月: 2023年3月

What Is a PLM System?

A PLM (product lifecycle management) system is a system that centrally manages product information, including product design data, specifications, parts data, instructions at the manufacturing site, manufacturing performance information, purchasing information, and supplier information.

It is also called a product life cycle management system. By managing product development and manufacturing processes it has the advantage of improving product quality, shortening development time, and increasing productivity.

Similar product management systems include PDM (products data management) systems, but while PDM systems manage information in the design and development process, PLM systems manage information related to the entire product process, from planning, design, manufacturing, procurement, sales, and maintenance. PLM systems manage information related to the entire product process, from planning to design, manufacturing, procurement, sales, and maintenance by linking them together.

Uses of PLM Systems

PLM Systems are used to maximize profitability during the entire product life cycle. In other words, PLM systems help companies increase revenue and reduce costs by bringing products to market earlier by shortening development periods; it reduces manufacturing costs by linking and managing parts data, and procurement and manufacturing information. It also works by improving product quality by sharing customer feedback information at all stages of the process. PLM is a system that helps companies increase revenues and reduce costs.

For this reason, PLM systems were introduced early on in the manufacturing industry in general, and in particular in the assembly and manufacturing industries, such as the electrical and electronics industry, the automotive industry, and the aircraft industry, where parts data and parts procurement information are important. Since then, the use of PLM systems has expanded and is used in a variety of fields, including parts, molds, construction materials, medical care, and food products.

In addition, with the recent spread of communication through the Internet of Things (IoT: Internet of Things), there is a movement to use PLM System to manage and utilize data obtained through IoT, which is also attracting attention.

Principle of PLM Systems

PLM systems are equipped with various functions to manage and utilize information centrally from each process of the product lifecycle, such as product planning, sales, design, manufacturing, procurement, sales, and maintenance.

1. Project Management Function

This function manages product projects, schedules, and resources. It may also include portfolio management and budget management at the product planning stage. Functions that can manage progress against plans are primarily used by project managers and can be useful for resource allocation and coordination. 

2. Data Management Functions

This function is equivalent to a PDM (products data management) system. It manages design data, a bill of materials (BOM), design change management, configuration management, quality management, and supply chain management. It has the ability to manage and share information on products leads to speeding up the development process and strengthening quality control. 

It can be integrated with drawing tools (CAD: computer-aided design) and analysis tools (CAE: computer-aided engineering), which are necessary functions for product design.

3. BOM Management Function

In addition to the design BOM, the PLM System also manages the manufacturing BOM, which is created by the manufacturing department.

The manufacturing BOM includes not only the parts that make up the product but also auxiliary materials such as paints, sealing materials, and packaging materials used at the manufacturing site.

4. Process BOP Management Function

This function manages the bill of process (BOP) in the manufacturing stage. By sharing manufacturing processes and work instructions, it contributes to improving work efficiency at the manufacturing site and standardizing work so that work can be performed even by non-experts.

It manages the number of man-hours per process and allows for the trial calculation of processing costs necessary for costing and the optimal allocation of man-hours according to the skills and experience of workers.

How to Select a PLM System

When choosing a PLM System, there are five key factors to consider:

1. Alignment With the Company’s Business Areas

Because PLM Systems vary in function and configuration depending on the solution/package, the selection of a solution must be appropriate for the product areas, scale of production, and implementation requirements of the company’s offerings. Enhanced management functions will lead to improved safety, quality, and workability.

2. System Scalability

As companies continue to expand their business, PLM Systems must be scalable to allow companies to respond to changes. Especially in the case of improved product performance, there is always a need to improve the functionality of the management system as well. It is advisable to choose a system that allows easy addition of new functions and new modules.

3. Security

Since a PLM System contains important information held by a company, security is extremely important. Therefore, it should have features such as access control, data encryption, and backup functions.

4. Availability of Customer Support

Customer support is an important aspect of implementing a PLM system. It is advisable to choose a service that provides prompt and appropriate support in case of problems.

