment also under consideration.