This is a proposal for the implementation of "Science SQC" (a program based on the new scientific SQC method in Manufacturing) in order to elevate the quality of the business process. We construct the "Availability and Reliability Information Administration System -ARIM-BL" as a practical example of "Inline-Online SQC." As for the key technology of "Science SQC," it is indispensable to implement "Inline-Online SQC" by utilizing both methods consistently. It makes the dark points in business process clear and manages to communicate between man and information. This study describes the total integrated process information system, which links together between Production Engineering division and Manufacturing Engineering division. It is representative of intelligent "Inline-Online SQC." We have introduced the demonstrative and effective system into FBL (Flexible Body Line), which was the core of TPS (Toyota Production System).
To achieve worldwide high productivity and quality assurance of global production, the authors considered the necessity of including the above with strategic application of the TPS, and clarified the Advanced TPS as the global production by manufacturing technology for the strategic administration of production facilities. Nowadays, we have established manufacturing technology by innovative maintenance of Toyota, a most advanced automotive manufacturing enterprise. Therefore, we propose the V-MICS (utilizing Visualization-Maintenance Innovated Computer System) consisting of five steps (AML-1 to AML-5). Concretely for transfer of the maintenance skill, in particular we will accomplish a procedure combining DB (database) and CG (computer graphics). With regard to the former we will construct a DB for easier accumulation of know-how for parts replacement and other jobs. As regards to the latter, we will provide the instructions to enable even a person not familiarized with machine-drawings to carry out dairy inspection. As a result, we will not only attain considerable reduction of the maintenance cost, but also realize a lot of benefits such as more improved availability when we start up the global production in the world.
The Japanese industrial companies demand changes. Simultaneous achievement of consistent quality worldwide, simultaneous startup and QCD (Quality, Cost and Delivery) is necessary to achieve successful global production. The authors think that evolution of technology and skill to realize a guarantee of high quality in production workplaces of production shop is necessary for a global production strategy. Therefore, in this paper, the authors focus on “intellectual working value” and propose the basic principle of intellectual working value improvement and the “Working Value Improvement Management Model”. Furthermore the evolution of technology and skill realizing a high cycle of manufacturing technique in a Japanese offshore production factory was verified at Toyota Motor Corporation.
It is necessary to establish higher levels of equipment reliability in a short time, the market demands ever shorter lead times for the release of new models. Also, the demand for new-model cars is very strong immediately after their introduction. The conventional method for enhancing equipment reliability is by screening alone. However, this requires screening operations on production lines and so has been an obstacle to line production and prevented shortening of lead times. We are now able to dramatically enhance equipment reliability in a very short time by detecting failure modes and forecasting the number of occurrences using a scientific technique based on reliability engineering.
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