What Is a PDM System?

A product data management (PDM) system centrally manages all product-related data, including CAD data, design drawings, specifications, documents, and Bill of Materials (BOM). It facilitates improved design efficiency by enabling simultaneous collaboration among designers on the same project.

Beyond mere data management, PDM systems incorporate workflow functionalities to streamline and standardize processes.

Uses of PDM Systems

PDM systems are instrumental in enhancing design and development efficiency, as well as boosting production efficiency. Predominantly utilized in the R&D departments of manufacturing companies across industries such as machinery, electronics, semiconductors, automotive, pharmaceuticals, food, and cosmetics, they excel in large-scale projects by facilitating seamless information sharing and correlation of extensive design-related data among stakeholders.

Principles of PDM Systems

Equipped with a suite of functionalities, PDM systems are versatile tools for product development management.

1. Data Management Function

Centralizes management of information from product planning through to final design, encompassing specifications, CAD data, drawings, and BOM details. Features version control to ensure the use of up-to-date data.

2. Workflow Function

Facilitates standardized design and development workflows, including approval processes, work submission and review, and project timeline monitoring.

3. Search Function

Enables efficient information retrieval from the system’s extensive database using various criteria to facilitate data reuse.

4. Security Function

Ensures information security by enforcing access control based on the “need to know” principle, restricting data access to authorized personnel only.

How to Select a PDM System

1. Functionality

Verify the system’s capabilities, such as drawing, BOM, change, and project management, to ensure they meet your product development needs. Change management’s specifics may vary depending on product features.

2. Ease of Use

Consider the system’s usability for a diverse team, including contractors and employees of varying experience levels, ensuring it is user-friendly for all.

3. Customizability and Expandability

The ability to customize and scale the system to accommodate new products and functionalities is crucial for ongoing development success.

4. Linkability

Assess the system’s integration capabilities with other essential systems such as CAD, PLM, MES, or procurement management, depending on your company’s operational needs.

5. Security

Confirm the system’s security measures to protect against data breaches and unauthorized access, including robust access management protocols.

What Is a Construction Management System?

A construction management system is a system that allows construction sites and construction managers to manage various data and processes related to construction projects centrally, such as orders and contracts for work and construction, the progress status of construction, and the collection of sales proceeds.

Because it plays an extremely important role in cases where projects are executed on a long-term schedule, most companies have implemented this system. Conventional paper-based or multiple-system management methods are prone to information oversights and double management of data, and the exchange and management of information is complex.

As a result, rework due to omitted updates, errors in the construction process, and other losses occur in ways that are different from the original construction work. By implementing a construction management system, information can be centralized and managed in one place, making it easier to check information and make quick decisions.

The same system can manage multiple processes, such as budgets, orders, and cost control, allowing for real-time confirmation of work status and progress management. This is an effective tool for improving the efficiency of process management and productivity of the entire construction project.

Uses of Construction Management Systems

Process management systems are used to streamline the work that occurs in factories. By easily and in real-time grasping a variety of information, construction management operations can be made more efficient.

In the past, data related to a construction management system and construction was generally managed on paper or using multiple systems. When information is shared among multiple departments or when multiple construction projects are managed simultaneously, communication and data management tend to become complicated. In addition, when data is used for accounting purposes, it is necessary to fill in and enter the data again.

By introducing a construction management system, it is possible to manage all construction-related data in one place and share it easily. In addition, some construction management systems also support accounting tasks, such as ordering and receiving, and can help reduce the burden of accounting tasks, such as ordering and estimating.

In addition, since drawings, photos, and other data can be managed and shared on the system, not only does it make it easier to grasp the status of the project, but it also eliminates the need for paper output for data management and sharing, which is a major advantage in promoting a paperless environment.

Principle of Construction Management Systems

Construction management system basically consists of the following functions, which vary from product to product.

