EIZO Uses XVL to Improve Quality and Shorten Development Time

Use Case: EIZO Corporation using XVL

Global Manufacturer of High-End Display Systems uses XVL to Improve Quality, Reduce Errors and Shorten Development Time

-EIZO Innovates Manufacturing Processes to Maintain Leadership -

Corporate Profile

EIZO Corporation is a Japanese company that develops and manufactures high-end display products and other solutions for markets such as business, healthcare, graphics, air traffic control, and maritime. EIZO, pronounced AY-ZO, means "image" or "vision" in Japanese.

Monozukuri is a common term to manufacturing companies in Japan. The broader meaning encompasses a synthesis of technological prowess, know-how and spirit of Japan's manufacturing practices. EIZO has been implementing Monozukuri by breaking down barriers between development and production with the themes of  “Full use of the latest technology,” “Reduction of lead time to market release” and “Total quality management.”

Business Challenges

Like other global leaders, EIZO faces strong external pressures such as diversification of market needs, shortened product lifecycles and intensifying price competition. At the same time, EIZO has experienced internal challenges such increasing costs of development, production, logistics and inventory, a rigid organization and siloed departments.  All these pressures have forced EIZO to innovate its business practices.

Business Strategy and Objectives

In response to these challenges, EIZO has pursued a strategy of Monozukuri consisting of the following 6 initiatives:

1. Reorganization

2. Development and production innovation

3. Platform-based design

4. Front-loading

5. XVL utilization

6. Human resource development

To implement the innovation strategy, they established a “Monozukuri Innovation Committee” and organized teams to promote the initiatives.  One of the teams, the Development and Production Innovation Team, identified the following priorities for manufacturing innovation:

1. Platform-based design

2. Standardization of parts

3. Front-loading

4. Production automation and human resource development

Platform Based Design

Their first priority was to establish a system of platform-based design.  Platform-based design involves capturing existing expertise in mechanical, electrical and software design, then sharing and expanding that knowledge to build a standardized platform for future product designs.

Platform-based design was the critical path. Once this was established, they proceeded with their other priorities:

1. Standardization of parts

2. Front-loading

3. Production automation and human resource development

How EIZO Used XVL to Accomplish Their Business Objectives

Using XVL for Front-Loading

XVL played key roles in helping EIZO innovate their manufacturing processes.  Take, for example, front-loading. In the product development process from design to prototyping to mass production, problems that are discovered later have much greater impact on cost and schedule than problems that are discovered earlier.  So, one way to reduce cost and time-to-market is to find and fix problems early in the process. This is referred to as front-loading. As part of their “Monozukuri Innovation” strategy, EIZO undertook front-loading to reduce development costs, reduce the number of prototypes and shorten time-to-market.

Their front-loading strategy consisted of:

1. 3D Product Visualization

2. Design Validation

3. Quality Engineering

They emphasized 3D product visualization to find problems and validate quality during production planning. They chose XVL for the visualization because it is ultralightweight in file size (roughly less than 1% or the original CAD model size) yet it still retains CAD-level accuracy. These two points were crucial because validation cannot be performed unless the data is accurate and the drastically reduced file size of the XVL model allows complete product analysis of all subassemblies and parts in a single instance  

The production department now converts 3D CAD design data to XVL and performs design reviews.  They use the XVL models for shape validation, cross-section validation and interference and clearance checks. They report any problems they find back to the design teams, so that the issues can be resolved before production starts.

Using XVL to Enhance Production Processes

EIZO is also using XVL to enhance their manufacturing processes.  In one example, the production department now verifies mold design by converting mold design CAD models to XVL and reviewing the design updates in 3D.  XVL tools show the differences between model versions, which enables them to quickly find and report any issues to the design teams. This allows the design teams to fix any problems before the production teams update the molds.

Furthermore, production experts on the shop floor are now using 3D work instructions on touchscreen computers to assemble prototypes.  The 3D visualizations enable them to review products and processes at a glance, which was difficult with conventional 2D drawings. With the 3D work instructions, they are enjoying the benefits of “not having to imagine the 3D shape from 2D drawings” and “easily understanding the mounting positions of parts.”  Introducing 3D visualization has significantly reduced the number of assembly errors and RFCs. The goal now is to reduce the overall development time by half.

Based on these results, 3D visualization is now being extended throughout the organization, to overseas subsidiaries and to suppliers.  3D data is even being used to create web content for customers.

Using XVL for Human Resource Development

EIZO has been upgrading production facilities by introducing automatic equipment; however, this has also increased the demands production configurability and flexibility.  They have analyzed the production process and identified areas where humans have advantages over machines. Now they are improving production skills through training and recruiting.  They opened a “Skill Building Center” to maintain and enhance production expertise. This center uses 3D XVL models to show production processes. It enables the technicians to easily understand productions tasks that are difficult to follow with video, which shortens the training period and improves retention.

Summary

EIZO has pursued a strategy of Monozukuri, or manufacturing innovation, to improve quality, reduce costs and shorten time-to-market.  They have reorganized design and manufacturing, implemented platform-based design, used a strategy of front-loading to identify and resolve issues early, enhanced their production methods and invested in human resource development.

EIZO believes that XVL from Lattice Technology has been critical to the success of their Monozukuri innovation.  XVL, with its excellent visualization performance, has played a key role in bringing the departments together and innovating their business processes.