Industrial report about a Brother Industries Limited, contains production management systems

1. Tribhuwan University
Institute of Engineering
Thapathali Campus
A Presentation on
Industrial management of Brother Industries Ltd.
Presenters:
Sushil Chapai (071-BME-440)
Sushil Kumar Mandal (071-BME-441)
Tark Giri (071-BME-442)

2. ACKNOWLEDGEMENT
We would like to express our deep gratitude and sincere thanks to Asst.Prof.Raj Kumar Chaulagain,
Department of Automobile and Mechanical Engineering, IOE Thapathali Engineering Campus for making us
develop the managerial skills theoretically and practically. He provided us with continuous ideas about the
case study and inspired us for doing the study. We would be grateful to Brother Industries Ltd. for providing
us with necessary details and information through it’s Website about the company. Without the knowledge of
Company, we wouldn’t have succeeded to perform this study. Last but not the least; we would like to extend
thanks to all teachers and friends who directly or indirectly helped in the preparation of this case study report.
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3. Table of Contents:
• Introduction to product and company
• Plant Location
• Factory Building and Plant Layout
• Material Handling
• Production, Planning and Control
• Product Research, Development and Design
• Process Planning
• Loading and Scheduling Techniques
• Inventory Control
• Material Requirement Planning
• Forecasting
• Plant Maintenance
• Quality Control
• Production Video
• References
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5. Introduction to Brother Industries Ltd.
• Japanese multinational electronics and electrical
equipment company headquartered in Nagoya,
Aichi, Japan, established in 1908.
• Founded by Kanekichi Yasui
• Key products include laser printers, Multi-
Function Centers (MFCs), fax machines,
labelers, label printers.
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6. History
• Brother's history began in 1908 when the Yasui Sewing
Machine Co. was established in Nagoya, Japan.
• The corporate name was finally changed to Brother
Industries, Ltd. in 1962.
• Brother entered the printer market from 1965.
• In 1971, Brother successfully developed the world’s
first high speed dot-matrix printer.
• In 1995, Brother marketed its Laser Digital Multi-
Function Centre, Which integrated printing faxing and
copying functions into a single unit.
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7. Product introduction
• A printer is a peripheral which makes a persistent human-
readable representation of graphics or text on paper or
similar physical media. In other words a printer is any device
that prints text or illustration on paper.
• With the development of technologies, there have been
introduced various technologies for printing.
• There are various types of printers like dot-matrix, inkjet,
laser, line, LED/LCD, thermal etc. that have been made by
Brother, and they all are for different purpose.
• Dot-matrix Printer creates characters by striking pins
against an ink ribbon. Each pin makes a dot, and
combinations of dots from character and illustrations.
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8. • Ink-jet Printer sprays ink at a sheet of paper. It produces high
quality text and graphics. Laser printer uses the same technology as
copy machines.
• Laser printers produce very high quality text and graphics.
• LCD & LED Printers are similar to laser printer, but uses crystals
or light emitting diodes rather than a laser to produce an image on
the drum.
• Line Printers contain a chain of characters or pins that print an
entire line at one time. Line printers are very fast, but produce low-
quality print.
• Thermal printers are inexpensive printers that work by pushing
heated pins against heat-sensitive paper. Thermal printers are
widely used in calculators and fax machines.
• Brother printers have been winning awards for years – offering
high quality, well designed printing solutions with excellent
customer value.6/13/2017 8

