"GD.findi" was developed with the express purpose of fostering innovation in the manufacturing industry. Here, we will introduce a variety of utilization models for both production planning and within production facilities.
Unlike conventional production simulations, GD.findi was developed using present manufacturing industry practices as a guideline to operation. As these guidelines are constant throughout the industry, please use these example applications as a reference.
As part of its efforts to expand its new product lineup, electronic devices manufacturer Company D carried out renovation through addition of a new production line. By making effective use of design data, we provided assistance in process design and distribution design, which produced dramatic improvements in productivity, and energized the company's production centers thanks to wholehearted participation by its entire workforce.
Wanting to expand its business and diversify its product lineup, food manufacturer Company Y relocated operations to a new factory. We provided assistance in coming up with the best possible factory design based on the company's medium-term business plan. This enhanced productivity and bolstered the company's capacity for producing many varieties of products in small lots.
In order to adjust its production capacity, motor vehicle manufacturer Company T had been implementing plant layout planning, although previously it had been unable to effectively utilize complicated materials flow simulations. However, by making use of Lexer technologies, it was able to efficiently verify floor routes, on-site routes and transport plans, and create a system under which in-company consensus can be effectively achieved.
As it had become dependent for its production preparation operations on overseas locations, the printer manufacturer Company E was facing myriad problems. By introducing Lexer's production line simulation capability, it was able to return to company headquarters in Japan the work concerning mother line planning. It furthermore was able to establish an integrated system covering everything from factory design through manufacturing.
In order to be able to carry out concurrent designing for product designs and production line designs, motor vehicle manufacturer Company D used Lexer's simulation technology in its quest to achieve front loading of its production preparations. By incorporating the use of Lexer technologies into the production preparation stage, the company was able to reduce instances of having to rework process planning and trial manufacturing. That in turn reduced design alteration costs and brought forward the mass production stage.
In conjunction with its plan to expand its derivative products, refrigerator manufacturer Company D carried out production planning and process planning for producing diverse models in small lots. Specifically, it utilized MBOM information to carry out production simulations and develop process planning and production line layout designs for responding to multiple-model mixed production.
When expanding its production centers and its vehicle model lineup, motor vehicle manufacturer Company X realized how critical were rational judgments concerning the optimum production bases and suitable designs for production lines. It therefore made use of product design information and process planning information, as well as production line information, in order to carry out production simulations and investigate technologies for drafting plans.
High-pressure cylinder manufacturer Company B was seeing its work in process increasing along with its expansion of its multiproduct production. By carrying out production simulations designed to reconsider its process planning and work-in-process materials flow, even while it maintained a high level of utilization for its production lines, the company proved able to implement process planning for minimization of work in process and the design of production line layouts.
Although food manufacturer Company F needed to expand its derivative products lineup to appeal to the souvenir market, it faced time loss difficulties related to the retooling work during changeovers in production lots. By using simulations to reconsider work plans and personnel assignments for such retooling work, maintenance, etc., the company was able to drastically reduce the time required for changeovers among products.
Company Z, a shipbuilder, was facing problems concerning its materials flow plans for outsourced shipbuilding blocks and plans for appropriate locale planning for stock sites. The company was able to respond in its construction plans so as to create optimum workplaces and stock sites, as well as materials flow routes, and also improve the lead times. At the same time, it achieved improvement in operating rates.
Company M was developing production bases in various overseas locations, but it faced problems in production preparations for launching mass production. Although the products being produced at these overseas production bases would be uniform and the production processes would not change, the production volumes would vary by location. Moreover, the company had to respond to constraints in existing facilities and issues related to production worker skills by developing production center-specific process plans. It also faced management problems. For one thing, since it had no choice but to rely on its local staff, it was not able to draw up and implement appropriate process plans. Furthermore, from the perspective of the parent company in Japan, it could not control how the process planning should change. By introducing Lexer simulations, the company was able to use the Cloud to provide mother line plans from Japan, and directly control how they were incorporated at the overseas production bases. Since with these simulations it was in a position to monitor things at the plan creation level while engaging in production preparations, it could thus achieve global production preparations that were efficient and carried out at a high level of management.
Company T is engaged in the manufacture of high precision pressed parts. However, it is dependent on a limited number of planners. That is because drawing up the production plans for the types of press lines required in order to be able to respond to small-lot orders from various manufacturers of assembled products is an extremely complex task. When formulating production plans that cover both retooling work and employee assignment, it is a very time-consuming process to be able to ensure that these production plans are indeed viable. Enhancement of productivity, operating rates, TAT (turn around time), etc., requires a wealth of experience and professionalism, as well as considerable investment of time. In response, the company introduced Lexer simulations and is now drawing up its daily production plans by using data in the EXCEL format as the basis for carrying out simulations.
In this way, by carrying out production plan simulations it is able to ensure that there are no problems with the plans (in terms of repetition, negligence in following a plan, etc.), and also determine what the operating rates for various facilities would be. Furthermore, because of the ability to verify instantaneously that there are no problems with areas like work in process, it is therefore in a position to incorporate this data into better-fashioned plans, while other staff members are also able to efficiently formulate plans.