Advantest Corporation
A progress meeting is held every morning to check progress by comparing the schedule and documents.
By combining production plans and performance information on the MES, you can always grasp the forecast and actual results of the manufacturing process.
To keep track of progress at factories far away, workers need to compare schedules point by point via phone or email.
Information is shared in real time, so it can be understood at a glance
The work of creating documents on-site alone takes more than an hour per day
Reports are generated automatically, so no labor is required
Production Planning Department Manager Mr. Yu Nomura
Production Planning Department Mr. Yasuyuki Takatoku
Manager, Production Planning Department Mr. Mitsuteru Tajima
Advantest Corporation (hereinafter referred to as Advantest) is a company that manufactures "semiconductor test systems," devices used to check that semiconductors are operating properly.
The development of semiconductors is advancing rapidly with the spread of IT equipment, and the company's strength lies in its ability to provide the equipment necessary for testing them in a timely manner.
Yu Nomura, Director of the Production Planning Department
“Recently, the uses of semiconductors have been expanding in line with the progress of the world, including in automobile driving.
We believe it is important to respond to these semiconductor manufacturers in an accurate and timely manner."
In the semiconductor industry, the percentage of manufactured products that meet quality standards, known as "yield," has a major impact on manufacturers' costs. Advantest, which provides equipment to test yields, plays an important role for semiconductor manufacturers.
Yasuyuki Takanori of the Production Planning Department said, "We use up to 10 or more types of forms to produce one model."
These reports were originally paper documents, but in order to improve the efficiency of production management, i-Reporter was introduced and the process of digitization was promoted.
However, one issue that arose during this process was that simply digitizing the documents themselves did not allow for immediate confirmation of work progress.
"Even if we entered the actual results into the ledger, we still had to make a judgment manually to see if they matched the schedule. For this reason, we previously had to gather together every morning for a 'progress meeting' to cross-check the schedule and ledger."
To visualize this work progress, it is necessary to create a system to link i-Reporter reports with data from the MES (manufacturing execution system).
The means to achieve this was the i-Repo Project.
When an order is received, the construction period and process are entered into the MES (Manufacturing Execution System). Each process has detailed tasks, each of which has a set schedule. This data on the MES can be input into i-Repo Project via WebAPI. Once this data is entered, i-Repo Project automatically generates i-Reporter forms tailored to the process.
At the manufacturing site, i-Reporter forms are checked using tablets and work results are entered. When the data is entered, the start and completion records, including when and who carried out the process, are also sent to the manufacturing execution system (MES).
Based on this information, the MES combines production plans and actual performance information, making it possible to constantly grasp the forecast and actual results of the manufacturing process.
In addition, the i-Repo Project makes it possible to visualize progress in real time using Gantt charts and other methods, allowing users to intuitively understand whether production is proceeding according to plan.
By establishing this system, it has become possible to visualize the progress of work, but Takanori says that this is not the only benefit of introducing the i-Repo Project.
"I also think that the i-Reporter report is generated as soon as an order is placed, which is a very useful feature.
Previously, it took more than an hour a day just to create the forms on-site, but now that forms are generated automatically, that time has been reduced to zero."
Furthermore, by introducing the i-Repo Project to subcontracted factories, progress management in remote locations has also become more efficient. Previously, to determine progress at remote factories, reports had to be received by phone or email and then compared point by point with the schedule, but now information is shared in real time through the i-Repo Project, so the progress can be seen at a glance by opening the i-Repo Project. Paper usage has also been reduced, leading to an estimated annual savings of around 20,000 sheets.
Mitsuteru Tajima, Manager, Production Planning Department
While progress management has become visible, huge amounts of work performance data generated during the process are beginning to accumulate daily.
Takanori's manager, Tajima, says that Advantest's next goal is to analyze this data and use it to improve business processes, such as optimizing them.
"By using CIMTOPS' i-Repo Project and i-Reporter, we have finally built a foundation for digitizing and visualizing progress management. As the next step in visualization, we would like to move forward with efforts to utilize and analyze the accumulated data, and furthermore, to use that data to create new value for our business," he says.
The above reviews are quoted from ITreview.(https://www.itreview.jp/products/i-reporter/reviews)
※ITreview is a real-name, company-verified review platform featuring authentic feedback from professionals on the front lines.