MES (Manufacturing Execution
System) |
Having been fully implemented
for all mass production items at our DDS
Komagane Plant since April of 2002, MES
characteristics are as follows and have
been playing a major role in production
control. |
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- real time production
control
- improved quality control accuracy
- improved lot tracing
- faster data searching (collaborating
with QA control system "Manmos")
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Production lot numbers
are the key to obtaining the above fore
mentioned data. MES is also linked with
our ERP system which controls material
orders and production plans. |
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| MES Operation Flow |
- Actual input on manufacturing
premises
On-time input for each production lot
Start & finish reports
Rejection report
Completion report
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- Searching
Actual Data
MES makes it possible to search data in
real time.
Data by defect root cause
Data by manufacturing conditions for each
lot
Data for WIP
Other required data
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Analyzing actual performance
and draw out answers to solutions |
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| Machine Layout Changes |
NHK suspensions are made
by several manufacturing processes.
Originally,
our machines were consolidated in process
by process. However, we have arranged
to lay out the machines as complete lines
which we call 'thorough lines'. This
made
it possible to lay out machines which
are assigned to each line in process
order,
and to produce products in lot order
making the flow easier. Fortunately,
we are able to reduce WIP in the process
and also to shorten LT. |
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| Profile Control and Abolishing
Trial Runs |
Profile Control is our
method of stabilizing three characteristics
for suspensions (resonance, gram load
and pitch & roll). By controlling
the profile of each bending position
on
suspensions, we can determine optimum
manufacturing conditions and proceed
pilot-less
when changing production lots and manufacturing
conditions. NHK realized profile control
and pilot-less by implementing the following
improvements;
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Improved alignment
accuracy in press forming
Fixing equipment locations by adjusting
machine layouts
By fully implementing 3D measuring
machinery we could establish profile
measurement technology.
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Profiling control and
pilot-less has made it possible to run
production
systems by MES in which lot numbers are
key. This is the current base for
production of NHK suspensions. Of special
note, pilot-less production allows us
to reduce our production lead time. |
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| Pitch & Roll Adjustment; Gram
Load Adjustment |
The accuracy requirements
for suspensions are getting tighter with
each new generation of hard disk drives.
To meet these requirements, not only must
we improve material and machinery performance,
but we must also apply adjustments to
our methods. Of special note, we are implementing
both P/R and G/L adjustment machinery
to improve the accuracy of both. |
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