[Case Study] Troubles Caused by Chocolate Stops on the Line
Frequent "choco stops" during line operation! Introducing a case of improvement with the implementation of positioning sensors!
At one point on the production line, frequent troubles (chocolate stops) were occurring, and during these troubles, the line could not be stopped, causing the work from the previous process to enter the trouble area and become defective. We wanted to introduce AB control, so we summarized the current issues, which revealed three main factors: "troubles are not detected, and work is being input," "work continues to flow even while workers are engaged in recovery operations, making it unsafe," and "the working environment is poor, and the photoelectric sensor is not detecting." Therefore, we installed the positioning sensor "PS-4482" from Makome Research Institute on the line conveyor and the magnetic body "MG-102A" on the work pallet. As a result of the improvements, we achieved a work loss amount of 0 yen and realized a cost reduction of 26,568,000 yen per year. *For more details, please refer to the PDF document or feel free to contact us.
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【Case Summary (Partial)】 ■Trouble Situation and Losses - Trouble Frequency: 6 times/28,800 seconds - Work Loss Amount: 184,500 yen/1 unit - Annual Work Loss Amount: 26,568,000 yen - Loss: 184,500 yen/1 work per line stoppage ■Points of Improvement and Expected Customer Benefits - Installed PS-4482 at trouble spots to detect the condition of the workpiece - Able to detect detailed information about the workpiece due to 4-channel information output - Sensing in harsh environments, which was not possible with photoelectric sensors, is now achievable - Positioning sensor "PS-4482" installed on the conveyor, enabling AB control ■Effects and Benefits of Improvement - Trouble Frequency: 0 times/28,800 seconds - Work Loss Amount: 0 yen - Annual Work Loss Amount: 0 yen *For more details, please refer to the PDF document or feel free to contact us.
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For more details, please refer to the PDF document or feel free to contact us.
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CAD data（6）
| Model number | overview | File |
|---|---|---|
| MG-102A | SW use ferrite magnet with cover |
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| MG-102A | SW use ferrite magnet with cover |
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| PS-4482 | 4ch positioning sensor |
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| PS-4482 | 4ch positioning sensor |
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| SW-2507F | Positioning sensor |
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| SW-2507F | Positioning sensor |
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Company information
Utilizing our original technology of saturable coils, we offer a fundamentally simple magnetic detection element technology that provides high precision and long-term stability even under adverse conditions. We have received strong support from a wide range of industries, including unmanned transport carts, industrial equipment, labor-saving machines, material handling, machine tools, injection molding machines, civil engineering and construction robots, food machinery, industrial machinery, nuclear facilities, and ships. We also excel in sensors for motorsports such as F1 and Moto GP, tilt meters for construction machinery, and magnetic sensors used for ultra-high precision measurements in scientific fields. Some of our products are also used in applications like multi-story parking and golf cart guidance sensors. All of our products are developed and manufactured 100% in Japan, with over 80% of our product lineup being custom-made based on individual customer requests. We have many custom options available, including waterproof, explosion-proof, heat-resistant, water-resistant, and radiation-resistant specifications. If you have any issues related to sensing or measurement, please feel free to consult us. IoT Platform: Our sales and technical staff are fully committed to addressing everything from minor customizations of existing products to proposing new detection principles. You can also rely on us for assistance with improvements. Our standard products come with a reassuring 3-year warranty. Location: Ina, Nagano Prefecture. Published on Ipros Monozukuri.