9. Plant location:
• Brother Industries Limited being
multinational company, it has multiple
manufacturing factories and are located in
various places of the world.
• One of them is Brother’s and which is located
at First Philippine Industrial Park in Batangans
near Manila (with GPS coordinates of
14°08′11″N 121°07′18″E).
• First Philippine Industrial Park, established in
1996, comprises 349 hectares located in the
city of Tanuan and the municipality of Santo
Tomas.
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10. Factory building and plant layout:
• Horizontally spaced with three floor and site area of
approximately 134,000 m2 and gross floor space of
approximately 52000 m2.
• There is some area left for future expansion of the plant and
it is planned already.
• Ground floor has been used for heavy assembly and as ware
house and upper floors have been used for manufacturing
small parts and for manufacturing electronics parts.
• Almost parts are produced and assembled here in the same
company and some other parts like ink, cartage and packing
material are brought from outside of this plant.
• The plant is white colored to reduce the inside temperature of
the plant and roofed with tin and windows are provided to
make a way to sunlight and air conditioned system is kept for
proper supplement of fresh air.
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11. Material handling:
• As a Printer requires more of the small parts so for proper
handling of them Robotics arm and conveyer are provided.
• For some of the complex and sensitive assembly process
benches are provided so that employee can make it without
any difficulties.
• Though human involvement is more in manufacturing
process, some of the tasks are automated using computer
system for easy manufacturing process.
• Parts required for full manufacturing almost are
manufactured by the company itself but few of them are
bought from other companies.
• Products after full assembly is subjected for testing and
packed into the Paper box or wooden box depending upon
the size of printer.
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12. Production, Planning and Control:
• Before the production of new products they are designed
properly and production planning is made by the discussion
of designer, board of directors and architect.
• Production of any product is done in numbers as per required
in the market and products are also made advanced and
advanced with rapid change in technology.
• Products which are ready to send into the market are first
collected in the product house and are sent to the dealers and
showrooms and through them, to the customers.
• The most important thing is to get feedback from the
costumers and their opinions regarding products.
• Brother consists of Brother Value Chain Management
(BVMC) system. That means the Brother Group considers
demands and expectations top priority as their guide for all
of their business operations including product planning,
development, design, manufacturing, sales and service.
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13. Product Research, Development and Design:
• R&D is defined in the research and experimental
development, which comprise creative work undertaken on a
systematic basis in order to increase the stock of knowledge
and the use of this stock of knowledge to devise new
material, products or devices, new processes systems and
services or improving substantially those produced or
installed.
• New products are updated or redesigned or even newly
designed on the basis of recently invented technologies and
responses from the costumers.
• Company also consists of a group for sole purpose of
research on the technology and performs experiment on
them.
• Brother considers design as the very core of innovation, the
moment when a new objects is imagined, devised and shaped
in prototype form.
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14. Loading and Scheduling Techniques:
• Scheduling is a important factor in Brother industries to
allocate plant and machinery resources, plan human
resources, plan production processes and purchase materials.
• In manufacturing, purpose of scheduling is to minimize the
production time and costs, by telling a production facility
when to make, with which staff, and on which equipment.
• There is several paths that the products have to go through
for machining and assembly process. Plant layout itself being
horizontally spaced, process goes on line production
technique.
• Process which are time consuming are done in multiple
machines so that it avoids production delay.
• All the products are not made at a same time, some common
machines are ran to produce few products at time and are
depended on the market demand.
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15. Inventory Control:
• Inventory control in Brother industries is used as the
process of ensuring parts and products remain in stock
to avoid shortages, overstocks, and other costly
problems.
• The goal of inventory control is to generate the
maximum profit from the least amount of inventory
investment without hindering customer satisfaction
levels or order fill rates.
• There were number of different techniques employed
by this industry to ensure its inventory control is
maximizing efficiency and profitability.
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17. Material Requirement Planning:
• Material requirements planning (MRP) is a computer-based inventory management
system designed to assist production managers in scheduling and placing orders for
items of dependent demand.
• The first MRP systems of inventory management evolved in the 1940s and 1950s
and the Brother Industries Limited has implemented this system from 1956.
• They used mainframe computers to explode information from a bill of materials for a
certain finished product into a production and purchasing plan for components.
• Nowadays, material requirement planning is systemized with the help of fast
processing digital computers and they are operated all the time, functioned with
proper program to give reliable feedback of the progress of current manufacturing
process and helps in further planning of the organization.
• Brother has implemented many of the systems and human groups with relevant
function for the material requirement planning where they analyzes the technological
needs of products, running progress of the industry, product market, availability of
raw materials and world’s economics condition and also perform discussion on the
feedback provided by the costumers.
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18. Forecasting:
• Forecasting is a planning tool that helps management
in its attempts to cope with the uncertainty of the
future, relying mainly on data from the past and
present and analysis of trends.
• In the Brother Industries Limited the investors utilize
forecasting to determine if events affecting a company,
such as sales expectations, will increase or decrease the
price of shares in the company.
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19. • For instance, data is collected regarding the impact of customer satisfaction by changing
business hours or the productivity of employees upon changing certain work conditions.
• Stock analysts use various forecasting methods to determine how a stock’s price will move in
the future.
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20. Plant maintenance:
• Plant maintenance usually refers to the methods, strategies,
and practices used to keep an industrial factory running
efficiently.
• The general aim of plant maintenance is to create a productive
working environment that is also safe for workers.
• Brother applies (RCM), is a maintenance strategy that is often
employed in factories. This is an approach that not only seeks
to maintain minimal levels of plant efficiency, but also looks
for ways to improve production.
• Brother also applies preventive maintenance, is also an
important aspect of making sure a plant runs efficiently and so
Brother does. This can prevent equipment from breaking
down, or help to anticipate a possible problem that would
otherwise cost the plant money because of a work stoppage.
• Mechanical or electronic failures may occur from time to time
in a complex system like a feed machines, but proper attention
to preventive maintenance is done in Brother6/13/2017 20

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22. Quality control:
• Quality control is a process through which a
business seeks to ensure that product quality is
maintained or improved and manufacturing
errors are reduced or eliminated.
• Quality control is done by training personnel,
creating benchmarks for products quality, and
testing products to check for statistically
significant variations.
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23. • Quality Control often consists of four parameters: Plan,
Do, Check and Act.
• Brother has defined quality as fitness for use,
conformance to requirements, and pursuit of excellence.
• In order to implement an effective quality control
program, Brother first decides which specific standards
the product or service must meet. Then the extent of
Quality control actions is determined (for example, the
percentage of units to be tested from each lot).
• Next, real world data is collected (eg: the percentage of
units that fail) and the results reported to management
personnel. After this, corrective action is decided upon
and taken (eg: defective units must be repaired or
rejected and poor service repeated at no charge until the
customer is satisfied).
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25. References:
1. http://search.brother.co.jp/en_all/search.x?q=management+syste m&searchBtn4=%E3%80%80&ie=UTF-8&page=1
2. http://www.brother-usa.com/printer/
3. http://www.brotherusa.com/sitesearch.aspx?SK=printers+types&searchBtn4=++&s
ort=date%3AD%3AL%3Ad1&output=xml_no_dtd&oe=UTF8&ie=UTF8&client=fe_www_com&proxystylesheet=fe_ww
w_com&site=c ol_www_com_cominf_sol
4. http://www.office.xerox.com/digital-printingequipment/printers/enus.html
5. https://www.google.com.np/maps/place/First+Philippine+Industrial+Park,+Inc./@14.1315471,121.1172724,15z/data=!4m
5! 3m4! 1s0x0:0x8406db46db1afbec!8m2!3d14.1372205!4d121.135152
6. http://www.ruadesign.org/productdesignCh1.html
7. https://www.camcode.com/asset-tags/what-is-inventory-control/
8. http://www.brother.com/en/corporate/history/index.htm
9. http://www.investopedia.com/terms/m/mrp.asp
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