Kyoritsu Electric Corporation List of Products and Services

The "Defective Count Management System" is a system that manages the number of defective products that occur on the manufacturing line. Until now, the number of good and defective products in the manufacturing area has been managed entirely on paper, which has resulted in time-consuming analysis when a large number of defects occur, placing a significant burden on site managers. This system has various aggregation and output functions, allowing input of site data and linking it to the number of good and defective products, which aids in analyzing the causes of defects. Additionally, it features a simple process progress management function utilizing the input of good and defective product counts. 【Features】 ■ Input the number of good and defective products that were previously managed on paper at the site using a terminal ■ Link various measurement data collected on-site to product data ■ Allow site managers to easily check the progress status from a PC ■ Aggregate and output the inputted number of good and defective products, site data, etc. *For more details, please refer to the PDF materials or feel free to contact us.

Until now, we have managed the manufacturing conditions for each product on paper, and every time we changed the product being produced, operators manually entered the manufacturing conditions one by one into the control device. Additionally, due to the large number of manufacturing condition items, there were instances of setting errors in the control device. The "Product Management System" manages different manufacturing conditions such as batch size, temperature, and time in a database based on the combination of equipment and product, allowing for easy downloading to the control device with simple operations. With the introduction of this system, the task of setting manufacturing conditions in the control device has become easier, eliminating setting errors. 【Purpose of System Implementation】 ■ Centralized Management of Operating Conditions - To centrally manage the manufacturing conditions downloaded to the control device and to preserve them for the long term. ■ Efficiency Improvement - To reduce the time required for setting manufacturing conditions in the control device. *For more details, please refer to the PDF document or feel free to contact us.

There have been operational mistakes resulting in the acceptance of unacceptable raw materials during the receipt of incoming materials. When issues arise with the raw materials, the extraction of used products is conducted on a paper basis, which takes time. The "Raw Material Weighing Management System" is a system that centrally manages master data, incoming instructions, order information, and incoming/weighing performance in a database. Based on the incoming instructions, the raw material receiving operation is carried out, and barcode labels for the received raw materials are issued at the individual packaging unit level. After selecting the weighing raw materials and orders, the raw material barcode is scanned, the weighing operation is performed, and a barcode label for the weighed product is issued. The incoming and weighing performance information is then summarized on a daily basis and handed over to the higher-level system. 【Purpose of System Implementation】 <Cost Reduction, Business Efficiency> ■ Integration with Higher-Level Systems: Reducing registration and maintenance tasks ■ Manufacturing Responsibility System: Operational restrictions through the setting of work permissions ■ Lot Traceability: Tracing raw materials from the upstream process of incoming raw materials and the downstream process of weighing raw materials *For more details, please refer to the PDF document or feel free to contact us.

The "Container Automated Transport Management System" is a system that manages production instructions, transport management, container bin management, and shelf management. It provides From-To instructions for transport equipment in processes such as raw material input, blending, raw material supply, product receipt, cleaning and drying, and product bagging, using automated warehouses as raw material warehouses, intermediate warehouses, and product warehouses. The design facilitates easy recovery from transport troubles, and the implementation achieves a reduction in recovery time during troubles through the visualization of equipment and device information. 【Purpose of System Implementation】 ■ Visualization - Real-time confirmation of the operation and abnormal conditions of manufacturing equipment and transport devices. ■ 24-hour Operation Support - By using general-purpose OS computers, transport management, transport control, shelf management, and container management are performed via PLC. - Data on the PLC side is backed up from CPU1 to CPU2, and regular backups are also performed on general-purpose PCs. *For more details, please refer to the PDF document or feel free to contact us.

The "Manufacturing Management System" receives manufacturing instructions from the host, issues instructions to the manufacturing line, retrieves information from the manufacturing line, and performs status monitoring and alarm monitoring. The manufacturing line primarily communicates data through a master PLC, which conducts management processing. It obtains manufacturing performance data from the manufacturing line and sends the performance data to the host. With the implementation of this system, the workload has been reduced due to the receipt of manufacturing instruction data from the upper level, operations have been standardized to minimize work errors, and the operational status during manufacturing can now be monitored in real-time. 【Purpose of System Implementation】 <Improving Operational Efficiency> ■ Integration with Upper Systems: Reduces registration tasks and errors through manufacturing instructions and performance handover. ■ Understanding Manufacturing Status: Allows real-time monitoring of the manufacturing line's status. *For more details, please refer to the PDF document or feel free to contact us.

Until now, the management of manufacturing performance data has been conducted independently for each process, and since it was not centrally managed, it has been difficult to grasp the overall manufacturing situation, such as inventory, yield, and defect status. Therefore, there was a need to centrally manage manufacturing performance data across multiple processes. In the "Process Management System," operators register the manufacturing performance of each process on the operation screen, and based on the registered manufacturing performance data, inventory information and yield information are output in report form. It enables product traceability by lot or part number and transfers manufacturing performance and inbound/outbound performance data to higher-level systems. 【Purpose of System Implementation】 <Factory Visualization> ■ Want to understand inventory and yield status ■ Want to centralize the management of manufacturing performance data that is currently independent for each process ■ Want to conduct traceability management of products on a lot or part number basis *For more details, please refer to the PDF document or feel free to contact us.

