Issue 1: A manufacturing system that cannot ensure reproducible quality
At the Chinese factory, many processes were managed using a labor-intensive approach, and there was an insufficient supply of jigs and equipment, making it difficult to ensure a certain level of quality.

・Proposing manufacturing jigs (e.g. robot soldering jigs, connector insertion cradles, cradles for mounting heat sinks, etc.) to reproduce uniform quality in domestic factories

- The use of jigs allows for the automation of work and improves reproducibility, contributing to stabilizing quality

Issue 2: Material procurement and supplier restructuring
Since many parts were sourced from Chinese suppliers, it was necessary to establish new procurement routes within Japan.

・Propose alternative parts that are easily available in Japan

・For some parts, we will create a system to collect leftover materials from Chinese factories and use them in Japan.

・Re-obtain special prices for semiconductor parts, while also reducing costs

Issue 3: Black Box of shipping inspection details
The specifications of the FCT (function test) equipment that had originally been used were unknown, and there was no one in the company with the knowledge at the time.

・Through thorough analysis of the actual product, reverse engineering the functions, wiring, and software structure of the FCT device

・Based on the results, we propose redevelopment and remanufacturing for the domestic market.

・Proposal for creating and digitalizing inspection reports

Issue 4: Establishing a quality control system and ensuring traceability
To maintain the same quality in Japan, it was necessary to audit the manufacturing plants and visualize the processes. Also, from the perspective of traceability, it was not possible to track the process from material procurement to production.

・Select multiple EMS candidate factories based on our own evaluation criteria, without relying on name value

・Factory audits were conducted with customers present, and Macnica prepared an evaluation report from a third-party perspective

・Develop delivery specifications and then exchange them to clarify quality requirements and ensure traceability.

Issue 5: The need for running changes
While taking measures to stabilize the supply volume, it was also necessary to start up the line smoothly without interrupting the customer's own final assembly process.

・ the Company and our factories thoroughly manage the process, including the trial production period, material procurement, and mass production schedule.

・Supporting our customers with internal reporting by answering any questions and providing regular information