Aiphone Communication (Thailand) Co., Ltd.
Hisashi Miyahara President
Yasuyoshi Sato Production & PCB Assembly Senior Manager
――Please tell us about your business.
Established in 1948, Aiphone (Location: Nagoya City, Aichi Prefecture) is engaged in the development of various systems for detached houses, apartment buildings, medical and welfare facilities, offices and factories as a security and care business. Our company in Thailand started operations in 2000 as an intercom manufacturing base. We handle roughly 350 models, 6% of which are exported to Japan and 4% to Western countries.
――What have you been struggling with in work analysis so far?
The analog method of having improvement department staff go to the site, time the process with a stopwatch while looking at the hands of the work staff, and write it on paper has reached its limit. I understand that many manufacturers have similar problems, but even though we are promoting automation, there are many processes that rely on human hands for products, and it took time and effort to analyze the work. The average achievement rate of "display time" is 70%. It was difficult to raise this rate by 1%.
――So you switched to the digital method of shooting and analyzing videos?
We introduced the video analysis software "OTRS" in 2019. We install equipment in an appropriate place on the site, photograph the production line, and view and analyze it with dedicated software. The first thing I felt when I watched the video was the improvement of "visualization". Of course, the staff of the improvement department, who make full use of stopwatches and paper, are also "seeing", but in terms of accuracy, they are not reliable compared to machines. Videos will time you at the right time, and if you feel there's something you missed, you can rewind. On the other hand, the human eye may or may not notice something, nor can we go back in time to actions that we may have overlooked.
――What are the feelings of the staff on the "analysis side"?
If the improvement department staff stands next to you and stares at you, it is natural that the work staff will be worried about it. There are many times when you can't do your usual work. This also reduces the accuracy of work analysis. On the other hand, the pressure exerted by photographic equipment is much less than that of a real person. If the staff doesn't care, they can do their normal work even during the analysis.
――Has video analysis software improved the achievement rate of "display time"?
Since standard times are set for each of the 350 models handled, it is difficult to present an exact number, but if we apply the average value of 70% mentioned earlier, it has improved to 80% with the introduction of software. Currently, we have raised it further through various efforts rather than relying only on software, and have maintained it at about 83%. Although it is a well-known fact, raising the achievement rate to 90% or 100% is not the right answer. This is because a goal that can be achieved may not be a goal. In the first place, work analysis is not just for the purpose of setting better display times.
――So you've realized a wide range of analysis?
We evaluate that the work analysis by video recording corrected many inaccuracies and made visible many points that were not visible. By looking back at the recorded video, we were able to immediately analyze that "there is a waiting list, the line balance is not adjusted, and accurate process design has not been realized," and we have been able to respond quickly to the current situation of high-mix low-volume production and the introduction of new models.
――What is your direction as a company through work analysis?
The purpose is to evaluate the staff involved in the work, and there are also expectations for multi-skilled workers in the future. And I think it will lead to the major goal of "labor saving" by improving work efficiency as a company.
――Thank you very much.
Aiphone Communication (Thailand) Co., Ltd. Address:700/455 M.7 Amata City Chonburi Industrial Estate, Bangna-Trad Road, Km. 57, Donhuaroh Sub-District, Muang Chonburi District, Chonburi 20000 Tel:038-717-217~20, 038-198-501~4 Fax: 038-717-221, 038-198-505