1. Construction Order Management

The system can manage information on construction projects for which orders have been received. Especially when handling multiple construction projects, it is possible to manage data by construction and item. Sharing this information among various departments will lead to data sharing and enhanced collaboration.

2. Execution Budget Management

Create and manage execution budgets for each construction project. Since the system also has functions for estimation and payment processing, it can be easily linked to the sales department. The construction management system facilitates the creation of an executable budget, which previously had to be set for each construction project, and allows visualization and sharing of information, including profit and loss.

3. Order Management and Payment Management

Items such as construction work, construction type, and vendor can be categorized and managed. Documentation support, such as invoicing, is also available. Receipts can be managed by item, such as invoice amount, deposit amount, and balance.

4. Construction Cost Management

Cost management can be performed for each construction project. Future payment schedules and the cost to total sales ratio can also be managed.

5. Process Management

Process and progress management can be performed for each construction project. Daily reports can be input and managed, which were previously done manually by workers, so that the contents of daily reports can be immediately reflected and work progress and problems can be easily checked in real time. The system also has functions for hazard prediction and safe process management by identifying risks related to construction work.

These functions vary from t system to system. By selecting a system after confirming in advance whether it has the full range of functions needed by your company and whether it covers the scope of work that needs to be streamlined, you will be able to introduce the system more smoothly.

In addition, construction management systems are designed with Gantt charts and graphics to make the managed data easier to read. The system is designed in such a way that there are no recognition differences in where to look or what is represented, no matter who looks at it or when.

How to Choose a Construction Management System

When choosing a construction management system, it is important to consider the following:

1. Functionality

It is important to confirm that the system has the functionality your company needs. In addition to the functions your company needs, such as construction progress management, budget management, and materials management, check whether the system has functions that enable effective construction management or new functions you want to work on.

2. Usability

It is important that the construction management system is easy for users to use. We check if the system has an intuitive operability and highly visible UI (user interface) so that users can use the system smoothly. It is important to actually try using the system before introducing it. 

3. Customizability

There are a variety of possible construction projects, ranging from short- to long-term projects, to projects that require management of numerous workers over a large area. It is necessary to select a construction management system that can be customized flexibly so that the company can properly manage the project according to the range of construction projects it is involved in.

4. Security

Since a construction management system handles confidential information, it is necessary to pay attention to the security aspect. It is important that the system has a backup function to prevent information leaks and unauthorized access, as well as to be prepared for any contingencies that may arise.

5. Cost

Cost is the most important aspect. In addition to the initial cost at the time of introduction, some systems have running costs, such as server usage fees and maintenance costs. Since systems are updated daily with new functions, the budget must be set aside to accommodate version upgrades.

What Is a Project Management System?

A project management system is an information management system that monitors and controls the goals, budget, schedule, tasks, and resources of a team-based project.

By integrally managing the order, development, purchasing, production, shipping, and other processes for each project, a project management system supports overall project management, which is becoming increasingly complex and large-scale. Similar systems for managing schedules, etc. include production management systems and process management systems, which are mainly used in the manufacturing industry.

On the other hand, project management systems are applicable to all industries, not just manufacturing. Depending on the field, scale, and complexity of the project, there are various levels of systems, from simple ones that use Excel templates to customized ones that are tailored to the company’s business model.

Uses for Project Management Systems

Project management systems are used in all industrial sectors, including manufacturing, software development, information services, retail, trading, food and beverage, construction, and financial institutions. Project management systems are particularly effective when workflows are complex and task management is difficult, when large projects involve numerous people, or when multiple companies are working on a single project.

Project management systems manage the entire process for each project, but different industry sectors have different processes and require different sets of functions. It is a useful tool for project managers and project team members to manage projects more effectively and efficiently.

Since project managers need to keep track of the overall progress of the project at all times, it is essential that they select a Project Management System that will be used particularly frequently and that is best suited for their project and industry sector.

