Smart factory experience

Smart factory experience Best Practices

Best Practices

“FLYQUD Co., Ltd.,” Innovation achieved through phased advancement of the smart factory system!


FLYQUD is a representative Korean embroidery company that produces not only general computer embroideries but also special embroideries such as lawn, spangle, image, emblem, wappen, code, tape, or handle embroidery. The company supplies embroideries to the 20 hottest Korean women’s wear bands such as Shinsegae, Samsung C&T, Beanpole or MCM, and operates an online shopping mall “Qupmall,” where their own products are introduced and sold.

They operate their own design research institute and take pride in their products’ designs, quality, and technical innovation. Many of their designs and specialized embroidery techniques have been patented. As a result, the company was selected as a “Hi-Seoul Brand” company in 2017, which is granted by Seoul City and the SBA to excellent innovative companies located in Seoul. In 2020, the company was recognized for its technology by obtaining DQMS and technical competence T3 grade.
Introduction of smart factory for systematic production scheduling
Efforts of FLYQUD for innovation also shined in the promotion of the smart factory system. FLYQUD, which has steadily promoted the smart factory system since 2016, is cited as a representative smart factory exemplary case. The reason for the citation is because after they introduced the smart factory system, the company indexes showed improvement in all areas such as defect rate, target production quality achievement rate, productivity per person, production cost, and delivery compliance.

However, it is not like their road has been smooth from the beginning. Since embroidery products should be produced upon the request of customer companies due to the nature of the products, overall work procedure from schedule to design and manufacturing methods must be planned and understood by all employees. However, understanding hundreds of work instructions was realistically not possible. So, the company wanted to convert the existing work instructions and orders into a program. Although it was difficult from the beginning, FLYQUD continuously held meetings and performed research to make their own customized smart factory system and finally solved this problem.
When we introduced the smart factory system, the first area we applied it to was production scheduling.
Before introduction of the smart factory system,
we used to put a large sheet of paper on the wall and write work progress status by hand.
Now we handle it all online and this has dramatically improved work efficiency!
Han Yeong-soo, General Manager of Management Department of FLYQUD
Actually, scheduling could be managed systematically after the introduction of the MES MES(Manufacturing Exwcution System) production management system, real-time monitoring in manufacturing field, control, tracking status of logistics and work details, field system focused on defect management, etc. system, which enables organic connection of each step so the process defect rate has been reduced by 60%, manufacturing lead time by 40%, and work hours by 16%. The delivery compliance rate has increased by 20%. ​

FLYQUD performed OEM OEM(Original Equipment Manufacturing) A production method where the selling company places an order to the manufacturing company and receives half-finished or finished products for sales for some quantity of products to meet price and volume requirements. Quality management was inadequate due to the distance problem with the Chinese factory and technically, the workmanship was low. However, as productivity continued to increase after the introduction of the smart factory system, we were able to convert to 100% domestic production. Now that 100% self-production was possible, product quality has improved and customers’ needs are well satisfied. This change greatly improved customer companies’ satisfaction.

