What is equipment utilization rate? A comprehensive explanation of the calculation method, factors causing decline, and countermeasures.
Benefits of Smart Factories and Tips for Promotion
Improving productivity through the utilization of IoT! This explains the importance of smart factories, which are currently attracting attention.
In recent years, there has been growing attention on smart factories, which are expected to maintain and improve productivity while reducing the number of employees through the utilization of IoT. Additionally, the impact of the COVID-19 pandemic has increased their importance. However, in reality, many companies have not made progress in transforming into smart factories, and there are several barriers that pose challenges. This document will introduce the barriers hindering the transition to smart factories and methods to overcome these obstacles and promote the transformation.
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Chapter 1 Four Benefits of Smart Factory Transformation - What is a Smart Factory? The Growing Importance - Benefit 1: Visualization of Production Line Status and Centralized Management - Benefit 2: Efficient Utilization of Production Resources - Benefit 3: Stabilization and Improvement of Quality - Benefit 4: Response to Diverse Customer Needs Chapter 2 Four Barriers to Smart Factory Transformation - The Current State of Smart Factory Transformation in Japan - Barrier 1: Difficulty in Cross-Departmental Initiatives - Barrier 2: Lack of Personnel with Technology and Expertise - Barrier 3: Difficulty in Selecting Optimal Tools - Barrier 4: Security Risks Chapter 3 What is Needed to Promote Smart Factory Transformation? - Utilize Business Data Across the Company - Develop Personnel Capable of Requirements Definition - Understand Current Issues and Improve Production Management Systems - Implement Security Measures Combining IT and OT Defense
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【Purpose and Benefits of Implementation】 Improvement of Productivity and Resolution of Bottlenecks: Visualizing the progress and operational status of processes to reduce waiting times and setup losses. Elimination of Dependence on Individuals and Technology Transfer: Standardizing and digitizing the know-how of veterans to establish a system where even less experienced workers can perform uniform tasks. Realization of Preventive Maintenance: Operating maintenance plans based on operational data to prevent line stoppages due to unexpected equipment troubles. Improvement of 5S and Flow on the Shop Floor: Digitizing the movement of people and objects to create a factory layout that eliminates waste in searching and unnecessary movement. 【Examples of Improvements and Achievements】 Case 1 (Automotive Parts): Digital standardization of assembly process work procedures. Smooth technology transfer to younger employees, reducing setup time by 35%. Case 2 (Precision Machining): Thorough implementation of preventive maintenance through visualization of equipment operation. Reduced unexpected equipment stoppages by 80%, achieving stable production. Case 3 (Metal Processing): Transition from paper-based daily report management to a production management system. Real-time "visualization" on the shop floor reduced indirect work hours by 40 hours per month.
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Continuing to stay close to our customers, we have built up business knowledge and empathy to understand their challenges. By handling a wide range of operations in a one-stop manner, including system design, development, operation, hardware and software proposals and sales, and network construction, we remain a partner that supports the creation of "valuable systems," sometimes in a collaborative manner and sometimes in a leading role. Our company changed its name on April 1, 2025. (Former company name: Daiko Electronic Communication Co., Ltd.) The data and presentation materials published are from the time of the announcement.
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