Improvement of Production-Plan Accuracy and Productivity by Applying FOM to Automobile Parts Process

This study aims to improve productivity by analyzing manufacturing-process data and deriving problems using a FOM system. Additionally, an accurate demandforecast production plan is established to increase manufacturing competitiveness. As a case study, MES data are analyzed using an FOM assistant for Company I, which is an automobile parts manufacturer, and the correlation among man, machine, material, and method is identified. The production plan fluctuated significantly and the productivity declined owing to the inactivity time (equipment waiting, mold setting, etc.). The method of converting to external preparation by dividing internal and external preparations, standardizing the mold setup, and using data is presented.<br/>In addition, the importance and evaluation method of establishing a high-accuracy production plan were presented, and the introduction of APS was proposed to increase the accuracy of the production plan by predicting, revising, and supplementing demand by period, customer, and product through accumulated data analysis.