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Global Cataler Production Management System
(G-CPS)
This “Global Production Management System” unifies the production systems of the Cataler Group, and aims for optimal MONOZUKURI. It was planned as part of the IT strategy “i - Cataler 2022” (*) to realize Cataler's management strategy. It is responsible for operation standardization, inventory optimization, productivity improvement, labor savings, maximization of profits through globally optimized production, risk management for global production continuity, and contingency planning.
*i-Cataler 2022
An IT strategy project to unify the systems of 8 locations around the world, consolidate information, and carry out optimal MONOZUKURI. It consists of "i-Factory," which aims to maintain and improve quality and productivity through visualization, and "G-CPS," a production management system for globally optimized production.
*i-Factory
A system that aims to improve quality and productivity by utilizing IoT and other technologies to visualize quality and production status in real time at all Cataler Group production sites, and then quickly implement PDCA (Plan-Do-Check-Act) cycles.
Realize mission-critical systems in a cloud environment
After considering the issue from the perspectives of "revenue maximization" and "risk management," without being bound by conventional wisdom, the decision was made to operate the core systems in a cloud environment.
BCP (Business Continuity Plan) for production (supply of products to customers)
By operating the core systems in a cloud environment, there is no need to have G-CPS infrastructure at each location. In addition, not having the data in-house and being freed from data center operations such as data backups and hardware updates not only reduces costs but also reduces the operational burden. Moreover, the ability to switch data centers in a short period of time in the event of unforeseen circumstances led us to conclude that a cloud environment would be superior to an on-premise (*) environment from the standpoint of BCP.
*On-premises
To install equipment (hardware) on the company's premises, and operate the system owned by the company
Role of Cataler Global Production Management System
(G-CPS)
G-CPS is planned to realize the global optimum production of i-Cataler 2020 and is responsible for "operation standardization," "inventory optimization," "productivity improvement," and "labor-saving".
- Operation standardization
- The G-CPS has standardized the tasks of production planning, logistics management, and actual production management, which used to be left largely to the discretion of individuals, so that anyone can perform their tasks at a high level.
It also makes it easier for managers to understand the situation, leading to a higher level of management.
- Inventory optimization
- By being able to see not only the current inventory of products and materials, but also the future inventory, future production plans and material purchase plans can be identified quickly and accurately.
In addition, the visualization of inventory enables us to determine whether we are maintaining appropriate inventory levels.
- Productivity improvement
- Production instructions are not simply based on making what is needed, but are determined based on a complex set of factors, such as availability of materials and setup. Since G-CPS possesses a mechanism to take these factors into account, the person in charge can determine the optimal production sequence based on the information supported by the system, leading to improved productivity.
- Labor-saving (*)
- Until now, wasteful practices such as "managing the same data in multiple locations" and "inputting data to digitize what had been managed on paper" had occurred, but by centralizing data management with G-CPS, the person-hours required for data management have been greatly reduced. In addition, by linking with i-Factory, real-time production status data is obtained directly from the equipment, reducing the person-hours required for data management on site and leading to labor savings.
*Labor-saving: To reduce the number of workers involved in labor by improving work, equipment, and processes.
- Global optimization of production
- A flexible production system that complements each other's capacity at each site is necessary to achieve cost reductions and improved profitability while meeting customer demands. By implementing G-CPS on a global basis, each site will be able to discuss the same data, thereby improving production efficiency.
Future Plans
With the Internet of Things (IoT) gaining attention in recent years, Cataler has begun to collect and utilize data through visualization of human movements, factory production and inventory status, and equipment conditions in order to improve productivity and quality.
In the future, we will realize an organization in which new attempts are actively made globally with G-CPS at the center.