{"id":32652,"date":"2026-09-02T07:08:23","date_gmt":"2026-09-01T22:08:23","guid":{"rendered":"https:\/\/www.machicoco.co.jp\/archives\/32652"},"modified":"2026-10-04T20:37:46","modified_gmt":"2026-10-04T11:37:46","slug":"manufacturing-smtc2i0h510","status":"publish","type":"post","link":"https:\/\/www.machicoco.co.jp\/en\/archives\/32652","title":{"rendered":"How to restructure processes when estimates don&#039;t match due to switching from overseas manufacturing to domestic production."},"content":{"rendered":"<!-- lm-skin -->\n<style id=\"mc-article\">\n\/* \u8aad\u307f\u3084\u3059\u3055\u3060\u3051\u6574\u3048\u308b\u3002\u8272\u306f\u8db3\u3055\u306a\u3044\uff08\u7dda\u306f\u898b\u51fa\u3057\u3068\u540c\u3058\u8272\uff1dcurrentColor\uff09 *\/\n.elementor-widget-theme-post-content{max-width:800px;margin-inline:auto}\n.elementor-widget-theme-post-content p{font-size:17px;line-height:1.95;margin:0 0 1.15em}\n.elementor-widget-theme-post-content li{font-size:17px;line-height:1.95;margin-bottom:.35em}\n.elementor-widget-theme-post-content h2{font-weight:800;line-height:1.55;margin:56px 0 18px;padding-left:15px;\n  border-left:7px solid currentColor}\n.elementor-widget-theme-post-content h3{font-weight:700;line-height:1.6;margin:34px 0 10px}\n.elementor-widget-theme-post-content figure{margin:30px 0}\n.elementor-widget-theme-post-content figure img{width:100%;height:auto;border-radius:14px;box-shadow:0 12px 28px rgba(0,0,0,.12)}\n.elementor-widget-theme-post-content figcaption{font-size:.82rem;opacity:.7;margin-top:10px;text-align:center}\n.elementor-widget-theme-post-content img{max-width:100%;height:auto}\n\n\n\n@media(max-width:600px){.elementor-widget-theme-post-content p,.elementor-widget-theme-post-content li{font-size:16px}.elementor-widget-theme-post-content h2{margin-top:44px}}\n<\/style>\n<!-- \/lm-skin -->\n\n\n\n<h2>&quot;Can we request this domestically using the current procedure manual?&quot;<\/h2>\n\n\n<p>Products that were manufactured in China<br>\nWe received an inquiry from someone who wanted to switch to domestic manufacturing due to the impact of tariff friction.<\/p>\n<p>There is a manual created for the local assembly plant.<br>\nIs it okay to simply request quotes from local factories in Japan based on this information?<br>\nThey were worried about that.<\/p>\n\n\n<h2>If you get an estimate following the procedure manual, the amount won&#039;t match.<\/h2>\n\n\n<p>Instruction manuals for overseas markets specify in detail the division of tasks and the order of processing.<br>\nIf you commission a local factory in Japan to perform the work in this exact order and sequence,<br>\nYou may receive a quote that is higher than you expected.<br>\nThe process itself is not wrong.<\/p>\n<p>The reason the amounts don&#039;t match is not because of the contents of the procedure manual,<br>\nThe problem lies in the way the factory is used, which is the premise of the instruction manual.<\/p>\n\n\n<h2>The division of the process is determined according to how the equipment is used.<\/h2>\n\n\n<p>Equipment usage, process divisions, and inspection standards often differ between overseas and domestic markets.<br>\nEven with the same product, the decision of which processes to consolidate into a single line and where to divide the processes depends on the specific product.<br>\nIt varies depending on the equipment configuration of each factory.<br>\nProcedure manuals for overseas markets are tailored to the equipment and personnel allocation of the local factory.<\/p>\n<p>If this process is simply carried over to a local factory in Japan,<br>\nNormally, tasks that can be processed in one factory can be handled together.<br>\nThis often leads to having to request the work to be divided into multiple stages.<br>\nWhen the process is divided into separate steps, setup changes, inspections, and transportation are required each time.<\/p>\n<p>Because domestic small factories often provide estimates for each process,<br>\nThe more steps involved, the more likely costs are to increase.