Engineering the perfect print

The essence of Epson Corporation’s management mantra lies in the Japanese tradition of Monozukuri (the art and science of manufacturing) and putting into practice the Sho Sho Sei technology strategy that ensures development of products which are compact, energy saving and of high precision.

Epson’s Global President Minoru Usui explained these two concepts to journalists visiting its manufacturing facilities in Japan: “Epson’s strength lies in the Japanese tradition which has helped us to vertically integrate manufacturing processes to implement constant improvements in our core devices and other original technologies. Now, we are back with compact, high precision and energy saving products.”

Mind to actionMonozukuri in its literal translation means the “process of making things” but in the Japanese context has a far deeper meaning. It is, according to experts, imbibing and disseminating a philosophy that promotes the spirit to produce excellent products and the ability to constantly improve the production system and streamline its processes. It is, in short, a state of mind which translates into action. And the Sho Sho Sei vision is Japanese for compact, energy saving and high precision. But it is more than just a slogan, and drives manufacturing, R&D and core competence.

The two principles have stood Epson in good stead and helped the company to recover from the global recession of 2008-12, which saw a decline in sales, and deliver a new period of growth. “My aim is to make Epson a company that is indispensable to its customers and society. Technological innovations at Epson will make a real difference,” says Usui. Epson, he adds, has maximised its expertise and core patents to produce products that are not easily duplicated by others.

The products he refers to include new advanced ink jet printers, robotic manufacturing systems, visual devices such as projectors and augmented reality head gear and new wearable computing devices. In fact, technology based on Sho Sho Sei principles is behind the Micro Piezo MEMS technology that drives the chip used on most of Epson’s new ink jet devices, from commercial-grade printers down to home office printers.

Getting into gear So, how do Monozukuri and Sho Sho Sei operate at the work place? We were taken on a guided tour of Epson’s PrecisionCore production line at its Suwa Minami plant in Nagano — some 200-odd kilometres from Tokyo.

First up we were asked to slip into tight fitting jumpers, gloves and masks while a gush of air cleansed us of all contaminants.

We were now ready for the clean room — a temperature and humidity controlled set-up where the air is maintained in a highly purified state. It is here that products being fabricated require a 100 per cent contaminant-free environment.

What is impressive is the manner in which the production line keeps chugging even as there is a synchronicity between the activities of man and machine in a controlled environment.

Keeping the process going with precision day after day is, to say the least, a daunting challenge. There can be no slip-ups. That is part of the work ethic and commitment.

At usual heavy industry manufacturing shop floors it is easier to understand the production process. Speak to a worker, watch the product take shape as you walk down the assembly line and you get the drift of the entire process. But things are quite different in a high-tech clean room. This highly-purified, temperature and humidity-controlled manufacturing zone where machines outnumber workers has a work charter of its own.

This is challenging as it is creative in human resource management. “Apart from constant education and training we use a mix of shuffle and mingle to get the best out of people. Sometimes the printer staff is shifted to the wrist watch engineering unit and vice versa. This cuts the monotony,” says Yasuto Kanai, the General Manager known for his expertise in managing clean rooms.

Mantras for perfection He explains how Monozukuri imbibes the 5S Japanese workplace management system — Seiri , Seiton , Seiso , Seiketsu and Shitsuke — that essentially imply sorting, simplifying, systematically cleaning, sustaining and standardising. These are the mantras that together ensure precision engineering. In clean rooms, standard operating procedures have to be very strictly adhered to and the staff is given a five-day week to return fresh even as the production line continues 24-by-7.

Lifelong learning Apart from this, Epson has put into place several procedures so that its employees are on the ball and know their jobs inside out. One is an online course in its management philosophy to enable employees to see the links between it and their own jobs.

The second is Epson’s Monozukuri Juku , an in-house manufacturing school that transfers the company’s invisible assets to the next generation of employees. The school, according to the company, “has a hands-on environment in which young technicians and engineers can learn practical skills in manufacturing and production control.”

Finally, Juku works as a place to develop a range of skills in people. “Employees learn to solve problems on the manufacturing floor and receive training in the art and science of manufacturing, including the basics of machining, electrical equipment, and mechatronics. Some employees train to become key skilled technicians by using training techniques developed for the Skills Olympics,” says the company. And in a sense proves that like other Japanese majors, it too is steeped in its country’s manufacturing traditions, benefiting from them all the way.

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