Principles of Project Management Systems

A project management system has a variety of functions, but basically consists of the following functions:

1. Task Management Function

The workflow of a project is broken down into smaller tasks, and the inputs (materials, documents, etc.), specific tasks, outputs (return on investment and deliverables), task completion conditions, task priority, etc. are set for each task. Task priority should be set to clarify dependencies among tasks, and if a task cannot be started until that task is completed, or if the task has a large impact, the priority should be raised.

Some systems have a function that allows the approval process to be implemented on the system, for example, when the task completion is conditional on the approval of the responsible person.

2. Schedule Management Function

For each project task or process that brings together multiple tasks, a schedule is formulated based on work content, work hours, and manpower, and put into a Gantt chart. The Gantt chart shows the work content of each process on the vertical axis and the schedule bar on the horizontal axis.

It refers to a diagram that enables visual confirmation of the dependencies between processes and the status of the project. This Gantt chart is used to monitor the progress of the process and manage the schedule to ensure that deadlines are strictly adhered to. To make progress easier to understand, we also have the ability to display it on a graphical dashboard.

In some project management systems equipped with AI functions, the system can simulate past delays and the number of man-hours required for back-end processes, and make suggestions for optimal resource management and extract risks.

3. Information Sharing Function

This function allows all personnel involved in a project to share the necessary information. In addition to schedules, it centrally manages information throughout the project, including documents such as work procedures, meeting minutes, reports, inventory status of materials, and equipment maintenance information.

Also referred to as a collaboration tool, it facilitates communication and cooperation with all team members by providing e-mail, chat, and videoconferencing.

How to Choose a Project Management System

When choosing a project management system, you should pay attention to the following points:

1. Usability

It is important that the system itself be easy to use and intuitive for users. It is also important for project management that the system can be accessed from smartphones and tablets, and that updates from each device are reflected in real time.

2. Scalability

The project management system itself must be scalable to accommodate the future expansion of the company or project. The ability to add additional functions, modules, and expand capacity should be confirmed.

3. Customizability

Check if the system can be customized to fit the company or project. Projects fluctuate in many ways, such as company policies, client policies, and public trends. It is important that the system has the ability to be customized to respond flexibly to ever-changing projects.

4. Security

Project management systems contain highly sensitive information. It is necessary to confirm that the system has appropriate security measures in place, as well as a backup system in case of an emergency.

5. Supportability

It is important that appropriate support is available in the event of a problem. Make sure that support is available quickly and accurately. Some project management systems are made overseas, so in such cases, it is also necessary to confirm that support is available in your local language.

What Is Cost Control System?

A Cost Control System is a system for calculating, analyzing, and simulating costs.

To begin with, cost generally refers to the expenses required for manufacturing and selling products and providing services. Data related to cost can be categorized into material cost, labor cost, and manufacturing cost by form, direct cost and indirect cost, variable cost, and fixed cost. In addition, this data can vary fluidly or be prorated across the entire product. A Cost Control System is a system to grasp and control such costs accurately and in real-time.

Cost Control Systems collect and manage cost-related data, which must be handled in conjunction with other business systems such as inventory control, sales management, and accounting. Therefore, Cost Control Systems are often provided as a part of ERP (Enterprise Resource Planning) functionality, enabling smoother and more accurate cost control through data integration with other business systems.

Usage of Cost Control System

Cost Control Systems are used to identify and analyze costs, maximize profits, and respond to risks through optimal cost control. Proper cost control contributes to higher profits, lowers the break-even point, and increases business stability.

To this end, it is important to grasp and visualize data on which and how much costs are being incurred. By implementing a Cost Control System, it is possible to collectively manage data related to costs and calculate them in real-time. In addition, the profitability of each product and the cost required for each process can be determined from these data, contributing to the improvement of productivity.

Features of Cost Control System

The following items can be managed by implementing a Cost Control System:

1. Cost Accounting

Cost accounting is the automatic calculation of costs based on cost-related data. Cost accounting is classified into individual cost accounting, total cost accounting, full cost accounting, partial cost accounting, etc., depending on the application.

