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"To compete with the world, the core areas of production sites must be digitalized." —— Tobata Tallet Co., Ltd. has introduced Kaizen Maru as a tool to realize the Toyota Production System (TPS) through IoT. The challenge was the "variability in work time due to human factors." By utilizing contact switches, we analyzed where the variability in work time occurred. The decisive factors were the "price" and "freedom of data utilization" that other tools do not offer. As a result of linking the data from Kaizen Maru with our in-house developed system, the labor required for daily report aggregation was reduced to zero, the identification of equipment downtime causes became three times faster, achieving an annual cost reduction of over 321 hours and 660,000 yen. Furthermore, data-driven Kaizen has been revitalized, leading to an increase in improvement proposals from the field. No wiring work is required, and measurements can start in as little as three days. For those looking to enhance competitiveness through DX of core processes, please refer to the detailed case study.

• Other production and development software and systems

A sewing factory, Nichihan Textile, that handles Okinawa's traditional "Kariyushi wear." Progress management was completely analog, and it was only through the operator's "gut feeling" and handwritten daily reports that we could identify where bottlenecks were occurring. Kaizen Maru was introduced in the final assembly process of shirt production. It was a decisive factor that it could be flexibly customized even in a complex sewing environment where processes frequently change, and that there was ample hands-on support available for sites lacking expertise. Currently, output is automatically collected via sensors and visualized in real-time on monitors. With the management side having "objective numbers," misconceptions like "that person is slow" have been dispelled, deepening trust in the workplace. The design is simple enough for anyone to understand the situation at a glance. If you are struggling with complex processes in small-batch production, we also offer free consultations, so please feel free to reach out.

• Other production and development software and systems

Founded in 1952, Sumikura Steel has honed its steel processing in the iron town of Kitakyushu. They faced challenges such as wanting to "quantify skilled experience to create a more efficient production system" and "share the operational realities of the large factory with the team." At Kaizen Maru, we first redefined "what constitutes operational rate," and installed sensors in optimal locations across the 30,000 square meter site. Simultaneously, we improved the factory's Wi-Fi, creating an environment where operational status can be checked in real-time via smartphones. After implementation, a proactive mindset emerged on the shop floor regarding "how to operate more efficiently," and daily efforts were fairly evaluated using objective metrics. The accumulated data is also utilized for making decisions on personnel allocation without excess or waste. No wiring work is needed, and measurements can start in as little as three days. If you have the same challenges, please check the detailed case study.

• Other production and development software and systems

Do you have such concerns? "I don't know where to start," "I want to organize the issues on-site," "I can't find good tools," "I can't change from paper operations." We can solve those problems. This service was developed for companies that are just starting their digital transformation, based on the concerns of many manufacturing companies. Please feel free to consult with us.

• Other production and development software and systems

This is an optimal visualization tool for complex environments where processes frequently change, such as in small-lot, multi-variety production. It allows you to graduate from analog progress management and the "gut feeling" of identifying bottlenecks, automatically collecting real-time output. Its strengths include flexible customization tailored to the site and "hands-on support" that provides reassurance even without IT knowledge. By evaluating the site with objective data rather than subjective feelings like "that person is slow," the trust relationship between managers and the site is also deepened.

• Other production and development software and systems

This is a DX tool that digitizes the core processes of the production site. By utilizing sensors such as contact switches, it automatically collects data from on-site equipment and analyzes in detail where there are variations in work time. The biggest feature is the "freedom of data utilization." The data obtained through Kaizen Maru can easily integrate with existing systems developed in-house or daily report management tools. It activates improvement activities based on data and establishes a system to increase improvement proposals from the field. 【For concerns like these】 ■ I don't want to burden the manufacturing site ■ The manufacturing site is not strong in IT ■ I want to avoid the risk of halting the manufacturing site

• Other production and development software and systems

This service digitizes the "on-site conditions" that relied on the intuition and experience of craftsmen, supporting technology with data. It covers the entire vast factory area and shares operational realities in real-time, strengthening collaboration as a team. To provide support for re-evaluating the definition of "what constitutes operational efficiency," we ensure a smooth introduction even for those new to digital transformation (DX). Based on the acquired data, it enables quick decision-making on "how to allocate personnel to reduce burdens under various conditions," creating a workplace that excites employees. 【For concerns like these】 ■ I don't want to burden the manufacturing site ■ The manufacturing site is not strong in IT ■ I want to avoid the risk of the manufacturing site stopping

• others
• Other mounting machines

"Kaizen Maru" is a Kaizen support service that realizes data visualization with consideration for the workplace. We provide total support from the introduction and installation of dedicated devices to "data analysis, proposal of improvement measures, and operation" after visualization. It is possible to visualize issues in real-time while keeping the business processes as they are. 【Features】 ■ Introduction of devices for real-time numerical visualization ■ Consideration and operation of Kaizen measures based on analysis results ■ Total support by experts *For more details, please download the PDF or feel free to contact us.

• Other production management systems
• Software (middle, driver, security, etc.)