Tylon Corporation, part of the Daiho Group of Japan, was first established in Malaysia in 1988 and a manufacturing operation added in 1995. It has now expanded to a single large site in an industrial zone, covers 4 buildings, and employs more than 1,000 people.Tylon Manufacturing (Malaysia) Sdn Bhd is principally involved in the manufacture of plastic injection molds for electric component products like TVs, Audio systems, Air-conditioners, computers etc., that are the casing components for advanced home appliances, factory automation and office automation equipment. Their customers include Panasonic, Matshushita, JVC Electronics, Hitachi, Brother, and Fujitsu.
To meet the high standard of product quality demanded by their customers, Tylon relies on advanced technology and a rationalized production system. State of the art 3D CAD/CAM systems and machinery are being used extensively in the plant, with the technological know-how being provided by some major Japanese machine makers. Local employees are carefully nurtured and trained while foreign expatriates are stationed in the plant from time-to-time to ensure its smooth operation.
The Tylon Mold Factory is at the cutting edge of the plastic injection molding industry, employing 60 trained personnel from various sectors of engineering. At its modern 15,000sq.ft manufacturing facility in Shah Alam, Selangor, the company produces plastic casing moulds for some of the largest Japan producers in Europe and Asia.
There are two end products, the mould and mould spare parts. All operations go through machining processes in the Machines Department which consists of Machining Centres, NC Milling Machines, NC Graphic Machines, Large NC Graphic Machines, Electric Discharge Machines, all of which have different capabilities depending on the type of mould and spare part being produced. The finished mould model is sent to the Finishing Department for final quality checks that involves operations such as polishing, fitting, touching, assembly, testing, measurement and other repairing processes.
One of the major issues is the complicated product routing where operations for the same job will go through the same machine group again based on the adjustment of the parts specification. The Finishing Department is responsible for the allocation of the machines operators into various teams who are required as the final process of the model. Synchronization between the Manufacture Engineering Department and Finishing Good Department is necessary in order to meet the job due dates. Pressure from tight production schedules and the need to reduce machining mistakes is extremely important due to the high cost of raw materials. Operators will be suspended due to these mistakes.
Tylon decided to implement two Preactor 300 FCS systems, one in the Manufacture Engineering Department and the other in the Finishing Department. This took a few months to accomplish due to the complexities of integrating the two departments. A Performance Indicator Application was also implemented. This not only served as a communication terminal between the two planners but also provided various reporting functions to help the planners monitor the activities of machines and operators.
This companion application mimics some functions of the Preactor Viewer to help the planners to communicate with each other, it also allowed real information sharing between two Preactor users in order to update the Preactor Master Schedules within the intranet environment. Simultaneously, Preactor also provides the actual working time to pass to the Accounting Department to calculate the actual production cost.
As a result of this process, Tylon were able to improve data accuracy and thereby provide a more reliable schedule and a better method of tracking work in progress. By having Preactor as a graphical planning and scheduling tool, the department was able to provide instant and updated information to management and production floor. Furthermore, the high-speed simulation functionality of Preactor allowed both of the production planners to run and test forecast and spot orders enquiries for future schedules.
Strategically, the cost report generated from Preactor has allowed Tylon to monitor their production operation costs closely which provides a better opportunity to be able to give competitive prices to their customers.
Future phases include the installation of the Manufacturing Execution System (MES) on the shop floor which will collect machine data directly to improve the accuracy of the schedule.