Due to the operation and fault recording by equipment personnel and the aggregation by process managers, it was difficult to grasp the real-time operating status, and various entries and aggregations were made depending on the equipment. The "Equipment Operation Management System" is a system that collects operating status from approximately 400 pieces of equipment in a line production method and performs unified operation management. Additionally, using MELSEC CC-LINK as the equipment local network, it collects and manages all operating statuses from the conveyor belt to processing, coating, firing furnace, and inspection machines based on the same criteria. Furthermore, the client's operating status can be displayed in a browser and output to Excel, eliminating the need for a dedicated computer. 【Purpose of System Implementation】 <Unified Management of All Equipment> ■ We want to manage the operation of all equipment (approximately 400 units). ■ We want to understand losses due to failures in preceding and following processes and delays in replenishment. ■ We want to manage product flow through real-time status monitoring. *For more details, please refer to the PDF materials or feel free to contact us.

The system automatically sorts the destination of products in the manufacturing site. Based on data from inspection equipment systems in the previous process and higher-level systems, it determines whether products are good or defective according to predetermined conditions and automatically decides the sorting destination on the manufacturing line. By quickly and accurately processing the sorting of products into good and defective categories, it can help improve manufacturing efficiency and reduce manufacturing costs for customers. Previously, the inspection data inquiry, judgment of good and defective products, and sorting operations were performed manually, which took time and effort, becoming a bottleneck in the manufacturing process. The judgment results for each product were recorded on paper, and the higher-level system was updated later through manual input. [Purpose of Implementation] - Reduce human errors and workload - Automate judgment processing to speed up the manufacturing site - Prevent defective products from flowing into subsequent processes - Continuously update the judgment processing results in the higher-level system for real-time tracking of defective product counts *For more details, please refer to the PDF document or feel free to contact us.

This system uses electronic scales to perform raw material weighing, confirmation weighing during input, sample weighing for analysis, and output weighing, creating weighing record sheets. A tablet PC is adopted as the weighing terminal, and by utilizing Bluetooth communication to connect each device in an M2M manner, it enables output of reports from the electronic scale to the printer without human intervention. The wireless system configuration allows for space-saving, making it suitable for various customer environments. In the introduction, there was a background of wanting to "replace the existing electronic scales with a weighing system" and "create a configuration that allows for flexible changes to the indoor layout rather than a fixed one." 【Purpose of Introduction】 ■ Space-saving Effectively utilize indoor space without securing a dedicated area for the weighing terminal. ■ Freedom in indoor layout Ensure that the placement of devices is not restricted by connection to communication cables. ■ Simplification of operations during weighing tasks Enable printing of weighing record sheets without screen operation on the weighing terminal. *For more details, please refer to the PDF document or feel free to contact us.

Due to the inability to centrally manage production data, there were issues such as not being able to grasp the situation in the cell production area and frequent work omissions and mistakes because tasks were based on paper work instructions. The "Cell Production Management System" manages production information for each process such as picking, assembly, inspection, and shipping in real-time at the cell production site, while also enabling product traceability through real-time management of each product. Additionally, by displaying work instructions linked to actual tasks, it is possible to eliminate work mistakes and prevent the outflow of defective products. [Purpose of Implementation] ■ Visualization of the cell production site - Accurately grasp the progress and status of products and output - Quickly track when, who, what, and how tasks were performed ■ Quality improvement: Prevent quality loss by eliminating work mistakes and increasing yield ■ Reduction of worker burden: Reduce the burden on workers and aim to shorten production time *For more details, please refer to the PDF materials or feel free to contact us.

There were many manually operated devices, which placed a burden on workers as they had to travel back and forth to the site. Additionally, there were frequent operational mistakes by inexperienced workers during manual operations, as well as variations in quality due to reliance on the workers' experience and judgment. The "Reaction Kettle Control System" automatically blends raw materials processed in the reaction kettle according to specified recipes and transfers them to the reaction kettle. It automates a series of controls from heating to drying within the reaction kettle, automatically transferring the reaction products to the product tank and switching to a different tank when the transfer destination is full. The entire process is managed under lot control, and after the final process is completed, a performance file is created. It is centrally managed in the process management room, and remote manual operation is also possible depending on the situation. [Purpose of Implementation] ■ Centralized Monitoring and Operation We want to reduce the burden of traveling to the site by remotely operating on-site equipment from the process management room. ■ Stabilization of Quality We want to automatically calculate blending amounts to prevent operational mistakes and stabilize product quality. ■ Automation of Records We want to eliminate the creation of records by workers and automatically collect accurate data to improve operations. *For more details, please refer to the PDF document or feel free to contact us.