There are different types of costs, such as standard cost, actual cost, and scheduled cost, and these costs can be calculated automatically. 

2. Cost Variance Analysis

Cost variance analysis is to calculate standard cost and actual cost. Whether the variance is favorable (actual cost is lower than planned cost) or unfavorable (actual cost is higher than planned cost), it is important to understand the cause of the variance and to improve the accuracy of cost forecasting.

3. Profit and Loss Calculation

Profit and loss calculation is to calculate profit and loss by product to determine profitability. In addition to ordinary cost accounting, Cost Control Systems enable total cost control at each stage, which makes it possible to determine marginal profit and analyze profitability, opportunity loss, etc.

4. Cost Simulation

Cost simulation is to grasp various cost fluctuation factors and make future forecasts based on accumulated cost data. It enables prompt response to future risks such as raw material price hikes and labor cost increases.

5. Allocation

Allocation is the process of defining and distributing costs that are difficult to strictly incorporate into cost accounting, such as costs that cross over divisions or products, or common costs of divisions. Because product management requires complex allocations across different departments, Cost Control Systems are effective in calculating allocations.

How to Select a Cost Control System

It is important to choose a Cost Control System that fits your industry. We recommend that you look at case studies to see if other companies in your industry or business sector have introduced such systems, and select a system that best suits your production style, such as mass production, make-to-order production, or prospective production.

In addition, a PoC (proof of concept) is necessary before introducing the system to see if it can be integrated with the systems handled by your company and if it can be customized to meet your business requirements.

What Is a Production Control System?

A production control system is a system used to manage the various operations of a manufacturing company in an integrated manner.

For example, a production control system is used as an inventory control system to determine how many parts of inventory are left. A production control system can also be used as a process control system or a quality control system.

Production control is the management activity in the manufacturing industry to produce products of a given quality, at an appropriate cost, in the required quantity, and on time. A production control system centralizes information related to production, such as purchasing, orders, inventory, processes, quality, and costs, in order to manage production systematically.

In the past, they existed in a simple form, where products and parts were numbered at the manufacturing site and the progress of the production process was managed. However, it has evolved over time and is now a form of computerized supply chain management for all processes.

Uses of Production Control Systems

Production control systems are used in all areas of the manufacturing industry. From the smallest factory to the largest company with multiple factories, production control systems are used regardless of the size of the company.

However, it is important to note that the production control requirements differ depending on the product, production method, and size of the company. Some production control systems are small enough to perform process control, quality control, and inventory control at the manufacturing site, while others cover a wide range of areas, such as demand forecasting, purchasing management, and cost control.

It is recommended that an optimal production control system be built for each manufacturing site, and it is important for each company to implement a Production Control System that is suited to its needs.

Composition of Production Control Systems

Production control systems work in combination with process control systems and quality control systems. A production control system is an integrated system that brings together several control systems.

The main control systems included in a production control system are:

1. Process Control System

A process control system manages each process at the manufacturing site and checks the progress of each process in order to deliver the final product on time. When a part of the process is subcontracted, the system checks the status of input to and acceptance from the subcontractor.

2. Quality Control System

A quality control system is a system that checks and manages the quality of purchased raw materials, parts, etc. at each stage from receipt to shipment of final products in order to prevent product defects.

3. Inventory Control System

An inventory control system is a system that manages the location of items in a warehouse, records of items being moved in and out of the warehouse, etc., in order to maintain an appropriate level of inventory. Inventory control covers not only the inventory of final products but also the inventory of raw materials and parts used in manufacturing.

Therefore, in addition to inventory information in the warehouse, it is necessary to integrate information on material purchases, manufacturing processes, sales, etc. for inventory control.

4. Demand Forecasting System

A demand forecasting system is a system that forecasts demand using a model appropriate for the product based on past performance. It helps to optimize inventory and allocate resources appropriately.

Other Information on Production Control System

Applications of Production Control Systems
In addition to the systems mentioned above, a production control system may also include a purchasing management system, a cost management system, and a sales management system. By integrating all of these systems with the Production Control System, proper management at each stage can be achieved.

