Case Studies

Contec built the D-CORE manufacturing execution system for Nakamura Choukou’s new silicon slicing factory in eight months. The plant now runs at more than 10 times its original volume without operational problems.

Overview

Nakamura Choukou Co., Ltd. makes DINA-PRISM, a diamond saw wire used to slice electronic materials for solar panels and LEDs, and uses it to slice silicon ingots. It also makes precision parts and jigs from ultra-hard alloys and polycrystalline diamond. Its diamond wire technology won the 4th Japan Grand Prize METI Minister’s Award in 2012.

Challenge

Slicing ingots for a major electronics maker required production traceability and operation-rate tracking that the existing system could not handle, so staff relied on their own tools and forms, which caused errors. To support growth to one million units a month, the company needed a new system in time for a new factory: eight months instead of the usual one to two years.

Solution

Contec built the D-CORE system around an MES, drawing on its experience with slicing systems and designing for volumes 20 to 30 times actual production. A team project structure shortened development, and Contec’s own software met requirements that package customization could not.

Yutaka Watanabe, Section Chief of the Management Division, said the company had no experience with mass production and worried about building a system from scratch, so it had Contec propose a solution from the estimate stage and support it during and after construction.

Results

• Integrated product and quality data across production, receiving and shipping reduced workload and improved quality
• Less indirect work, higher production efficiency and lower costs
• Real-time process management with handheld terminals and barcodes

Watanabe reports that operations now run at more than 10 times the original volume without problems, with new functions added since.

Contec products used

• D-CORE MES

Originally published by Contec Co., Ltd. at contec.com.