On Site Observations:

1.   Non-Judgment, Non-Blaming mindset is the basic approach. A forgiving workshop provides motivation to the workers.
2.    Products’ quality is observed by the production operators. There is no QC department.
3.    SOPs are digitally explained. Operators use 3D demonstrations on a computer to learn the process. Special stations are provided to check quality before they move on to the next process.
4.    Almost 70 people of production operators are housewives of university students. They were trained for three weeks before they actually do any job.
5.    25% of employees are R&D department personnel.
6.    1-2 % customer return from the new products that need to make an improvement, and Zero Defect for regular products. We believe defects are rooted in engineering and developing the product, and human nature is good and not bad to make a defected product on purpose.
7.     80% of the company products are exported, and their selling price is higher than private automobiles.
8.    All conveyer lines were removed almost ten years ago, and products are made by digital cell production.
9.    Top-Down concept directed 6 years ago. 3D-CAD is installed in the R&D department. Then determined that 3-D CAD should be utilized throughout all other departments.
10.    The Concept of Digital Factory is to Integrate CAD(Design), CAM(Modeling), CAP(Production), CAT(Testing), and CAE(Engineering) by DIGITAL DATA.
11.    Line production is a NARROW road, while the Digital Cell Production is a WIDE road that provides diversified production.
The Merits of 1 by 1 Production are;
a) Process Change is unnecessary.
b) The action at the time of a production stop is easy.
c) Two or more products can be produced simultaneously.
d) Change of factory layout is easy.
e) Consideration of line balance is unnecessary.
f) Feedback from a mistake or faulty parts are faster.
The Demerits of 1 by 1 Production are;
a) Skillful workers required.
b) Differences in quantity can be large.
c) Inspection equipment is needed by each of the workers.
The Data Collection Function; Product name and serial#, Worker name, Work start time, Working hours for every process, Inspection results (Number of times NG), Nonconforming, Repair, Time in which the product is completed, and the Released time.
Analyzing these Data leads to; Work efficiency, Frequency of a work mistake, Analysis of inspection data, and Nonconformity ratio.
Improvement of Quality, Costs, and Delivery would be the result from DIGITAL FACTORY.
Reducing assembly time. Standard time was 92 minutes. Operator A spent 125 minutes when he started to produce the product and reduced assembly time to 80 minutes after making 90 of the same product. Operator B spent only 67 minutes for the first product and reduced the time to 55 minutes after making 95 units.
Improvement in Quality; Almost all human errors can be spotted, warned and recorded by PC. A failsafe method is established in the workshop.
Operators go to the warehouse and pick the parts for the products they are planned to produce. They use a special digital device to pick up the right part from the shelves.
Set Supply System aided by computer with no mistakes.
The First Key of Success is; Powerful Top-Down concept developed by the Production Department.
The Second Key of Success is; Face challenges without the fear of failure. Reducing Assembly Time, Improvement of Quality, Paperless Production, Reducing Space, Reducing Loss Time of Mastering New Work, Effective Use of Data, Early Start of Production Preparation, and The Development to Built-To-Order are the outcome of the effects of Digital Cell Production.
The Third Key of Success is; Collaboration with R&D Department. In some new models, 80% of the old parts planned to be used in new versions of the products.
The Fourth Key of Success; Tenacious Action. If we act until an effect shows up, an effect will surely show up!
Conclusion: Digital Data is an indispensable tool for winning. By spreading 3D-CAD powerfully, a Manufacturing industry will be revived.