Cell production system
A production method in which a product is completed by one or a few workers is called a cell production method. Compared to line production, this approach has merits such as being better suited to high-variety low-volume production and having higher adaptability to production changes. However, since this production method requires a wider range of skills for each worker, improving worker efficiency and eliminating waste are required for efficiency. In class, students will learn the ability to detect wasteful work and propose improvements by using the cell production system.
Line-of-sight measurement system
Attaching a line-of-sight measurement device to the faces of operators allows you to collect data on where they are looking while carrying out their work. This data can then be analyzed to discover information such as what areas operators pay attention to and how their line-of-sight is distributed during work, which can then be used as a base for eliminating waste and cultivating operation improvement abilities. In addition, these devices can be used for work-related education as well, such as by showing the line-of-sight data of experienced operators to beginners. This will help to develop their analysis and thinking ability.
Operation analysis tool
"OTRS" is an operation analysis tool that can be used for applications such as time research and movement analysis. Instead of holding a stopwatch and timing them, this tool allows you to click your mouse to indicate the start and stop times of individual pre-defined operations while watching a video. OTRS then automatically calculates the total time spent on each step. In addition, you can adjust the video playback speed for analysis purposes, which makes reconsidering operation definitions and monitoring the fine details of operations easy. Analysis using OTRS allows you to set time standards and extract tips from veteran workers, improving operations and developing your ability to propose new methods.
Production system simulator
The production system simulator is an experience-based learning facility which enables you to construct a virtual factory inside a computer. Modifying aspects like the processing speed for each manufacturing stage, buffer size requirements, and number of machines is an extremely time-intensive and expensive process for trial runs of an actual production system. However, with this production system simulator, you can easily modify a variety of different conditions and view the results as 3D animation. Using the production system simulator, you can learn about competitive production system design and operation methods.
Music box production line
We have a music box production line in our university. Numerous processes are linked together in order to screw vibration plates for making music onto music boxes which have been loaded onto pallets transported by a belt conveyor.
Students can learn how the efficiency of music box production declines due to certain bottleneck processes which create delay.
The freeflow line assembles three parts in four processes. Also, in the final process, finished products are removed and taken to a different line.
The belt conveyor between each process serves as a buffer for adjusting the production line. By studying the line, students will understand efficient operation of a production line.
Also, students will learn about line structure efficiency for evaluating whether each process is allocated in balance.
Machine tools are the basis of manufacturing. Experience in operating machine tools will create a big difference in how a professional views manufacturing.
At the Department, students perform manufacturing while confirming the accuracy of work which they fabricated themselves. This gives students a deeper understanding of industrial engineering and management.
Students will experience manufacturing by fabricating work themselves by using representative machine tools such as lathes and millers.
An automated warehouse uses computer control for the receipt and shipment of goods. Automated warehouses are an important element of logistics systems which include factories.
In actual society, automated warehouses are used to store a wide range of products from automobiles to books. Automated warehouses are also used for inventory between processes at factories.
Students will use automated warehouses in order to acquire knowledge related to logistics, layout, and transportation as required for managers and executives at production plants and logistics facilities. Students will also learn about basic functions and operating algorithms for automated warehouses.
Picking robots are used in production lines for goods such as food products, medical instruments, and electronic devices. These industrial robots enable automation of parts assembly for precision devices.
The picking robot system uses a robot to pick ten triangular parts which are placed randomly on a belt conveyor. The system aligns parts with boxes and packs parts at high speed.
Students study work efficiency by using a video camera to film work performed by robots and the analyzing details such as time that robots grip parts, the time that robots move without gripping parts, the time required from gripping the first part until gripping of the tenth part is finished, and the movement of robots during work.
The Department also has ERP (Enterprise Resource Planning) systems, which are installed at about 40% of major corporations. The systems are used for experiments and graduate research.
In practical exercises, in addition to production management theory for traditional MRP (Materials Requirements Planning) systems, students use ERP systems in order to experience and acquire actual skills (creation of parts charts, work zones, and work procedures; and creation of production plans and schedules) in production manufacturing sites.