<\/p>\n\n\n<h2>We&#039;ll see how much of the work is entrusted to one company and where it&#039;s divided.<\/h2>\n\n\n<p>When putting together an estimate,<br>\nThe first thing we look at is which processes can be consolidated and entrusted to a single factory.<br>\nIf a factory is skilled in both processing and assembly, it&#039;s better to entrust them with multiple processes together.<br>\nThis reduces the number of steps required and makes it easier to keep costs down.<\/p>\n<p>Another thing we&#039;re looking at is the scope of outsourcing only the assembly while supplying the parts,<br>\nThis is about defining the scope of work, including material procurement.<br>\nThe more advantageous option will vary from project to project, depending on the supplier and cost of the materials.<\/p>\n\n\n<ul>\n<li>Is the factory capable of handling everything from processing to assembly in-house?<\/li>\n<li>If parts are supplied, how much will the procurement and inventory effort increase for the supplying party?<\/li>\n<li>If the process is divided, how much will the number of transportation and inspections increase?<\/li>\n<\/ul>\n\n<h2>An example of rearranging the process and distributing it among multiple local factories.<\/h2>\n\n\n<p>Instead of simply following the procedures written in overseas manuals,<br>\nWe have considered a method of rearranging processes to suit the strengths of each of the multiple small factories.<br>\nIn one project, the parts were supplied and only the assembly was outsourced to one company.<br>\nWe compared different approaches, where the entire process, from material procurement to processing and assembly, is outsourced to a single company.<\/p>\n<p>Because different factories specialized in different parts, we used a combination of supplying parts directly and placing bulk orders for each process.<br>\nWe were able to reduce the number of setup changes required throughout the entire process.<br>\nIf you keep the order of the steps written in the procedure manual the same, and only divide the factories that are responsible for each step,<br>\nThis duplication of procedures is difficult to eliminate.<\/p>\n<p>The entire process structure needs to be reviewed to match the configuration of domestic factories.<\/p>\n\n\n<h2>Instruction manuals are not meant to be copied, but rather used as materials for rearranging.<\/h2>\n\n\n<p>The approach to adapting overseas-specification procedure manuals for domestic use is as follows:<br>\nThis is not limited to changes in tariff policies like this one,<br>\nThis can be used for all aspects of outsourcing manufacturing, including shifting production from overseas to domestically.<\/p>\n<p>Instead of simply accepting the steps written in the instruction manual as the correct procedure,<br>\nReframe the process as the necessary steps to produce that product,<br>\nIt&#039;s best to think in terms of rearranging things to match the strengths of the factory you&#039;re in charge of.<\/p>\n\n\n<h2>MACHICOCO handles everything from process planning to selecting the processing location.<\/h2>\n\n\n<p>MACHICOCO is a company based in Higashi-Osaka.<br>\nWe manage product development projects in collaboration with engineers at local factories.<br>\nWe don&#039;t own large-scale facilities in-house; instead, we collaborate with engineers specializing in each stage of the process.<\/p>\n<p>In consultations like this one, where manufacturing is shifting from overseas to domestic production, the question is how to rearrange the processes in the procedure manual.<br>\nShould we supply the parts ourselves or place a bulk order?<br>\nWe&#039;ll start by considering how to define the boundaries of which factory will be responsible for what tasks.<br>\nWe can handle everything from design verification and prototyping to subsequent considerations for mass production.<\/p>\n\n\n<h2>When seeking advice, having the current procedure manual and the actual item in hand will expedite the process.