Even employees who were passive during the introduction became very active after its implementation. They now say “We cannot go back to the paper era. Now we cannot do anything without this.”
Before and after implementation of the smart factory system at a glance
한눈에 보는 스마트공장 도입 효과
FLYQUD has achieved lots of good results since it established various smart factory systems. First, since the ERP system was implemented and production schedules have been shared in real time, decisions are now being made in a timely fashion. The implementation of MES has reduced the material and quality management time and enabled employees to check out exact real-time production information data. In addition, the implementation of POP enabled exact work instructions, which has led to a great reduction in the product defect rate.
Establishment of prompt decision-making system through implementation of the ERP ERP(Enterprise Resource Planning) A management method that enables employees to share corporate information and generate new information and make prompt decisions system
In the past, work instructions were written on papers or made verbally, and there were frequent incidents where they were lost or damaged during delivery and communication errors occurred. However, since the POP system has been implemented, workers now prepare work immediately after checking out the work instructions on the computer. Since displays of products on the monitor can be directly compared with produced products, the defect rate has been significantly reduced.
Checking exact real-time production information data after the implementation of MES
In the past, managers had to manage material location, quantity, and quality one by one. Lots of time was consumed and accuracy was low due to the handwritten records. However, material location and quantity can be checked at once through a quick search with the implementation of MES. With production information being checked in real time, work preparation time has been greatly reduced and data reliability is improved.
Improving product defect rate through the implementation of POP POP((Point Of Product) A system that collects and processes production information from machines, facilities, and workers in real time during the factory production process and then provides the results to the field managers
In the past, work instructions were written on papers or made verbally, and there were frequent incidents where they were lost or damaged during delivery and communication errors occurred. However, since the POP system has been implemented, workers now prepare work immediately after checking out the work instructions on the computer. Since displays of products on the monitor can be directly compared with produced products, the defect rate has been significantly reduced.
General Manager of Management Dept., Han Yeong-soo reports about FLYQUD,
“Domestic production competitiveness has improved thanks to the smart factory system!"
한영수 경영관리부장이 말하는 (주)플라이쿱, ‘스마트공장 덕분에 국내 생산 경쟁력이 향상되었습니다!'
QWhat made you introduce the smart factory system?
AUntil one embroidery product is completed, lots of steps are needed from design planning and sample making to customer company counseling, design modification, analysis of the customer company’s characteristics and design, completion of samples, preparing work instructions after the final confirmation of the customer company, production/inspection and delivery. Since the embroidery industry usually delivers small quantities of many kinds of products, deciding what equipment is needed, what work needs to be done, and when to start the work to meet the delivery schedule is very complicated. When we are busy, 100 - 120 work instructions are issued. We really had a hard time with scheduling. So, while we felt limitations in various areas, the government said that it would support half of construction costs for implementation of the smart factory system. That’s why we decided to introduce the smart factory system.
QSo far, what systems have you introduced and what are the effects?
AWhen we first introduced the smart factory system in 2016, we started computerizing schedule tables and work instructions that previously were written by hand. During the 2nd advancement period in 2018, the existing MES was updated and POP was introduced. As a result, workers could enter production information in person and this enabled more accurate measurement of work time. During the 3rd advancement in 2019, an equipment management system that measures electricity used in each piece of equipment in real-time was constructed. As a result, overall improvement was very noticeable in productivity, defect rate, delivery compliance, and work time. First, the process defect rate has been reduced by 60%. Also, since inventory, work volume, and work time were recorded in detail, productivity has noticeably improved. Product examination time was over one hour before, but data can now be checked in real time, which reduces delivery time. The actual performance index shows that manufacturing lead time has been reduced by 40% and work time by 16%, while delivery compliance has increased by 20%.
QWhat are your future plans?
AIn the future, we want to introduce a vision system that repairs machines automatically like a remote unmanned robot system when there is an electricity problem, and checks if products match the drawings and adjusts automatically if they do not. The reason why we want to continuously implement the smart factory system is to steadily improve productivity. If our productivity is improved, we will become more competitive globally . Since we are confident about our technology and the quality of our products, if productivity is significantly improved by automation, exports will naturally follow. Through this, growing into the world’s best embroidery brand company is our ultimate goal.
Effect of the introduction of the smart factory system at a glance
한눈에 보는 스마트공장 도입 효과
FLYQUD said they saw the effects in multiple areas after the introduction of the smart factory system. First, the process defect rate was reduced by 60%. And lead time was reduced by 40% and work hours by 16%. As a result, delivery time was also improved by about 20%.
Field personnel comments about FLYQUD,
“The work environment became more convenient thanks to the smart factory system.”
What was most different after the introduction?
Before MES was introduced, embroidery drawings were printed and delivered on paper.
However, it can be delivered online now and this removed our concern about losing or damaging the drawings.
Yoo Hyo-sang, General Manager of Design Department
Was there any difficulty after the introduction?
At first, it was hard to adapt to the smart system because most employees are in their 40’s.
However, they say they cannot work without the smart factory system now.
Choi Seong-jin, Manager of Management Planning Team
What is the most noteworthy improvement after the introduction?
All departments can access the information they need for work transparently now
and this makes schedule coordination much easier.
Finally, communication between departments has become smoother and this is most satisfactory.
Lee Hong-bok, Chief of Online Business Department
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