Purchasing Management System
A purchasing control system is a system for purchasing materials and other items for products at the production site. In fabless companies that do not have factories, not only materials but also products themselves may be purchased.

Cost Management System
A cost management system is a system that performs management such as cost calculation, analysis, and simulation. The purpose of implementing a cost management system is to understand and analyze costs, maximize profits, and respond to risks through optimal cost management.

Sales Management System
A sales management system is a system by which a company or factory receives orders and controls the flow of money and products. It can be described as a system whose purpose is to sell products and earn money.

What Is a Drive Shaft?

A drive shaft is a mechanical element that transmits power from an actuator, such as a motor, to a driven shaft via a transmission mechanical element.

Transmission elements include gears, timing belts, V-belts, and chains. Drive shafts must be able to rotate with high precision under high loads.

Therefore, they must be stronger and more precise than driven shafts. Drive shafts also require keys and other fastening mechanical elements to connect with the transmission mechanical elements.

Applications of Drive Shafts

Drive shafts are used in a wide variety of industrial machinery. Examples include construction machinery, machine tools, and various types of manufacturing equipment. Drive shafts are used in machines powered by motors to transmit the rotation generated by the motors.

Drive shafts are designed and manufactured arbitrarily according to the environment and machine system in which they are used. However, drive shafts of frequently used shapes are standardized and lined up as products by various FA equipment parts manufacturers.

Principle of Drive Shafts

Drive shafts are usually supported by bearings to ensure rotational accuracy. The bearing must support the rotating shaft of the drive shaft so that it does not shake while receiving the torque that the shaft is subjected to. The shaft part is generally manufactured with h6 or h7 tolerance. 

Drive shafts must be strong enough to withstand high torsional torque and wear resistance. Heat treatment, such as high-frequency quenching, is required for this purpose. Here, carbon steel for machine structural use such as S45C is used, and the surface hardness is quenched to HRC50 or higher.

To improve corrosion resistance, surface treatments such as iron tetroxide coating or electroless nickel plating are applied. For food or clean environments, SUSU304 is used.

Other Information on Drive Shaft

1. Drive Shafts and Driven Shafts

A driven shaft is a shaft that is driven by power transmitted from the drive shaft through mechanical elements such as gears and joints. The driven shaft is the output side, while the drive shaft is the input side, and is set to output the values intended by the designer, such as rotational speed and torque. Therefore, the power transmission mechanism must be selected after calculating the reduction ratio and rotation speed.

The drive shaft is an input shaft to obtain some output and is always used in combination with a driven shaft. If there is no driven shaft, the name drive shaft is not used because the input shaft is not used to obtain an output. A drive shaft is the name used for the shaft that inputs power. However, any shaft that is moved by power transmitted from the drive shaft is called a driven shaft. Therefore, shafts other than the final output shaft may also be called driven shafts, and propulsion shafts and transmission shafts are categorized as driven shafts.

2. Design of Drive Shafts

To design a drive shaft, it is first necessary to determine the magnitude of the input power and the desired output power. The input power is determined by the device used for power, such as an engine or motor, and the reduction ratio and rotational speed are calculated to obtain the output value.

Based on the calculated rotational speed and torque, a material is selected that is strong enough to withstand the load that the drive shaft is subjected to. The most important loads to which the shaft is subjected include rotational moment, torsional load, impact, and frictional force, but the most important are static strength and fatigue strength due to shaft torsion.

Since drive shafts are used in combination with bearings, not only the shaft material but also the diameter and length of the shaft are important. If the diameter of the shaft is too thin, it will not be able to support the torsional load sufficiently, resulting in a rupture. If the length of the shaft is too long, it will be affected by bending moments, leading to shaft deformation. The point where the shaft is supported by the bearing is also important. The distance from the bearing to the end of the shaft should be as short as possible to maintain the strength of the rotating shaft.