Visualization of Steel Processing Operations | Sumikura Steel Case Study
Kaizen Maru / Case Study - Steel Processing (Kitakyushu - Sumikura Steel)
Visualizing the "now" of factories through "on-site DX." Making the entire 30,000 square meters visible.
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.
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basic information
- Flexible sensor settings tailored to complex processes (such as sewing and assembly) - Real-time visualization of production output on monitors - Instant decision-making on bottleneck processes based on accumulated data - Support for implementation and operation on-site by experts
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Applications/Examples of results
[Achievements] Nichihan Textile Co., Ltd.: Manufacturing plant for Kariyushi wear. [Effects] Achieved accurate real-time understanding of output. Eliminated assumptions on-site with data, leading to improved productivity through optimized personnel allocation. [Applications] Progress management for small-lot production of various items, identification of bottlenecks, and data-driven optimal placement of personnel.
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Company information
Since its founding, the Ijigen Group has been dedicated to developing its own services based on "people" who can excel in three specialized areas: business, technology, and creativity. We have provided support to solve a wide range of challenges, including management, human resources, and business. The future we aim for is "a world where various people can take on challenges." As a partner that supports diverse challengers, we aim to create an environment that sometimes brings about "awareness" and enables them to take steps toward a better future. With this mission in mind, we tackle problem-solving with the creativity and support we have built over many years, contributing to the realization of a society where each individual can experience abundance.
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