|Company||Iwasaki Electric Mfg. Vietnam Co., Ltd.|
|Representative Director||Hiroyuki Fujihira|
|Address||Lot73, Road1, Linh Trung EPZ Ⅱ, Binh Chieu Ward,
Thu Duc City, Ho Chi Minh City, Vietnam
|Business lines||manufacture of various wire harnesses, industrial controllers, among others
|Number of employees||790 people (as of the end of April 2020)|
|Certification||ISO9001 certification, ISO14001 certification|
■ Small group activities and human resource training
Quality is built into products by people. Human resource training is therefore an integral part of our operations.
We develop annual plans for “human resource training” and “quality improvement activities,” and a full-time checker contacts each leader on a weekly basis to keep track of efforts in these activities and their progress, and reports the results to the top management. Important operations in the manufacture of products, such as soldering and crimping, are performed only by workers who passed appropriate qualification exam (including practical exam).
In addition, we carry out small group activities, which identify latent risks in operations and thereby prevent defects instead of taking action after a problem occurs.
■ 5S activities
In the factories, notices are put up and training/guidance are conducted, and tools and jigs are thoroughly put in order and tidied up.
■ Putting in order and tidying up jigs
■ Putting in order and tidying up tools
■ Daily inspections (inspections of applicators)
IEV shot counter 4
IEV notice (applicator maintenance)
Since the frequency of use of applicators depends on the model, a shot counter is installed to prevent failures due to fatigue.
The yellow lamp of the shot counter indicates a warning, and the red lamp indicates that the applicator must be maintained or replaced. Parts are checked and replaced by the maintenance person qualified by the crimping machine manufacturer.
Every crimping machines are inspected periodically by the manufacturer at intervals of six months or one year.
■ Quality improvement activities
The leaders of all departments/sections gather on a monthly basis and hold a quality meeting in which the occurrence of nonconforming products is reported or a lecture or another activity is provided for improving quality awareness.
In addition, in 2018, internal nonconformity history system was produced (QIS), and we proactively perform quality improvement activities using this data.
Our worksites are also committed proactively to such activities as “why-why” analysis and endeavor to improve quality in daily operations.
■ Production control system developed in-house
Our production bases both in Japan and in Vietnam are centrally controlled by the original production control system we developed. This system streamlines the process from the receipt of orders to packaging and shipment and realizes low costs and short delivery periods. This in-house-developed system ensures flexible and prompt system changes in response to changes in needs and has been kept upgraded since the start of operation and updated on a daily basis.
A production meeting is held every Friday with the participation of the representatives of all departments to speedily respond to variations in received orders.
■ Barcode-based progress control
Barcodes are adopted for tracking the production processes and picking parts, allowing us to grasp the statuses of parts and products in real time.
■ Activities for promoting local procurement
To reduce both costs and lead times, we are proactively promoting the local procurement of processed products (metal-worked and resin-molded products, printed circuit boards, etc.) and catalog products in Vietnam. With the aim of procuring products at lower prices and in a shorter time, we will make endeavors in daily operations and step up local procurement so that we can make proposals fit for customer needs.
■ Flexible production system and risk diversification
Our production system is very flexible; for example, we manufacture prototype products responding to emergencies in Japan, and mass-produce products in Vietnam where production costs are low. In addition, even if a natural disaster or unexpected situation occurs at any factory in either country, our backup system is failsafe as the production bases in Japan and Vietnam have the same equipment. We focus our energy on the realization of a production system and costs that ensure security for customers.
■ Introduction of the latest equipment
At the Vietnam Factory, the introduction of the latest fully automatic equipment, the utilization of work jigs, and other proactive efforts are in progress with the aim of improving quality and production efficiency. We are constantly making improvements to meet expectations of customers related to quality and cost.
■ Wire harnesses for industrial robots
These wire harnesses are the world’s most advanced wire harnesses for robots. We have finally realized our long-accumulated Japanese know-how here in Vietnam. Customers can order even wire harnesses with a high degree of difficulty with reliability.
■ Robot controllers
For robot controllers. We procure also metal sheets in Vietnam.
■ Products for pharmaceutical equipment
These products for pharmaceutical equipment are manufactured by setting motors, printed circuit boards, and wire harnesses in locally procured molded products. All products are shipped after a tablet count check.
■ Fusing products
These wire harnesses require delicate work of laying AWG28-size wires one by one on a wire arrangement plate while identifying wire colors and ultra-small-size dots. The Vietnam Factory can also manufacture fusing products.
■ Wire harnesses for medical equipment
These wire harnesses are for medical equipment and require complicated wire bundling work.