The Challenge
Sohbi Kohgei specializes in metal stamping and assembly of metal parts for office automation equipment, household appliances and automobiles. Headquartered in Osaka, Japan, it has been in the Philippines for 20 years and is certified to ISO 9001/14001:2015.
Sohbi Kohgei wanted to convert the paper based manual system and centralize Supply Chain Management across manufacturing units to move towards Digital Manufacturing so that Shop-floor Planning, WIP Traceability, Quality & Maintenance management processes can be automated for real time feeding of relevant data for swift shop floor decision making.
Cantier MES 4.0 Solution
Cantier team connected the factory equipment for automated data collection and implemented Supply Chain Management with focus on Sales, Purchasing & Warehouse operations as well as Shop Floor management with focus on Inventory, Planning, Production, Quality and Maintenance
Cantier worked with Sohbi Kohgei and delivered MRP (Material Requirement Planning) and MPS (Master Production Schedule) solutions that eliminated tedious manual preparation and monitoring of production and machine plan using the traditional Microsoft Excel tool. Cantier MES 4.0 also has enabled responsive and rapid collaboration between process responsibilities across the process chain providing the right information at the right time that allowed Sohbi Kohgei to make data-driven decisions and take immediate action.
Sohbi Kohgei was using SAP B1 for SCM and Financials before Cantier Solution implementation. However after understanding the integrated supply chain functionality of Cantier MES 4.0, Customer has opted to use Cantier Supply Chain functionalities apart from using the MES capabilities.
“As we challenge ourselves to be globally competitive, Sohbi Kohgei is committed to achieving innovative and intelligent manufacturing company in partnership with Cantier”.
Gen De Vera
General Manager
Sohbi Kohgei (Phils.), Inc.
The Results
Completing the 1st and 2nd phase of the Cantier-MES project, Sohbi Kohgei has gained following benefits:
Proper control of the shop floor operation and labor productivity leading to access to on time and robust production data.
Improved and clearer product/WIP traceability
Reduced manufacturing costs in terms of labor reduction and improved methods
More efficient production machine and equipment utilization through controlled equipment maintenance (EMMS)
Enabled deeper analysis in controlling the process through SPC data management.
Daily Production Dashboards improving Productivity with real-time decision making.
Improved Shop Floor Inventory & Operations visibility
Reduced Scrap & Waste, Equipment Down-time, and manufacturing cycle time
According to Gen De Vera General Manager the Cantier MES 4.0 has brought significant efficiency improvement in the process preparation and monitoring.
The way forward
As the next step becoming a smart factory, Sohbi Kohgei is now implementing the 3rd phase of the project – when IIoT data foundation created and MES will be seamlessly integrated. This will further enhance manufacturing operations having the IIOT solution with machine/equipment connectivity and data exchange that will lessen the coding work.
This phase will also enable to perform Real-Time Efficiency Tracking giving access to current production, efficiency, and down time data instantly presented in graphical executive and operational dashboards.
Eventually Sohbi Kohgei can accomplish continuous improvement as well as LEAN and Six Sigma business strategies that brings efficient and clear communication across all departments will be able to identify the top downtime causes that affect Overall Equipment Effectiveness.