Abstract
As the globalization of various industries continues, the achievement of more sophisticated functions, improved safety, and lower costs is required, particularly in the automobile industry, which is a representative manufacturing industry that has been the driving force behind the economic growth of Japan. Under such circumstances, there is much hope for the reduction of cost from defective work, achieved by implementing preventive measures for the recurrence of defects as a means for improving earnings. Although every company has been conducting various activities intended to reduce costs, not much progress has been made with the reduction of defects for molds because of various reasons. The cost of defective work associated with a defective mold, however, comprises 3% to 10% of the earnings, and is therefore, considered an important management issue. This paper proposes a highly accurate method for collecting information in real time, and it is intended for the collection of defect-information. This paper also proposes a method for deriving trend values by conducting comparative analyses using the matrix method on results reflecting indicated matters selected from the perspective of mold requirements (requirements of product design for the purpose of mold manufacture intended at creating simple mold structures; this makes it possible to create molds that can be manufactured with shortened manufacturing period, and it is used to process work in a short period of time and still satisfy quality requirements while holding down the cost) on product design and the mold trial results. The information is systematically converted into know-how based on this method, to contribute towards the prevention of recurring defects. It is applied to the external appearance components of audio panels to verify its effectiveness. It is possible to select indicated matters pertaining to slides of mold structures and the effectiveness is verified as a result.
