セル生産システムの課題 : 自律化と統合化の視点より
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概要
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Japanese production systems seem to be developed in two dimensions, that is, autonomy and integration. Through increasing autonomy and integration, they have improved their adaptability and productivity. In 1990's and thereafter, cell production systems have been widely and increasingly introduced in Japanese electric, electronics, communication, computer, control machinery, and other industries. I proposed the definition of cell production systems as "production systems composed of several cells, each of which is a set of equipments and operators having some degree of freedom and autonomic ability, covering some part of the manufacturing process." As for autonomy, the main issues to be discussed here are: production pace control, quality control, operator training methods, and operator skill management under the circumstance of decreasing ratio of regular workers. As for integration, especially for the parallel production lines configuration, there are issues of equipment costs, material distribution, declining specialization, and decreasing adaptability. The integration issues also include: intra and inter cell management, as well as relations with each cell to the whole system. Finally, measures to solve these issues of autonomy and integration are discussed, based on the following three types of cell production systems. (1) The lean type of cell production systems For autonomy dimension, managers need to train operators to keep standard pace and quality, support them by information systems, and let them devote themselves to KAIZEN to solve productivity issues. For integration dimension, managers need to connect cells with suppliers for shorter lead time in the whole supply chain. (2) The skill type of cell production systems For both autonomy and integration issues, managers need to train operators for mastering higher level skills, or varied abilities to cover longer process steps. Managers must be able to properly evaluate operators' skills and abilities. (3) The business type of cell production systems For much higher levels of autonomy and integration, managers need to educate employees to master not only operational skills, but also technology, research and development, and management. Cell operators must be supported to smoothly coordinate relations among cells, and between cells and the whole systems.
- 2009-03-10