<\/h2>\n\n\n<p>It would be helpful if you could send it when you come for a consultation.<\/p>\n\n\n<ul>\n<li>The overseas instruction manual you are currently using (if any)<\/li>\n<li>Product photos or actual item<\/li>\n<li>Drawings showing dimensions (if available)<\/li>\n<li>Product usage and operating environment<\/li>\n<li>Expected quantity<\/li>\n<\/ul>\n\n\n<p>Drawings are not required.<br>\nEven before the processing method is decided, we can consider manufacturing methods while looking at drawings and actual samples.<\/p>\n\n\n<!-- \u56f3\u89e3\u6848\uff1a\u6d77\u5916\u5411\u3051\u624b\u9806\u66f8\u306e\u5de5\u7a0b\u30d5\u30ed\u30fc\u3068\u3001\u56fd\u5185\u5207\u308a\u66ff\u3048\u5f8c\u306b\u5de5\u7a0b\u3092\u7d44\u307f\u66ff\u3048\u305f\u4f8b\u3092\u4e26\u3079\u305f\u6bd4\u8f03\u56f3\u3002\u4e0a\u6bb5\u306b\u300c\u73fe\u5730\u5de5\u5834\u5411\u3051\u624b\u9806\u66f8\u306e\u5de5\u7a0b(A\u5de5\u7a0b\u2192B\u5de5\u7a0b\u2192C\u5de5\u7a0b\u2192\u691c\u67fb)\u300d\u3001\u4e0b\u6bb5\u306b\u300c\u56fd\u5185\u306e\u8907\u6570\u753a\u5de5\u5834\u306b\u7d44\u307f\u66ff\u3048\u305f\u5de5\u7a0b(\u7532\u5de5\u5834\u3067A+B\u5de5\u7a0b\u3092\u307e\u3068\u3081\u308b\u2192\u4e59\u5de5\u5834\u3067C\u5de5\u7a0b+\u691c\u67fb)\u300d\u3092\u77e2\u5370\u3067\u793a\u3057\u3001\u6bb5\u53d6\u308a\u66ff\u3048\u306e\u56de\u6570\u304c\u3069\u3046\u5909\u308f\u308b\u304b\u304c\u8996\u899a\u7684\u306b\u5206\u304b\u308b\u3088\u3046\u306b\u3059\u308b\u3002 -->\n\n<p><a href=\"https:\/\/www.machicoco.co.jp\/en\/manufacturing\/\">Even at the stage where the processing method has not yet been decided,<br>\nYou can consider manufacturing methods while looking at drawings and actual samples.<br>\n<\/a><\/p>","protected":false},"excerpt":{"rendered":"<p>\u300c\u4eca\u306e\u624b\u9806\u66f8\u306e\u307e\u307e\u3001\u56fd\u5185\u3067\u983c\u3081\u307e\u3059\u304b\u300d\u3068\u3044\u3046\u76f8\u8ac7 \u4e2d\u56fd\u3067\u88fd\u9020\u3057\u3066\u3044\u305f\u88fd\u54c1\u3092\u3001 \u95a2\u7a0e\u6469\u64e6\u306e\u5f71\u97ff\u3067\u56fd\u5185\u88fd\u9020\u306b\u5207\u308a\u66ff [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":32850,"comment_status":"closed","ping_status":"","sticky":false,"template":"","format":"standard","meta":{"_acf_changed":false,"_jetpack_memberships_contains_paid_content":false,"footnotes":""},"categories":[171],"tags":[],"class_list":["post-32652","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-column"],"acf":[],"aioseo_notices":[],"jetpack_featured_media_url":"https:\/\/i0.wp.com\/www.machicoco.co.jp\/wp-content\/uploads\/2026\/09\/1790248486391-E6B5B7E5A496E8A3BDE980A0E3818BE38289E59BBDE58685E58887E3828AE69BBFE38188E381A7E8A68BE7A98DE38282E3828AE3818C.png?fit=2560%2C1340&ssl=1","jetpack_sharing_enabled":true,"_links":{"self":[{"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/posts\/32652","targetHints":{"allow":["GET"]}}],"collection":[{"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/posts"}],"about":[{"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/types\/post"}],"author":[{"embeddable":true,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/users\/1"}],"replies":[{"embeddable":true,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/comments?post=32652"}],"version-history":[{"count":3,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/posts\/32652\/revisions"}],"predecessor-version":[{"id":33429,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/posts\/32652\/revisions\/33429"}],"wp:featuredmedia":[{"embeddable":true,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/media\/32850"}],"wp:attachment":[{"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/media?parent=32652"}],"wp:term":[{"taxonomy":"category","embeddable":true,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/categories?post=32652"},{"taxonomy":"post_tag","embeddable":true,"href":"https:\/\/www.machicoco.co.jp\/en\/wp-json\/wp\/v2\/tags?post=32652"}],"curies":[{"name":"wp","href":"https:\/\/api.w.org\/{rel}","templated":true}]}}