We're looking for a way to bring the assembly process back to Japan, without knowing the overseas market rates.
We received an inquiry from a company that wanted to outsource only the assembly process to a domestic contractor in Japan because export costs from overseas had increased due to tariffs.
The client consulted us because they didn't know how much the overseas market prices differed from the domestic market prices, and they weren't sure if they could assemble the product in the same way if they were given the drawings and instructions as they were.
Even if you provide the drawings exactly as they are, it doesn't guarantee that they will be assembled with the same precision.
Drawings and procedures created for overseas factories are often written based on the assumption of local work methods.
Simply by looking at the documentation, it's impossible to determine whether a Japanese assembly partner can assemble the product using the same process and precision.
Because the supplier of parts changed and the workers' familiarity with the procedures also changed, it was necessary to check whether the drawings and procedure manuals contained sufficient information.
Adjustments made by fitting the parts to the actual object are often not documented in drawings or procedure manuals.
When outsourcing only parts supply and assembly, the way processes are divided and inspection standards are written can vary from factory to factory.
Some factories record an entire process together, while others break it down into smaller steps, making it difficult to standardize the format.
When adjustments are made on-site based on on-the-spot judgment, these adjustments are often not recorded numerically in drawings or procedure manuals.
If a worker makes adjustments based on experience, such as "I'll trim this a little to make it fit," simply providing a document will make it difficult to reproduce the same result.
First, check to what extent the tolerances and inspection standards are written down.
For this consultation, we had several engineers compare the drawings and procedure manuals.
The following points were checked at each stage of the process:
- To what extent are tolerances clearly defined as numerical values?
- Are the inspection standards written in a way that anyone can understand?
- Where are the parts that are being adjusted by trial and error?
Based on this confirmation, we separated the processes that could be transferred domestically using only document information from those that required on-site adjustments.
We identified the processes and restructured them into units that would be easier for the Japanese side to assemble.
We reviewed the drawings and procedures for each step of the process, and proceeded while confirming any unclear points with the engineers.
Instead of simply using the same process divisions as in the overseas factory, we considered a method to reorganize the processes into units that would be easier to assemble in Japan.
For areas where adjustments were previously made by trial and error, we also considered methods such as creating new jigs or rewriting inspection standards as numerical values.
When bringing overseas production back to Japan, the focus remains the same.
In situations like this, where we're shifting overseas production back to domestic assembly, or when searching for a new outsourcing partner, I believe it's useful to check how thoroughly drawings and procedures are documented.
When a factory changes, the way parts are received and the workers' familiarity with the process also changes. Separating information written in documents from on-site judgment makes it easier to decide whether to change suppliers.
From dividing the process to selecting the assembly site.
MACHICOCO collaborates with engineers in Higashi-Osaka to handle project management, bringing products to life.
We don't own large-scale facilities in-house. Instead, we work with engineers to review drawings and procedures, break down processes, and select assembly locations. We are involved from the prototyping stage and handle the process planning for mass production.
Even without drawings, you can consult with us if you have the actual product and can explain the procedure.
To expedite the process, please send us the following information when you come for a consultation.
- The drawings and procedures currently in use
- Photos and videos showing the assembly procedure.
- Actual sample
- Expected quantity and desired timing
Drawings are not required.
Even before the assembly method is finalized, we can consider manufacturing methods while looking at drawings and actual samples.
