Roland DG Co., Ltd., manufacturer and seller of commercial inkjet printers and 3D manufacturing tools, is expanding the floor space of its factory in Thailand under the jurisdiction of its manufacturing subsidiary Roland Digital Group (Thailand) Ltd. (Samut Sakorn Province, Thailand).
This increase in floor space is in response to one of the basic policies of the medium-term management plan (FY2021 to FY2023) announced on 12 February 2021, “Transformation into a muscular corporate structure”.
By completely transferring the mass production function of their domestic factory, Miyakoda Office (Kita-ku, Hamamatsu City, Japan) to the Thailand factory, they will promote the reduction of product costs and improve price competitiveness.
On the other hand, the company has set “transformation of business portfolio” as the basic policy of the medium-term management plan, and is proceeding with the development of products for emerging markets where further market growth is expected. The expanded Thailand factory is also intended to serve as a receiver for the production of products for these emerging markets.
The Thailand factory is their first overseas factory that started operation in October 2012. By maximising the strengths of their unique cell production method, Digital Stand*, which backs up the work of operators with digital technology, Roland DG can provide a stable supply of high-quality products, as in the case of Japanese production. They are promoting local procurement of parts other than the main parts, and have established an autonomous production system that does not depend on the Miyakoda Plant. In line with the expansion of production volume, they increased the floor space for the first time in 2014, and the latest expansion will be its second.
The layout will change after increased floor space and floor area of the entire plant. By transferring the production of mass-produced products such as inkjet printers and dental processing machines currently produced at the Miyakoda Plant, the number of production models will be increased from the current 16 models to 32 models, and the production capacity will be converted to large commercial inkjet printers.
There are plans to increase by about 40% from the conventional model to 17,000 units. By changing the layout of the production area, smooth conductors from the arrival of parts to storage, picking, production, and shipping can be secured, which also contributes to the improvement of operational efficiency. The floor expansion work is scheduled to be completed at the end of November, and the full-scale operation of the entire factory including the floor expansion is scheduled for January 2022.
From 2022, the Miyakoda Plant will specialise in functions as a mother factory that will play a role in the production of prototypes, support for launching new product production, and the development of advanced production technology. From the perspective of BCP (Business Continuity Plan), the production area after the transfer will maintain a certain level of production functions, but they plan to consolidate warehouse functions and convert them to office functions.
In addition, “digital stalls” are expected to have a wide range of needs as a mechanism to support high-mix low-volume production, centred on small and medium-sized manufacturers who are aiming to transform manufacturing, and are preparing to build and promote businesses that provide digital solutions in manufacturing.
Overview of floor expansion at Thailand factory
| At the start of operation in October 2012 | At the time of floor expansion in 2014 | When the floor is increased in 2021 | |
| Total floor area of production area | 2,600m2 | 2,408m2 (total 5,008m 2) |
2,154M2 (total 7,162M 2) |
| Architectural structure | Steel-framed 1-story (office part is 2-story) | Steel structure 1 story | 1 steel structure (2 stories in the dining room) |
| Production capacity | 6,000 units (converted to a large inkjet printer) | 12,000 units (converted to a large inkjet printer) | 17,000 units (converted to a large inkjet printer) |
| Production model | 2 models (large inkjet printer) | 5 models (large inkjet printer, cutting machine) | 32 models (large inkjet printers, cutting machines, dental processing machines, etc.) |
| Number of employees | 53 people (including 21 operators) | 108 people (including 61 operators) | 230 people (planned) (including 110 operators (planned)) |
| Investment amount | 200 million Thai baht (including land) | 70 million Thai baht | 75 million Thai baht (about 250 million yen) |
| Company Name | Roland Digital Group (Thailand) Ltd. |
| Location | 30/122 Moo 1, Sinsakhon Industrial Estate, Tambon Khok Kham, Ampur Muang, Samutsakhon 74000, Thailand |
| Business content | Manufacture of large commercial inkjet printers, cutting machines, etc. |
| Capital | 210 million Thai baht |
| Number of employees | 212 people (as of the end of May 2021, 102 of them) |
*Digital stalls:
Roland DG products are assembled with their proprietary “digital stalls”. While checking the 3D graphic manual displayed on the display of the personal computer, the operator takes out the necessary parts for each process from the small parts stocker and assembles the product using the electric screwdriver instructed by the graphic manual. Not only is it devised so that the wrong parts and drivers are not used, but quality is built in the process by conducting quality inspections in each process. It is characterised by supporting human memory and attention by utilising digital technology, and achieving high quality and productivity at the same time.
The work log data at each stall is saved on the server, and the site manager can grasp the work progress and connect it to improvement activities through data analysis, just by managing individual stalls. Another major feature is that users can optimally control the production of the entire factory.
Since 2001, the company has adopted a production method for each person, in which one operator assembles one product from start to finish, but since the Thailand factory opened in 2012, they have pursued higher productivity. Therefore, they have introduced a cell line production method that combines multiple digital stalls and assembles one product by multiple people. They will also introduce a module production method that specialises in assembling units common to each product, and will become familiar with module assembly and work in each process in a short period of time compared to the individual production method that assembles from the beginning to the end. It has the advantage of being able to do it.
At the Miyakoda Plant, the entire factory has been digitised by introducing robots that supply screws and other items to small parts stockers used in digital stalls, and by conducting automatic transport experiments on carts equipped with parts necessary for assembly. They are also pursuing further productivity improvements, and are working on continuous cost reduction activities, reduction of delivery lead times, and reduction of in-process inventory.
