Improvement of Quality Management System through DX of Tool Management: Case Study
Over 600 tools managed centrally with RFID, significantly reducing operational burden!
At Yutaka Manufacturing Co., Ltd., the development and manufacturing of electrical components for railway vehicles prioritize quality and safety, establishing a high-level quality management system. They strictly manage the usage and calibration status of over 600 tools and measuring instruments, and have begun exploring tool management utilizing RFID technology to further enhance quality. Challenges Before Implementation Workload Associated with Calibration Management Although the management and recording of calibration deadlines for measuring instruments like calipers are thorough, the workload was high. Difficulty in Understanding Usage Status While an asset management ledger is maintained, there were no records of usage, making it difficult to grasp the inventory status. Lack of Transparency in Usage History The frequency of use at the individual item level could not be aggregated, leaving the effective utilization of assets unclear. Features of the Implemented System By utilizing RFID technology, tools and measuring instruments equipped with IC tags can be registered for checkout and return simply by touching them to a reader. By registering calibration deadlines in the system, a warning is displayed on the screen when an attempt is made to check out an expired measuring instrument, preventing misuse in advance. This has enabled more precise quality management without increasing the workload.
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Main Functions and Features of the RFID System ■ Registration of Borrowing and Returning with IC Tags Simply touch the tool with the IC tag to the stationary reader to complete the registration. No manual input is required, preventing input errors and improving operational efficiency. ■ Management of Calibration Deadlines For measuring instruments that require calibration, deadlines can be registered. If the deadline has passed, a red warning is displayed on the screen. Extraction by specifying the deadline range is also possible, supporting reliable calibration management. ■ Registration of Reasons for Borrowing Reasons for borrowing, such as internal use, external lending, business trips, repairs, and calibration, can be recorded. This contributes to clarifying the purpose of use. ■ Inventory and History Inquiry Function Current inventory status and expected return dates can be checked immediately. In the history inquiry, borrowing and returning history is displayed chronologically, and can be filtered by user, item, and duration. This enables traceability of tools. ■ Metal-Compatible IC Tags Adopting small, ceramic-processed metal-compatible tags that do not interfere with work when attached to tools. They demonstrate stable reading performance even in field environments.
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Points of Business Improvement through the Introduction of RFID Systems ■ Further Improvement in Quality Control By systematizing the management of checkouts and returns with RFID, it has become possible to verify calibration deadlines through a dual check of "physical labels" and "PC screen warnings." This has enabled higher-level quality control without increasing the workload. ■ Efficiency in Tool Management Operations The registration function for calibration deadlines has made accurate and efficient calibration management possible. The operations for checkouts and returns are simple, allowing users to start using the system smoothly without confusion, which has facilitated the reliable collection of usage data. ■ Visualization of Operations It has become possible to grasp "who used what and when" in real-time, allowing for quick responses in case of forgotten returns. Usage data can be output in CSV format, enabling analysis for inventory optimization and effective asset utilization through the aggregation of usage frequency and other metrics.
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Founded in 1894 as a textile company, Takaya Textile expanded and established its electronics division in 1966, beginning the assembly of transistor radios. Currently, in addition to contract manufacturing services (EMS) related to electronic devices, the company actively manufactures and sells in-circuit testers (printed circuit board inspection devices), RFID-related equipment (technology that enables information exchange through short-range wireless communication from IC information tags), and engages in IT consulting and system solutions, among various electronics businesses both domestically and internationally. We will continue to evolve as a corporate group that contributes to the development of society, with textiles and electronics as our two pillars.