Overview FUJITSU Manufacturing Industry Solution FJGP4D

Overview of Service / Solution

FUJITSU Manufacturing Industry Solution
FJGP4D

Virtual Product Line Simulator

FJGP4D
Customer Benefits
What is FJGP4D?
Why Fujitsu?
Case Study
1. Problems with Process Planning, ICT Solutions
2. FJGP4D to Improve Manufacturing Process Planning

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 Customer Benefits
- Launch global mass production efficiently and reduce costs.
- Plan without running actual trials. Calculate productivity quantitatively. Determine the best plan theoretically.
- Realize "KAIZEN" and high productivity without stopping the current line.

FJGP4D is a powerful production support tool for visualizing process design.

We support effective process design and various kinds of evaluation in the field of assembly and logistics.

(1)Data Input FJGP4D Manufacturing

(2)Simulation on virtual Line (3)Analysis
Plan C
CAD data Determine the best plan
Plan B
Easy
generation of Plan A Walking Paths examination Process Balance
production
data

VPS/MFG Productivity
data Layout examination examination List of evaluations
Procedural Efficiency
instructions Productivity
Library Equipment Logistics
Factory 500 Type Cost
layout

What is FJGP4D?
Fujitsu’s FJGP4D automatically estimates production capacity from a process plan in order to obtain maximum
performance.

Review of a new production line Making improvements in advance

Product data
Verification of
productivity and
production efficiency

Work procedures

Quantitative
assessment based
on indicator values

Layout

FJGP4D (semi-) automatically - Predicts productivity, work efficiency, and

simulates the movements of costs
persons and flows of materials. - Develops measures to prevent potential
problems

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 Why Fujitsu?

- Fujitsu is a manufacturer that designs and manufactures products on its own, including supercomputers, servers,
telecommunications equipment, and mobile devices. Based on its experience in manufacturing, Fujitsu provides PLM package
software solutions.
· CAD: FJICAD SX and FJICAD MX
· MOCKUP: FJVPS
· PDM: FJPLEMIA/Concurrent Design Manager
· Virtual Product Line Simulator: FJGP4D
- Based on 30 years of experience in the industry, Fujitsu provides package software that caters to customers’ needs.
- By developing its own package software, Fujitsu maintains high product quality to meet customers’ needs.
- Fujitsu is capable of providing customers with a full range of services, including hardware (e.g., PCs and servers) as well as
networks, telecommunications equipment, and software.
- As an SI vendor, Fujitsu has helped many customers construct business operation systems for many years.
Outline Design Specific Design Production Preparation Production
Layout Design
Process

Planning / Designing Drawing BOM Parts Procurement Manufacturing

Prototyping Manufacturing Line Design

EXCEL / Word

2D CAD
Tool

CAE BOM CAPE CAM

FJICAD MX 3D CAD . MOCKUP FJGP4D
FJICAD SX FJVPS SCM
Management Tool

Document / Drawing Manager ERP

PDM

CAD Manager FJPLEMIA/Concurrent Design Manager

Case Study
Daihen Sangyo Kiki Takebe-Ironworks
Challenge: Issue :
- Due to rapid changes in production resulting from external Use of the 2D tool-based process design does not allow
causes, it was difficult to match operators’ skill levels with work enough time for an examination to be performed during the
levels. production preparation period.
Effects:
Effects:
- FJGP4D makes it possible to reduce the examination
- Walking distance: Reduced 43% time by 50% and to increase the efficiency of the
- Value of in-process items in stock: Reduced by 20-30%
process design for the heavy load process.
- Productivity: Increased
Before improvement (cell): 40% After improvement (cell): effects - By implementing KAIZEN activities before the start of
problem detected by FJGP4D quantitatively analyzed
mass production, the number of scheduled workers was
Modification of able to be reduced by 50%.
assembly procedures
and sub-assembly Installed equipment may be
layouts over-engineered.
Before

Before After
Because the work processes and walking routes are
complicated, mistakes occur easily.
Before After
Walking distance 174.1 m 133.5 m
Cycle time 55 min. 39.6 min.

Production time/Product
150 After
Actual time
Autual time

100
Cycle NET NET Capacity
Accompany Walk
Target time Time Time Rate Utilization
50 Plan A
248.6s 160s 88.6s 64% 66M 83%
40% increase in (current)
productivity Plan B
0 (KAIZEN)
226.8s 160s 64.8s 71% 42M 92%
Apr. May.Jun, Jul. Aug.Sep. Oct. Nov.Dec. Reductio
Reduction of Increase Reductio Increase
Effect n of 0s
23.8s of 7% n to 24M of 9%
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FUJITSU Manufacturing Industry Solution FJGP4D
1. Problems with Process Planning, ICT Solutions
Line plans developed using
Current production line plans
FJGP4D
Product data

- Plans provide relative

positions for different
- No detailed descriptions processes
Work procedure - Based only on imagination - Specific procedures
- Impossible to guess what - Processes can be
actual production will be like examined
Level of planning Level of planning

Low High
Layout

2. FJGP4D to Improve Manufacturing Process Planning

FJGP4D develops multiple Plan A Plan B Plan C
models for 3D line plans made Target
during the planning stage. value
The software can be used to
Layout design Line balance Movement lines Workability
assess layout designs, line
balance, movement lines, and Assessment Plan C
workability, as well as whether item adopted
production indicators achieve
target values– all without Flow of
m 15.2m 20m 18.7m
materials
creating actual production lines.
Assessment

Area efficiency % 22.3% 12.1% 13.5%

Line efficiency % 95% 91% 93%

Productivity per No. of

10,000 10,500 12,000
products

Minimum specifications Recommended specifications

Windows XP Professional SP3
OS Windows Vista (Business, Ultimate, Enterprise) SP2*1
Windows 7 (Professional, Ultimate, Enterprise) SP1*1
CPU Pentium 4 or higher Pentium 4 3 GHz or higher
Physical memory (RAM) 512MB and above 2 GB or more
Hard disk capacity Free space of 300 MB or more Free space of 1 GB or more
OpenGL*2 compatible OpenGL 1.5*2 compatible
Graphics card Display resolution: 1280 x 768 pixels or higher Display resolution: 1280 x 1024 pixels or higher
Graphics memory: 16 MB or more Graphics memory: 512 MB or more
Microsoft Excel 2003 or higher is required for document output.
Software
.NET Framework2.0*3 is required to run FJGP4DPES.
Japanese OS (supports Japanese and English)
Language
English OS (supports only English)

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