Speedy action for everything!

A Japanese company manufacturing digital camera, car audio and navigation has been steadily yet vigorously striving to expand their business (like any other company) encountered the need for speed. Their motto: “Speedy action for everything” implied that they really valued time and wanted to progress by reducing whatever they can to save time, and of course, to increase their profit.

This company battled challenges common to every manufacturer out there: uncertainty, frequent change in orders, equipment failures, worker holidays, visualizing orders and product finish time, shortening lead time, inventory reduction, etc.—all of which relates to the fact that there is undoubtedly an urgent need for speed. In line with this, the company also wanted to excel on three related areas:

  • Uniform management from beginning to completion
  • Optimize management system and speed up decision-making
  • Visualization of information in order to promote consensus view for all employees

After careful assessment of their options, they concluded that they need a production scheduler that already holds proven records when it comes to speed and accuracy, and can also help with other related areas in production. They placed their trust then, on Asprova’s high speed scheduling capacity to help them in their journey on this fast-paced industry. And they were not disappointed.

According to the higher-ups of the company, Asprova helped them improve in several key areas: assembling lines, post-processing, visualization – enabling them to clearly see the manufacturing flow, availability of components that can now be confirmed in advance, and other superb speed-related factors.

To read the full case study, please click here.

Rescheduling According to Production Results

Production Schedule Done Manually

A growing company has to deal with frequent order changes. It requires flexibility. And of course, under the umbrella of flexibility comes speed and accuracy. These things are inseparable factors and are a must when it comes to production. A fluorescent lamp manufacturer experienced this phase and decided that they should rely on Asprova’s help for a number of reasons:

  1. To respond to the growing number of orders and the frequent order changes.
  2. Visualization resulting to faster execution—prior to Asprova introduction, they made schedules manually; of course, they needed plenty of time to make them.
  3. Independence from sole human schedulers. Before Asprova, it was hard to pass on the knowledge or know-how when it comes to the scheduling steps and no one could initiate planning if the only one who knows how to do it is away, with the help of the scheduler, this wasn’t necessary anymore as anybody could do it.
  4. Work in progress—due to production inefficiency, the work in progress kept increasing; the company needed a scheduler that would free them from these troubles.

Results after implementation

There are lot’s of gimmicks nowadays that tell us one thing but doesn’t really deliver. Here however, Asprova will never let anybody down as it has proven itself again and again, through providing actual results to the fluorescent lamp manufacturer.

  • Dramatically increased the processing speed in production scheduling: About 100,000 jobs (number of jobs = number of lots x number of processes) can be scheduled in just 1.5 minutes.
  • Ability to deal with rush orders: Because of the ultra high-speed scheduling, this company was able to immediately and precisely project the delivery/due dates of rush orders.
  • Visually displaying progress through Gantt Chart: By tracking the real time progress of production lines through Gantt chart, users were able to find out problems immediately.

Do you still create your production schedules manually? Do you still rely on the experience and intuition of your production go-to-guy? Management of scheduling that relies on experience will eventually reach and impasse. If you’re still struggling on meeting rush orders, unable to visualize the possible future production problems, and reducing WIP inventory, it’s high time to try out Asprova.