JFE. Abstract: JFE JFE. JUST-Delivery. Re-1

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1 JFE JFE No p Innovation of Production Management in East Japan Works, JFE Steel Establishment of Highly Synchronized Manufacturing Processes Responding to Customers Demand KUROKAWA Katsumi HIYAJI Masaya NAGAOKA Yohei JFE JFE IT JFE JFE JUST-Delivery Re-1 JUST-Delivery Abstract: In November 1999, JFE Steel East Japan Works launched a project called, JUST-Delivery, which has innovated production management in Chiba District and has obtained successful results, such as highly synchronized manufacturing processes, short lead-time production, and reduction of excess inventory, by reconstructing production management s and strengthening production capabilities. Upon the consolidation of Kawasaki Steel and NKK in April 2003, JFE Steel East Japan Works reorganized the production control departments of Chiba and Keihin Districts into the one department. By the new project, Re-1, which applied the solutions developed by JUST-Delivery, to the production control s in Keihin District, the foundation of production control s for unifi cation of production management at Chiba and Keihin Districts has been built. 1. JFE JUST- Delivery NKK JFE 1 35

2 Fig Fig mm mm 1 2 Central entry Production design Hot strip Operational Fig. 1 Cold strip Stainless steel Shipment Production management s in Chiba District Fig. 2 Thickness conbination constraint of cold strip t 1 t 2 Function Production design allocation Process control Maximum difference between t 1 and t mm 0.15 mm 0.05 mm Inconsistency of constarints exists among production control functions. Sample inconsistency of production control constraints JFE No

3 DB Fig ksteps DB DB DB 2 24 Fig. 4 2 CPU 3 GUI graphical user interface RDB relational database ODBC open database connectivity 3 Web Integrated central control Hot strip Operational Fig. 3 entry Production design Production planing Cold strip Stainless steel Scheduling Hot strip Cold strip Stainless steel Shipment Integration of central s in Chiba District Usual case Suspension case No. 1 CPU No. 2 CPU No. 1 CPU No. 2 CPU Integrated central Central Operational Test Disk unit Fig. 4 Integrated central Test Central Operational Disk unit Suspended Schematic illustration of non-stop s 37 JFE No

4 ksteps Table Conclusion Table Number of constraints investigated entry Production design Function allocation Process control Total No change Deregulation Relaxation Intensification Total DB Fig. 5 Conventional Mon. Tue. Wed. Thu. Fri. Sat. Sun. Mon. Tue. Wed. Thu. assignment and Production design Lot organization and Scheduling for steel making Introduction of planning 1st 2nd 3rd 4th Fig. 5 Production term for steelmaking 1 week Planning lead time Shortening 4 days Planning frequency Once a week Every day Effect of shortening planning lead-time JFE No

5 4 1 2 TOC theory of constraints DB DB Production management in Keihin District and article management Production control Production management in Keihin District Re-1 5. Reorganization Production management in Chiba District Integrated central and article management JUST-Delivery Operational Production control Integrated production management in East Japan Works Production management in Chiba District Production control Production control Fig. 6 and article management Application of JUST-Delivery to Keihin District JFE JUST-Delivery Re-1 1 JFE vol p. 8 2 vol. 20 no p vol. 20 no p. 95 JUST-Delivery Re-1 Fig JFE No