To support traceability, the collection of manufacturing performance data has been digitized. This enables centralized management of manufacturing conditions and aggregated statistics by product type and process, establishing a foundation for utilizing manufacturing data.
Case study of database integration for manufacturing information management systems and production orders/actual performance information. Company A in the food manufacturing industry had systematized production information management, but faced challenges in the efficiency of integrating production data and utilizing data due to the need for individual management for each piece of equipment and machinery. With the introduction of MainGATE/PPA, they established an environment for integrated management of production information and online collection of actual performance, enabling efficient data utilization.
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Related Products: MainGATE/PPA MainGATE/PPA enables real-time understanding and management of operational information related to product manufacturing, achieving "visualization" of manufacturing information across various levels from the shop floor to the factory, and from managers to executives. Additionally, it can be used to analyze the causal relationship between manufacturing parameters and actual performance data on a lot-by-lot basis.
Applications/Examples of results
[Challenges Before Implementation] - Equipment and devices were managed individually, making it difficult to grasp the overall system due to its complexity. - The existing production information system lacked scalability, resulting in costs incurred each time a system addition or expansion was needed. - Planning and actual performance information were not accumulated, requiring manual verification and analysis of past data. [Implementation Effects] - Resolution of Complexity: Integrated equipment under PLC control and unified lower-level systems to create a more easily comprehensible overall system. - Improved Scalability: Built a flexible system capable of accommodating the expansion of target processes and the enhancement of manufacturing information. - Expanded Data Collection Scope: Collected critical data such as flow rates and concentrations, achieving system visualization. - Increased Efficiency in Report Creation: Streamlined the calculation of operating rates and report generation through screen operations.
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Case Study: Manufacturing Information Management System
Current Status and Challenges of DX (Digital Transformation) in Production Management in the Food Manufacturing Industry
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Providing solutions for various plants and factories such as food, chemicals, oil and gas pipelines, paper and pulp, and cleaning facilities. Our measurement and control systems have over 40 years of history since the launch of the first distributed control system in 1975. Based on our track record, we propose systems and solutions to support the latest technologies, IoT utilization, and the development of smart factories. - Steam generation heat pumps / waste heat utilization / visualization of thermal energy - Clamp-on steam flow meters / flow meters / flow sensors / thermal balance analysis - Industrial furnaces / electric furnaces / high-frequency induction furnaces / IGBT power supplies - Gas analyzers / gas measurement devices / gas analysis sensors - Predictive maintenance / anomaly detection maintenance / preventive maintenance / maintenance and prevention systems / smart security - Smart factory - MES / DCS / SCADA / edge controllers - EMS / energy management systems / visualization of energy - Smart glasses / remote work support systems - Multivariate analysis / MSPC - Engineering tools