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Nikkei Monozukuri

November 2004 Issue

P. 6 Mastering Manufacturing

Mitutoyo Corporation’s “Vernier Calipers:” The quick improvement of productivity makes it possible for the company to continue with its analogue “manufacturing”

P. 15 This Month’s Challenge

A small airplane can be automatically controlled

P. 17 World News

At last, I can get my $10 million, etc.

P. 38 Cover Story

Trouble Can Come to You

P. 40 Voices from Manufacturing Sites: The amount of trouble can be reduced, no matter how serious the environment

P. 46 Case Examples (1): A cost reduction leads to design errors. Since the number of complaints is small, measures for solving the problems cannot be taken.

P. 48 Case Examples (2): A mistake in a drawing was discovered in a mass production line. Common rules were added to the designing and inspection processes.

P. 50 Case Examples (3): Customers do not always use products in the way they are intended. Their unreasonable requests should be rejected in advance.

P. 52 Case Examples (4): There were errors in inspections under certain circumstances. An expansion of functions should be employed to cope with the increasing complexity of the products.

P. 54 Case Examples (5): Because specifications had not been properly formulated, adjustments had to be made many times. What is needed is a draft specification for learning what customers want.

P. 56 Case Examples (6): Three defects appeared at the same time in a product after it was launched into a new market. An on-the-job training system was introduced in order to learn from customer complaints.

P. 58 Case Examples (7): Though not included in the contract, a heavy loss was incurred due to the demand for cost reductions. The initiative was taken back by offering technologies that other companies cannot match.

P. 61 Kaizen in China

Part 8: It has been discovered that workers sleep on the night shift. Personnel management and its operation plan should be stringently checked.

Reports

P. 66 A 3-D acceleration sensor is on the verge of becoming a smash hit. The target is to incorporate it into cell phones and mobile devices as standard equipment.

P. 68 IC tags become more user-friendly at manufacturing sites

P. 70 A report on the CEATEC Japan 2004 technology tradeshow highlights competition over the picture quality of flat-screen TVs

P. 74 Dassault Systems enhance collaboration functions using R14

P. 76 Aichi Machine Industry begins operation of a new engine production line

P. 78 A new qualification system is established for verifying the appropriateness of security measures

P. 80 Ten companies have released their reports on intellectual property

P. 82 Toyota Motor promotes corporate reform by enhancing the development of human resources and increasing the speed of change in car models

P. 83 Okamoto Machine Tool Works develops a grinding machine that makes hyperplane processing possible by adopting a new hydrostatic bearing technology

P. 84 Nichia Corporation releases a headlight for vehicles that is equipped with a white LED lamp whose luminous efficiency is 50 lm/W

P. 85 Hitachi and Senju Metal Industry improve heat resistance to over 260°C by using lead-free solder

Features

P. 93 The secret behind the efficient manufacturing of an ordinary digital single-lens reflex camera is the balancing of low cost and high performance

P. 107 Scooters and rail cars grow “smarter” through the adoption of hybrid technology

P. 117 ISO9000 has become a mere facade

P. 125 Discussions are ongoing regarding the latest trends in the Japanese models of PLM and technological innovation

P. 148 Search for Manufacturing

This month’s research theme: How far does it extend, this new trend of Japanese manufacturers returning to Japan?

P. 173 Accident Investigation

Are wind and fire-extinguishing agent responsible for two fires that broke out at Idemitsu Kosan’s oil refinery?

P. 176 Understanding SCM from the Basics Up

Part 2: Visualizing the Processes

P. 180 The Method

QFD (Quality Function Deployment)
Part 1: Methodology for Organizing Information

P. 184 The Master

Part 6: Returning from a Minefield

P. 257 Documentary

Kenwood’s Production Innovation (Part 3): I’m glad to see how far our employees have managed to push reform in such a short period of time

P. 262 Studying Hot Products

Digital single-lens reflex cameras: Can their user base be expanded by riding the wave of the IT revolution?

P. 264 Interview

Dr. Yotaro Hatamura: Professor Kogakuin University

P. 152 Interesting News

P. 163 New Products

P. 188 Plaza

P. 191 Calendar