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Research paper : Toward the integrated optimization of steel plate production process (K. Nishioka et al.)−111−Synthesiology - English edition Vol.5 No.2 (2012) Kimitsu Plate Mill, manager of the plate department and others. Presently working as the Plate Mill manager. Until today, worked for the enhancement of productivity of plate manufacturing, development of TMCP technology, and integrated optimization. For the present paper, he worked as a member of the technical staff and assumed leadership in the planning and implementation of integrated optimization, and at the same time, in the development of the multi-scale hierarchically structured model of production control.Hironori UenoIn 1996, graduated from the Graduate School of Faculty of Science and Engineering, Waseda University. In 1996, entered Nippon Steel Corporation. At the plate mill of Kimitsu Works, worked mainly on higher efficiency, TMCP technical development, etc., improvement of operation techniques, as well as equipment planning and drastic improvement of plate manufacturing processes. In 2005, dispatched to the World Steel Association, and at present, the steel plate technical group manager of the Plate Mill, Nagoya Works. To this paper, he contributed as a member of the technical staff to shop floor reform and operation improvement.Hirofumi KawasakiIn 1980, graduated from the Graduate School of Mechanical Engineering of Osaka University. In 1980, entered Nippon Steel Corporation. Engaged in the improvement of plant operation techniques as a member of the technical staff belonging to the Plate Mill of Kimitsu Works. After posts as assistant manager in the Plate Technical Department in Head Office, superintendent (general manager) of the Plate Mill, Kimitsu Works, presently executive counselor in the Plate Division of Head Office. In 2008, received the Watanabe Kensuke Memorial Award of the Iron and Steel Institute of Japan. In relation to this paper, he was assigned the post of superintendent of the Plate Mill in 2001, and succeeded in the shortening of lead time and production increase.Yasunori BabaIn 1977, graduated from the Faculty of Economics, Tokyo University. In 1986, completed a doctorate course at the University of Sussex, Ph. D., SPRU fellow. After working as chief researcher in the National Institute of Science and Technology, and others, and from April 1993, the assistant professor at the Research into the Artifacts Center for Engineering, and in 1997 became the professor of the same Center. After July 2001, professor at the Research Center for Advanced Science and Technology. Also, from April 2007, professor at the Department of Advanced Interdisciplinary Studies, Graduate School of Engineering, Tokyo University. In this paper, he took charge of the synthesization and systematization of knowledge.Discussions with Reviewers1 Productivity of steel plate manufacturing processesComment (Kanji Ueda: AIST)This paper investigates the most difficult problems of optimal integrated production in process industries. It identified the items to be solved through practical undertakings, and developed models and summarized the actual data collected in specific steel plate manufacturing processes and is considered as appropriate in terms of synthesiology. The scenario in this paper is based fundamentally on the recognition of the difficulty of ensuring simultaneously the minimization of lead time and improvement of productivity. However, please describe clearly what is meant by the enhancement of productivity in this paper.Answer (Kiyoshi Nishioka)Productivity is the volume of production per hour, namely it is “efficiency.” The process reform/ process improvement in the steel industry used to focus on the enhancement of the efficiency of mainlines. However, the enhancement of efficiency of individual pieces of equipment or a group of equipment does not lead to the minimization of manufacturing lead time, and sometimes, it works counter to it. The main subject of our research concerns how to make these two coexist.2 Middle managementQuestion (Kanji Ueda)As one of the arguments in this paper, it describes the importance of the role of middle management in management innovation. Please be more specific in your definition of middle management.Answer (Kiyoshi Nishioka)When referring to middle management in this paper, we mean managers at the level of plant superintendent. Top management has the authority to change the corporate-level organizations and systems. Middle management, on the other hand, has the authority to change operation and evaluation within a given range of system and structure. This paper suggests that by synchronizing the reform of corporate-level organizations and work structures implemented under the strong leadership of top management and the innovative efforts of middle management in charge of on-site management, organizational activities that by nature tend to resist changes are rejuvenated completely and become capable of responding actively to the changing market environment.3 History of modeling multi-scale hierarchical structure and its future developmentQuestion (Kanji Ueda)Chapter 6 claims that a new model is proposed toward the systematization of manufacturing knowledge. The content is very interesting, but it is not clearly stated how this model was obtained. Please also describe how this proposed model should be deployed horizontally and to which industries and processes in the future.Answer (Kiyoshi Nishioka)The proposed model has not been deductively derived, and if a model that was developed through trial and error is understood inductively, the paper claims that it has a model structure that straddles time strata. In contrast to the conventional result-based production control that is based on manufacturing results, it is suggested that the multi-scale hierarchically structured model makes it possible to implement appropriate time control and production control by adding the viewpoint linking the causes and the result of phenomena that occur time-wise. The lean production control gave birth to an epoch-making production control that enables the pursuit of the limit of integrated optimization in the interrelation of lines called processing. In contrast, in the

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