NGK Spark Plug Co., Ltd./Niterra Co., Ltd. is a company with the world’s largest share of the market for NGK spark plugs, automotive oxygen sensors, and ceramic cutting tools. We asked them about the background and effects of using Asprova to reform their global production process in sensor manufacturing.
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??????????Asprova????????????????????????????????????????
It was first introduced in domestic factories in 2010, and then an “overseas expansion model” was developed based on the Japanese utilization model, and it was deployed to factories in China in 2013 and Thailand the following year in 2014.?As of 2024, over 20 Asprova systems will be installed across the group.
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2010??????????????????????????????????????????????2013????????2014???????????????
2024????????????20???Asprova??????????
What issues did you face before introducing Asprova?
Asprova?????????????
Previously, production planning was done using Excel macros. However, Excel macros had the following problems: 1) “The calculation speed is not fast enough,” 2) “When there is a large increase or change in orders, it takes time and effort to make corrections,” and 3) “The planning cycle is limited to monthly units, and the planning mesh is limited to date and time units.”
To solve this problem, we decided to introduce a full-scale production scheduler. This introduction was also part of a “production process reform” to improve production management across the entire Sensor Division.
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Why did you choose Asprova?
Asprova??????????????
After comparing several schedulers, they decided to adopt Asprova because it was superior in the following points: 1) “ability to detail plans down to the second,” 2) “high market share,” 3) “many integration track record with the ERP (SAP ) ” and 4) “multilingual support makes it possible to deploy to overseas bases.”
?????????????????????????Asprova??1). ????????????????2).???????????3).?ERP?SAP ECC????????????4). ???????????????????????????????????????????
What are the benefits of implementing Asprova?
Asprova??????????????
Benefit 1. “Shortening planning cycles and reducing inventory”
Benefit 2. “Finding potential points for improvement”
Benefit 3. “Smaller lots for transporting work-in-progress products between processes”
Benefit 4. “Change in employees’ awareness of production planning”
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Why did you aim to expand Asprova to three countries from the start?
Asprova??????3?????????????????????
The production process reform using Asprova began by establishing a model case for using Asprova in Japan, and then laterally expanding it to production bases around the world.
The main aims of unifying the production management methods at each country’s bases are: 1) “It will be easier to spread improvement methods established at a factory in one country to factories in other countries,” 2) “Production evaluation indicators (KPIs) will be unified globally,” and 3) “As standards will be clear globally, both those evaluating and those being evaluated will be more convinced.”
However, when introducing Asprova to China and Thailand, differences in equipment, background, and culture presented difficulties.
The main aims of unifying the production management methods at each country’s bases are: 1) “It will be easier to spread improvement methods established at a factory in one country to factories in other countries,” 2) “Production evaluation indicators (KPIs) will be unified globally,” and 3) “As standards will be clear globally, both those evaluating and those being evaluated will be more convinced.”
However, when introducing Asprova to China and Thailand, differences in equipment, background, and culture presented difficulties.
Asprova??????????????????Asprova?????????????????????????????????????
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??????????Asprova??????????????????????????????
What specific difficulties did you encounter?
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First of all, the local employees at the Chinese factory did not have sufficient knowledge and experience of planned production, so it took time to get them to understand “why production planning is necessary in the first place.” In addition, extensive support from the domestic headquarters was required until optimal operations were achieved. However, the Chinese factory had some favorable factors, such as “there were many local employees who could speak Japanese,” and “Asprova was introduced at the same time as the new factory was established. The business process was also built from scratch, so there were no changes.” Therefore, it was possible to transplant the domestic model case relatively smoothly.
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Next, for the Thai factory, because Asprova was introduced to an already operating factory, changes were made to the system and operations, and it took some time for them to get used to it. We had production planners come to Japan for training, but the language barrier may have made it a big burden. However, the Thai factory had a high understanding of the necessity of production planning from the start, and there were many veterans, so once they got used to the new methods, they were able to achieve results such as shortening lead times in a short period of time.
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Is there any advice you can give to people who are currently considering introducing Asprova?
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Asprova is a system that “if you install it and use it, you will definitely see results.” However, before fully implementing it, you will be able to see results sooner if you explain the basic concepts to your factory staff, such as “what is the purpose of production management in the first place?” and “why do you need to use a production scheduler?”
Asprova??????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????????
