Reduction of 321 man-hours | Case study of Tobata Turret Works
Kaizen Maru / Case Study: Toyota Style × IoT (Tobata Turret Works)
DX of small and medium-sized manufacturing industries fighting against the world. Annual cost reduction of over 660,000 yen.
"To compete with the world, the core areas of production sites must be digitalized." —— Tobata Tallet Co., Ltd. has introduced Kaizen Maru as a tool to realize the Toyota Production System (TPS) through IoT. The challenge was the "variability in work time due to human factors." By utilizing contact switches, we analyzed where the variability in work time occurred. The decisive factors were the "price" and "freedom of data utilization" that other tools do not offer. As a result of linking the data from Kaizen Maru with our in-house developed system, the labor required for daily report aggregation was reduced to zero, the identification of equipment downtime causes became three times faster, achieving an annual cost reduction of over 321 hours and 660,000 yen. Furthermore, data-driven Kaizen has been revitalized, leading to an increase in improvement proposals from the field. No wiring work is required, and measurements can start in as little as three days. For those looking to enhance competitiveness through DX of core processes, please refer to 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 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
[Results] Nichihan Fiber Co., Ltd.: Kariyushi wear manufacturing factory. [Effects] Achieved accurate real-time understanding of output. Eliminated assumptions on the shop floor with data, leading to improved productivity through optimal personnel allocation. [Applications] Progress management for small-lot production of various items, identification of bottlenecks, and data-driven placement of personnel in suitable positions.
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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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