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FLEXSCHE User Implementation Case Studies

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FLEXSCHE User Implementation Case Studies

User Implementation Case Studies PDF

Since March 2002, FLEXSCHE has been utilized by a wide variety of manufacturing industries.
This is just one example, but please take a look below.

Implementation Achievements

As of September 2024 (from March 2002)
Number of Licenses Implemented 1,533 licenses
Number of Companies Implemented 637 companies
(Excludes development licenses, research and educational licenses, FLEXSCHE Viewer, etc.)

Examples of Industries Implemented

ChemistryFoodBeveragesPrepared FoodsPharmaceuticalsCosmeticsInkCeramicsPulp and PaperPrintingTextilesPaper ProcessingFilm ProcessingSteelNon-Ferrous MetalsBuilding MaterialsSubstrate ManufacturingSubstrate AssemblyElectronic ComponentsElectronic equipmentElectric WiresMetal ProcessingMoldsEquipment and MachineryPress ProcessingMachine ToolsForgingInformation EquipmentMolding ProcessingJig ManufacturingFabric ProcessingChemical ProductsAutomotive PartsConstruction PartsPrecision EquipmentAutomobilesHeavy IndustryShipbuildingSemiconductors　and more

User Case Study List

Tsukiboshi Manufacturing Co., Ltd.

Produced in May 2024

Industry
Automotive Parts
For Motorcycles
Parts
Target Product Types
Metal Parts (Cold Forging)
Location of Implementation
Ishikawa Prefecture
ChallengesChallenges Before Implementation
  • Improvement of Process Due Date Compliance Rate
ReasonReason for Choosing FLEXSCHE
  • Only FLEXSCHE could accommodate our unique process management method
FeaturesFeatures of the Constructed System
  • Promoted company-wide implementation with the aim of realizing "Managed Manufacturing"
EffectsEffects of Implementing FLEXSCHE
  • Significantly improved production plan compliance rate by over 35%, making plan adjustments easier
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Further utilizing FLEXSCHE, aiming for smart factory transformation

Akasaka Diesels Limited

Produced in July 2022

Industry
Marine Equipment
Target Product Types
For Ships
Diesel Engines
Location of Implementation
Shizuoka Prefecture
ChallengesChallenges Before Implementation
  • Efficiency was required due to shorter delivery times for orders and the complexity of customer demands
ReasonReason for Choosing FLEXSCHE
  • Realized "This is it" after seeing the prototype of FLEXSCHE
FeaturesFeatures of the Constructed System
  • By visualizing operations through implementation, we identified latent issues and worked on business improvements
EffectsEffects of Implementing FLEXSCHE
  • Planning know-how was condensed into FLEXSCHE, eliminating the personalization of planning tasks

Okura Industrial Co., Ltd.

Produced in September 2019

Industry
Chemistry
Target Product Types
Synthetic Resin Film
Location of Implementation
Kagawa Prefecture and 9 other locations
ChallengesChallenges Before Implementation
  • The diversification of production items progressed, posing challenges for planning with conventional schedulers
ReasonReason for Choosing FLEXSCHE
  • Covered all functions of conventional schedulers, excelling in expandability, flexibility, and operability
FeaturesFeatures of the Constructed System
  • Achieved sequential implementation in 7 factories with different products over 8 months
  • Implemented the standard feature "Operation Sequence Chart" based on requests, making it even more user-friendly
EffectsEffects of Implementing FLEXSCHE
  • Factory operations were smoothened through visualization of the site
  • Planning tasks were streamlined by up to 50%, reducing personalization and easing the burden on staff
  • Stable operation for over 10 years, becoming an "indispensable" presence

Nakahara Co., Ltd.

Produced in March 2018

Industry
Sheet Metal Processing
Target Product Types
Construction Machinery Covers
Location of Implementation
Hyogo Prefecture
ChallengesChallenges Before Implementation
  • Limitations in planning with Excel, declining planning accuracy was a bottleneck for in-house production
  • Decided to strengthen production management aiming for further throughput increase
FeaturesFeatures of the Constructed System
  • Achieved self-implementation with the entire company working together
EffectsEffects of Implementing FLEXSCHE
  • Visualization of plans accelerated decision-making and improved throughput
  • Information collected from the manufacturing site during implementation was also used for leveling and revising estimated costs
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Implemented in high-difficulty processes for TOC practice
  • Indispensable for achieving goals such as "doubling current labor productivity"

Prime Polymer Co., Ltd.

Produced in September 2015

Industry
Chemistry
Target Product Types
Polyolefin
Location of Implementation
Chiba Prefecture and 6 other locations
ChallengesChallenges Before Implementation
  • Manual plan revisions were time-consuming, leading to lost sales opportunities
  • Human input was required to address the complexity of the "multi-variety continuous production process"
ReasonReason for Choosing FLEXSCHE
  • More flexible and cost-effective than other schedulers
EffectsEffects of Implementing FLEXSCHE
  • Monthly/annual plan creation time reduced from one week to a few hours
  • Unified master data through data integration with existing systems
  • Standardized company-wide operations, shared know-how, and smooth personnel changes
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Highly evaluated operational performance, leading to implementation in other factories and group companies

PIOLAX, Inc.

