Establishing an earthquake-proof manufacturing base
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Humans cannot prevent an earthquake from occurring. However, advanced preparation can greatly reduce the extent of damage. DISCO is pursuing preventative measures to minimize earthquake damage, assuming an earthquake the size of the Kobe (1995) or Kanto (1923) earthquakes.
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Head Office R&D Center with
seismic base isolation structure |
Kure Plant with seismic
base isolation structure |
Seismic base isolation structure |
The dicing blade (ZH series) manufacturing is carried out at two separate locations in Hiroshima- the Kure Plant and the Kuwabata Plant. Both plants are gradually replacing their current buildings; the new buildings use seismic base isolation structures to prevent earthquake damage to the furthest extent possible. The seismic base isolation structure reduces earthquake vibration, as illustrated, and is an extremely effective method to protect the manufacturing facilities from being critically damaged. The Kure Plant, which is the main factory, is increasing the safety levels by moving the manufacturing lines one by one to the new building with seismic base isolation structure, completed in November 2007. Meanwhile, the current building, with earthquake resistant structure, that houses the grinding wheel manufacturing lines, has been assessed by a company specializing in earthquake risk evaluation, and has implemented facility reinforcement and other safety measures as advised. In November 2011, DISCO plans to add an earthquake-proof building for the dicing blade production in the Kure Plant.
At the same time, DISCO is securing the procurement of raw materials by ensuring secondary sources. In addition, 6-months worth of specific critical raw materials are stocked in the automatic warehouse in the new seismic base isolated building at the Kure Plant, to be prepared for unforeseeable circumstances.
While focusing on damage prevention on the one hand, we are also establishing a system to ensure product supply in the remote chance that one of the factories is seriously damaged by an earthquake. In such a case, the other factory will take up the required manufacturing output and continue to supply consumable products to our customers. Further, we are considering our affiliate company DAIICHI COMPONENTS’ Chino Plant to manufacture major Precision Processing Tools products to allow for distributed manufacturing. The Chino Plant is in Nagano prefecture, 545 km away from the current Kure and Kuwabata plants, therefore, establishing an alternative manufacturing base at such a distance will further ensure a stable supply.
Considering the influence on the customer production, the recovery time objective has been decided as follows.
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Within 3 days after
being affected by a disaster |
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To start shipping of precision processing tools, which are already completed and stocked internally, and to disclose on DISCO website the schedule for restarting the production and recovery from damage. |
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Within 7 days after
being affected by a disaster |
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To restart the production of precision processing tools as a priority. |
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Within 30 days after
being affected by a disaster |
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To restore the production of the precision processing tools to the normal level. |
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| Recovery Time Objective and Operation Capacity |
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| Reserve information system in Kure Plant |
A particular focus is on the digitization and duplication of information data that is essential for the supply of products to customers. DISCO has established a backup information system to increase information security by completely duplicating the system, not just the data. Major computer systems are installed at both the Head Office R&D center in Tokyo and the Kure Plant in Hiroshima for duplication, with equivalent functions. Normally, the system in Tokyo is used, which is installed in a building with strong earthquake resistant structure. The servers are placed on a seismic base isolator, and the room is equipped with an emergency power generator and fire extinguishing facilities; however, in case it becomes difficult to run the system in Tokyo, we have a backup system to immediately start up the system in Hiroshima, and to switch operations. Data is constantly backed up and saved at both Hiroshima and Tokyo to prevent loss of information. To further ensure safety, we periodically perform switching tests and training for these computer systems.
The facilities are not the only important factor in earthquake-proofing the manufacturing bases. It is equally important to cultivate a "disaster-proof culture", by encouraging each individual to think about disaster and to raise their disaster awareness. In 2005, an original novella "The day DISCO quaked& was published in-house. It was a big hit. In response, all employees raised ideas for a faster recovery and to further reduce damage, many of which were implemented. .The continuations of the earthquake novella, "The door guiding into tomorrow" and "Cloud in the summer" are pieces chosen from many applicants in a in-company competition. This event has greatly contributed to raising disaster awareness by enabling employees to visualize an emergency situation, in a creative way.
A building with seismic base isolation structure was additionally built at the head office R&D center in Tokyo is equipped with the main computer system as well as a dormitory for single employees so that employees are able to be there within minutes in case of an emergency.
In January 2010, a new earthquake-proof building, which contains the production process of precision processing machines, was completed in the Kuwabata Plant. It is expected that these facilities will substantially increase DISCO's abilities to cope with earthquakes.
Meanwhile, DISCO has sales and branch offices in buildings highly resistant to earthquake to protect the people that support customers.
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