An IoT package for factories called "Factory Guardian" that can be implemented for around 4 million yen.
Factory guard
IoT for factories researched in the manufacturing industry! Constantly collecting and visualizing machine operation information! For analyzing production efficiency and reasons for downtime.
Using IoT, we want to continuously collect and visualize operational information from factory machinery to analyze production efficiency, reasons for downtime, and improve quality. However, how can we achieve this... "Factory Guardian" responds to such challenges. "Factory Guardian" is an IoT package developed through research on manufacturing factories. It offers a comprehensive proposal of necessary equipment and specifications in a package, making it easy to implement even without expertise in system construction. Since it is a packaged system, there is no need for the costs associated with custom-made solutions, allowing for very affordable implementation and significantly reducing the effort and costs of IoT adoption. Do you have any of the following challenges? - I want to easily implement IoT to improve production efficiency and quality, but I lack the know-how... - I've heard that implementing IoT incurs significant costs, making it out of reach... - I need a solution that is not just cheap but also effective for manufacturing... - I want a system that fits my factory... All of the above challenges will be solved by Yamashina's "Factory Guardian." *For more details, please refer to the PDF or contact us.
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basic information
● Sensors, etc. After consulting, we will propose solutions that fit your factory. ● System (Software) It is built on the basis of edge computing. Information from PLCs and sensors is processed and managed within the PC, making security measures easy to implement. Additionally, since large amounts of data are not sent to the cloud, it can be operated at appropriate communication costs. The system is developed by Japan Rad Inc., which has been active as a system integrator since 1971. ● System (Hardware) We use devices from Advantech, a manufacturer of industrial PCs. They are suitable for use in tough factory environments. ● Output Information Production quantity, production progress, operating rate, number of abnormal occurrences, operating status by equipment (andon), real-time abnormal reports, abnormal history, time-based operating status analysis, time-based non-operating factor analysis, production pitch, and the above will be displayed as needed in graphs and tables for the entire factory, each line, each equipment, each month, each day, etc.
Price information
The price varies depending on the scale of the system.
Delivery Time
※Approximately 3 to 4 months after the order is received.
Applications/Examples of results
The packaged IoT solutions, ranging from sensors to software, for the manufacturing industry have finally begun to be introduced to the market. In the future, many implementations are expected to be considered due to the advantages of easy adoption. Furthermore, our company, Yamashina, is engaged in the metal products business (screw manufacturing), and we will utilize this "Factory Guardian" to IoT-enable a total of 100 manufacturing machines of different models across two lines in our factory by April 2018 (demonstration has been completed).
Detailed information
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The operating status of the factory equipment is displayed in color-coded format. The planned production quantity, actual production quantity, production progress, operating rate, number of abnormalities, and the status of abnormalities are all displayed in a centralized manner.
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Production Real-Time Monitor It displays the current production plan numbers and actual figures, production progress, operational status such as stopped, waiting, and running, as well as a breakdown of reasons for inactivity.
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Operational Information Analysis Operational information such as stops, standby, and operation is displayed in a time series format, such as by day. At the same time, the breakdown of non-operational status (reasons for stopping) is also displayed.
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Production progress analysis (monthly) The planned production quantity and actual results will be displayed.
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Production pitch analysis It compares the production quantity per minute with the reference value and displays it in a graph.
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Company information
Established in 1917, during the dawn of mass production of screws in Japan, the company succeeded in producing the first domestic cross-recessed screws in 1949 and cooperated with the government to domesticate tapping screws in 1954. We hold data on over 200,000 types of screws and bolts, enabling us to manufacture a variety of products with high quality. Recently, we have been focusing on research and development investments, working on tapping bolts with a diameter of 6mm or more, high-strength aluminum bolts, tapping screws for thin steel plates, and tapping screws for CFRP, which will support the next generation. We are committed to challenging innovative technology development without being bound by history.