Produced in May 2015

Industry
Automotive Parts
Target Product Types
Various Automotive Parts
Location of Implementation
Tochigi Prefecture and 2 other locations, Thailand
ChallengesChallenges Before Implementation
  • Planning tasks were not standardized
ReasonReason for Choosing FLEXSCHE
  • Easily integrated with SAP in-house
FeaturesFeatures of the Constructed System
  • Have been using FLEXSCHE since 2006, now an indispensable presence
EffectsEffects of Implementing FLEXSCHE
  • Business continuity was maintained despite changes in planning personnel
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Expanded to overseas bases utilizing know-how accumulated domestically

Sekisui Kasei Co., Ltd.

Produced in September 2014

Industry
Materials
Target Product Types
Expanded Polystyrene
Location of Implementation
Nara Prefecture and 2 other locations
ChallengesChallenges Before Implementation
  • Integration of Process Planning with the Renewal of the Core System
ReasonReason for Choosing FLEXSCHE
  • Flexibility to uniformly accommodate various production processes
  • Ease of use surpassing Excel, which was used before introducing FLEXSCHE, was highly evaluated
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Expanding to overseas production bases, aiming to eliminate reliance on individual skills in planning operations

KITZ Corporation

Produced in July 2014

Industry
Industrial Machinery
Target Product Types
Valves
Location of Implementation
Thailand (2 locations)
ChallengesChallenges Before Implementation
  • Leveling is essential to avoid stockouts in post-replenishment production
ReasonReason for Choosing FLEXSCHE
  • Only FLEXSCHE could handle the "due date response operations" at the required level
  • Having experience in in-house development, we were surprised by the high operability of FLEXSCHE
FeaturesFeatures of the Constructed System
  • Coordinating with SAP for due date responses and work instructions
EffectsEffects of Implementing FLEXSCHE
  • Elimination and objectification of reliance on individual skills

Kaneka Corporation

Created in October 2013

Industry
Chemicals and Food
Target Product Types
Functional Resins, etc.
Location of Implementation
Several locations including Osaka Prefecture
ChallengesChallenges Before Implementation
  • Pursuing "better planning" is essential to achieve the company's long-term vision
ReasonReason for Choosing FLEXSCHE
  • Flexibility to express advanced concepts without add-ins and easily add unique functions
  • Quick feature upgrades reflecting user feedback
EffectsEffects of Implementing FLEXSCHE
  • Elimination and objectification of reliance on individual skills
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Plans to gradually expand to overseas factories

Eastern Co., Ltd.(Currently SIMMTECH GRAPHICS Corporation)

Created in October 2013

Industry
Electronic equipment
Target Product Types
Printed Circuit Boards
Location of Implementation
Nagano Prefecture
ChallengesChallenges Before Implementation
  • Previously, only 30% of the overall plan was created using Excel, and load considerations were not possible
ReasonReason for Choosing FLEXSCHE
  • Only FLEXSCHE could handle the complex constraints of NC processes
FeaturesFeatures of the Constructed System
  • Sharing work instructions and progress for each process via tablets and monitors
EffectsEffects of Implementing FLEXSCHE
  • The workload for planning drastically reduced to a fraction, shifting focus to improving planning accuracy

Kawasaki Heavy Industries, Ltd.

Produced in April 2012

Industry
Vehicles
Target Product Types
Railway Vehicles
Location of Implementation
Hyogo Prefecture
ChallengesChallenges Before Implementation
  • Cannot reduce material inventory without shortening lead time
  • Planning approximately 1000 processes exceeds human management capabilities
ReasonReason for Choosing FLEXSCHE
  • Can reschedule vast amounts of data in a short time
EffectsEffects of Implementing FLEXSCHE
  • Efficiency improvement by being aware of the identified bottleneck processes
  • Lead time reduced by one-third, material inventory reduced to one-sixth

KMEW Co., Ltd.

