Consultation for resolving the personalization of quality defects and inspection tasks for daily necessities molding.
Supporting the optimization of molding conditions for daily necessities and the standardization of burr and chip judgment criteria. Free initial consultation available.
In the daily necessities molding industry, it is essential to accurately determine the presence or absence of burrs and chips in order to maintain product quality amidst diverse small-lot production and short delivery times. Particularly, visual inspections are prone to variations in judgment criteria among inspectors, making the optimization of molding conditions, prevention of quality defects recurrence, and the inheritance of expertise from skilled workers critical challenges. This service supports the establishment of a stable quality management system through the standardization of inspection tasks and the review of workflows. 【Usage Scenarios】 - Standardization of visual inspections for burrs and chips after molding - Visualization of judgment know-how by skilled inspectors - Development of technical training systems for junior inspectors - Digitization of inspection records and improvement of business workflows 【Benefits of Implementation】 - Reduction of judgment variations through unified inspection standards - Prevention of quality defects recurrence and improvement of yield - Optimization of training costs through the inheritance of knowledge from experienced workers - Increased efficiency of inspection tasks and establishment of standard operating procedures
basic information
【Features】 - Support for standardizing inspection criteria and work procedures - Analysis of the causes of quality defects and consideration of recurrence prevention measures - Visualization and manualization of the judgment know-how of experienced personnel - Development of an educational system for skill transfer to young inspectors - Fundamental review of inspection records and business flows 【Our Strengths】 Through the business ecosystem 'exbridge', we collaborate with experts familiar with the challenges in manufacturing sites. We will listen to your current situation and propose the optimal approach for solving your issues.
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Model number/Brand name
JEMCO COOPERATIONS／exbridge
Applications/Examples of results
【Expected Utilization Scenarios】 ■ Standardization of Inspection Criteria Organize different inspection methods and pass/fail criteria used by various personnel and consider standardization. ■ Prevention of Recurrence of Quality Defects Identify the factors behind recurring defects and explore improvement measures to prevent their recurrence. ■ Succession of Expertise from Experienced Personnel Visualize the experience and judgment criteria of veteran inspectors to support the transfer of skills to younger employees. ■ Efficiency Improvement of Inspection Operations Review inspection procedures, recording methods, and verification tasks to consider reducing the workload. ■ Review of Quality Management System Organize issues related to the personalization of the quality management department and educational challenges, and explore directions for improvement. *The above are expected uses and do not indicate actual implementation results for specific companies.
Line up（5）
| Model number | overview |
|---|---|
| Standardization of inspection operations | We will support the establishment of a system that organizes the variations in inspection procedures and quality assessment criteria, ensuring a consistent level of quality regardless of the person in charge. |
| Quality defects and recurrence prevention. | We will visualize the causes of quality defects and management issues, and consider improvement measures to prevent recurrence. |
| Visualization of inspection know-how | We organize the tacit knowledge of experienced inspectors, including their experience and judgment criteria, to support the inheritance of skills and techniques. |
| Training of young inspectors | We will review the OJT and training procedures to support the establishment of a development system that makes it easier for young employees to acquire inspection skills. |
| Streamlining quality management operations | We will organize the workflow for inspection records, verification tasks, and information sharing to support the productivity improvement of the quality control department. |
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![[Free Consultation] Is quality unstable even with standard operating procedures? Measures against personnel dependency and work variation in the manufacturing site.](https://image.mono.ipros.com/public/news/image/1/2116324/IPROS10385353290531544663.png?w=280&h=280)
[Free Consultation] Is quality unstable even with standard operating procedures? Measures against personnel dependence and work variation in the manufacturing site.
Although the work standard documents are established, is there a difference in work quality and work time depending on the person in charge? In manufacturing sites, even if work standard documents and manuals are in place, actual work may depend on the experience and intuition of veteran employees. For example, are there any issues like the following? There are work standard documents, but they are not sufficiently utilized on-site. Even for the same task, the quality and work time vary depending on the person in charge. The judgment criteria and tips of veteran employees are not documented. Training new employees takes time, and the content of instruction varies by person in charge. Even if work procedures are changed, the updates to the standard documents lag behind. Variability in work leads to quality defects and rework. What is important in addressing these issues is not simply increasing the number of manuals, but understanding the differences between actual work and the standard documents, and creating a state where the judgment criteria and know-how of veteran employees can be shared within the organization. Gemco Co-operations supports the organization of challenges such as the visualization of technology and skills, standardization of operations, and human resource development in the manufacturing industry.
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![[Free Consultation] If a veteran quits, who can do that job?](https://image.mono.ipros.com/public/news/image/1/2116324/IPROS1409028421576110653.png?w=280&h=280)
[Free Consultation] If a veteran leaves, who can do that job?
We are currently accepting free consultations to think together with experts about the inheritance of technology in the manufacturing industry, eliminating reliance on specific individuals, and developing young talent! "Only that person can do this task." Is there such a situation in your manufacturing site? As experienced employees retire and labor shortages increase, there is a risk that the skills, techniques, and judgment based on years of experience and intuition may be lost without being adequately passed on. For example, do you have any of these concerns? - We cannot respond to equipment troubles without veteran employees. - There are work manuals, but actual decisions are left to individuals. - We want to develop young employees, but we lack people and time to teach them. - There are variations in quality depending on the person in charge, even for the same task. - We feel the need for technology inheritance, but we don't know where to start. The problem is not just the lack of manuals. It is important to make the tacit knowledge that experienced workers have—such as "why we perform this task," "how to judge abnormalities," and "where to pay attention"—shareable within the organization. Gemco Co-operations supports initiatives such as visualizing skills and techniques, standardizing work processes, improving on-the-job training (OJT), and developing young talent, tailored to the challenges faced in the manufacturing industry.
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