Produced in January 2010

Industry
Building Materials
Target Product Types
Exterior Wall Materials
Location of Implementation
Six locations including Fukuoka Prefecture
ChallengesChallenges Before Implementation
  • Urgent need to reduce inventory swelling due to short lead time response
  • Manual planning cannot meet the demands of a flexible production system
EffectsEffects of Implementing FLEXSCHE
  • Improved visibility allows quick response to changes with a wide impact without oversight
  • Time became available to aim for better planning
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • After introduction at the Kitakyushu plant, expanded to all seven plants

Nidec Sankyo Corporation

Produced in June 2009

Industry
Electronic Components
Target Product Types
Plastic Molded Products
Location of Implementation
China (2 locations), Indonesia
ChallengesChallenges Before Implementation
  • High difficulty in parts processing planning, standardization of planning operations was urgent
ReasonReason for Choosing FLEXSCHE
  • Smooth coordination and flexibility with SAP
FeaturesFeatures of the Constructed System
  • Entirely introduced by the in-house system department
EffectsEffects of Implementing FLEXSCHE
  • Planning workload halved, and knowledge transfer became easier
  • Machine shortages were resolved
FutureFuture Development Plans for FLEXSCHE (including those already completed)
  • Following success at two factories in China, expanded to Indonesia

Yamagata 3M Co., Ltd.(Currently 3M Japan Products Co., Ltd.)

Produced in June 2008

Industry
Materials
Target Product Types
Wall Coverings and Reflective Materials
Location of Implementation
Yamagata Prefecture
ChallengesChallenges Before Implementation
  • Planning to accommodate a wide variety of small quantities is challenging
ReasonReason for Choosing FLEXSCHE
  • Finally found FLEXSCHE as a scheduler that satisfies requirements from the past 10 years
FeaturesFeatures of the Constructed System
  • Introduced FLEXSCHE Communicator, planning divided between two people
EffectsEffects of Implementing FLEXSCHE
  • Significant reduction in planning workload, almost no calls during nights and holidays

Mainichi Shimbun Chugoku Shikoku Printing Co., Ltd.

Produced in January 2008

Industry
Printing
Target Product Types
Commercial Printed Materials
Location of Implementation
Okayama Prefecture
ChallengesChallenges Before Implementation
  • Standardization of planning operations was required as experienced planners approached retirement
ReasonReason for Choosing FLEXSCHE
  • Highly evaluated the flexibility of FLEXSCHE
FeaturesFeatures of the Constructed System
  • Left room for human corrections
  • Implementation period of 2 months
EffectsEffects of Implementing FLEXSCHE
  • Eliminated reliance on individual skills in planning operations, transferred to younger staff

Kyowa Seiki Co., Ltd.

Produced in May 2007

Industry
Equipment and Machinery
Target Product Types
Commercial Printing Machines
Location of Implementation
Hiroshima Prefecture
ChallengesChallenges Before Implementation
  • Sudden increase in production and a wide variety of small quantities caused confusion on the shop floor, which could not be addressed by the production management system alone
ReasonReason for Choosing FLEXSCHE
  • High operability and flexibility
EffectsEffects of Implementing FLEXSCHE
  • Planning work that took a whole day reduced to a single button press
  • Reduced lead time by 20%, applied to improvement activities and simulations

Nippon Steel Corporation Yawata Works(Currently Nippon Steel Corporation)

Produced in April 2006

Industry
Steel
Target Product Types
In-plant Transportation Planning
Location of Implementation
Fukuoka Prefecture
ReasonReason for Choosing FLEXSCHE
  • Evaluated the success of FLEXSCHE in the steelmaking department
  • Needed flexibility to independently develop due to special requirements
FeaturesFeatures of the Constructed System
  • Expressed complex constraints between cranes and pallets throughout the plant
  • Shared plan changes in real-time with FLEXSCHE Viewer, which were previously notified by fax

Hamamatsu Photonics K.K.

Produced in June 2005

Industry
Electronic equipment
Target Product Types
Special Optical Equipment
Location of Implementation
Shizuoka Prefecture
ChallengesChallenges Before Implementation
  • Planning for multi-process, wide variety of small quantities, and excessive inventory was difficult
ReasonReason for Choosing FLEXSCHE
  • Not only had many standard features like other schedulers, but also had the flexibility to adapt to the company's production style
EffectsEffects of Implementing FLEXSCHE
  • Planning time reduced by 40%, production lead time also reduced by 20%

Toyo Gosei Co., Ltd.

Produced in September 2005

Industry
Chemistry
Target Product Types
Photosensitive Materials
Location of Implementation
Chiba Prefecture
ReasonReason for Choosing FLEXSCHE
  • Excellent operability, not burdensome for workers
  • Easy to add functions and coordinate with other systems
FeaturesFeatures of the Constructed System
  • Real-time result collection using IC tags
  • Implementation period of 3 months
EffectsEffects of Implementing FLEXSCHE
  • Equipment operation rate improved by 17%, able to handle a 50% increase in production due to increased demand

Emulsion Technology Co., Ltd.

Produced in September 2005

Industry
Chemistry
Target Product Types
Rubber Products
Location of Implementation
Mie Prefecture
ReasonReason for Choosing FLEXSCHE
  • High flexibility, with expectations for standard features to expand according to future demands
FeaturesFeatures of the Constructed System
  • Multi-stage replenishment production and various constraints of 50 types of tanks
EffectsEffects of Implementing FLEXSCHE
  • Enabled more precise and accurate planning than the previously used scheduler, making short lead time response easier

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