協立電機 List of Products and Services

The "Piping Leak Inspection Device" features a simple structure that allows for cost-effective implementation and easy maintenance. It inspects the airtightness of products using digital panel meters and dedicated jigs without going through controllers like PLCs. The results are communicated to the operator through sound (melody) and light (lamp). With its introduction, initial investment has been minimized, and it can flexibly accommodate various product types. Additionally, due to its simple structure, system maintenance has become easier. 【Background for System Implementation】 - The existing inspection equipment has aged, and we want to update it. - We want to implement the inspection system with a minimal configuration and at a low cost. - We want to perform inspections for various product types with just a simple setting switch. *For more details, please refer to the PDF materials or feel free to contact us.*

• Measurement and Inspection

This product is a testing device designed for the load endurance testing of workpieces (test subjects). The background for the system introduction is the consideration of introducing new testing equipment and adding functionalities due to the aging of the existing equipment. By changing the fixture at the tip of the cylinder, it can accommodate various shapes of workpieces. The workpiece is installed in the testing device, and a load (0 to 2000N) is applied using the cylinder. 【Purpose of System Introduction】 ■ Continuous Automatic Operation - We want to continuously operate the same motion pattern for a specified number of times. ■ Improvement of Testing Accuracy - We want to continuously measure the load of the cylinder during testing and visualize it. *For more details, please refer to the PDF document or feel free to contact us.

• Other measuring instruments

The "Non-Rotating Torque Testing Device" is a system that allows for arbitrary variable adjustment of the testing environment using a constant temperature and humidity chamber. The applied torque can be selected as manual or automatic, enabling stable torque testing through a non-rotating torque generation unit and a non-rotating torque converter. It has been introduced due to the background of wanting to "perform stable torque application in a non-rotating manner to improve testing accuracy" and "arbitrarily vary the installation environment of the test subject to enhance testing efficiency." 【Effects of Introduction】 ■ Improvement of Operational Efficiency - Stable torque application has become possible, leading to improved testing efficiency. - The adoption of a small-capacity constant temperature and humidity chamber has shortened the stabilization time of the testing environment. ■ Improvement of Data Collection - The collection of testing data has been automated, improving the work efficiency of the testers. *For more details, please refer to the PDF document or feel free to contact us.

• Measurement and Inspection

This system is a battery capacity testing machine that combines charging and discharging functions for industrial batteries. The background for the system's introduction is the need for charging/discharging capabilities at the cell level for battery maintenance of electric unmanned carts and similar applications. With its implementation, the alarm function and data logging have reduced the frequency of checking test conditions, leading to a reduction in labor hours. Additionally, by allowing test settings to be made via a touch panel, testing has become smoother. 【Features】 ■ Settings necessary for charging and discharging tests can be easily configured from the touch panel. ■ It measures charging and discharging voltage, cell voltage, and temperature, allowing monitoring of state transitions during charging and discharging. ■ Various conditions such as voltage/time/temperature can be selected for charging and discharging completion criteria. ■ Cell voltage and battery temperature during charging and discharging are recorded by a data logger. ■ The recorded logging data is stored in the memory of the data logger itself. ■ Data can be replayed on a PC using a manufacturer-specific application. *For more details, please refer to the PDF document or feel free to contact us.

• Measurement and Inspection

The "Optical Power Logger" is a system that automatically measures the attenuation of optical cables. As background, we were considering the introduction of an automation system and the construction of a robust system that can operate 24 hours a day, using existing measuring equipment without purchasing new facilities. This system combines an optical power meter with a multi-channel multiplexer to record the characteristics of optical cables over long periods while simultaneously recording the temperature of the test environment using a thermometer. By preparing two sets of measuring devices, it is possible to operate under two different conditions (test environments), allowing for the recording of characteristics under various situations while also using environmental testing machines. **Effects of Implementation** **Improvement of Work Efficiency** - The adoption of FA computers allows for long hours of continuous operation with peace of mind. - Since it is operated automatically by software, daily checks can be reduced to about one or two times, contributing to a reduction in man-hours. - As numerical records are stored in electronic data, accurate comparisons and judgments can be made using digital values. - The shift to paperless recording through electronic data makes data storage and management easier. - Further software customization allows for the expansion of various functions. *For more details, please refer to the PDF document or feel free to contact us.*

• Other measuring instruments

The "Dielectric Strength and Power Consumption Testing Device" is a device that conducts dielectric strength tests and power consumption tests for electric actuators, allowing for product evaluation. To accommodate a variety of workpieces, the voltage values for dielectric strength and the applied voltage settings for power tests, as well as the threshold settings for measurement values, can be pre-saved for each model. Previously, dielectric strength tests and power consumption tests were performed manually, with measurement values assessed visually and data recorded by hand, resulting in variations in takt time depending on the operator. Although high voltage is used, the warning lamp only illuminated during the dielectric strength test to alert the operator, which raised some concerns about safety. With the introduction of this product, automatic testing can be performed simply by pressing a button, and data can be saved, making the process more efficient. [Effects of Implementation] ■ Improvement in Work Efficiency - Automatic testing and data saving can be performed simply by pressing a button, making it efficient. ■ Safe Operation - An area sensor is installed, ensuring safety by preventing contact during the dielectric strength test. *For more details, please refer to the PDF document or feel free to contact us.

• Measurement and Inspection

In continuous thickness measurement, rather than measuring the thickness at specific points of the object, continuous thickness data is collected, making it easier to judge the condition of the object. This system is designed for continuous thickness measurement, where the measurement target is clamped from above and below using displacement sensors. Since the measurement is taken from below, it can still be measured even if there is vertical movement. Additionally, the measurement amount from the displacement sensors is output as pulses and input into a high-speed counter unit of a sequencer. 【Measurement Method】 - Since 1 pulse equals 0.1 μm, the thickness is determined by multiplying the pulse count by 0.1. - The signals from the upper and lower displacement sensors are processed to determine the thickness. - The object is clamped with rollers and fed at a constant speed by two stepping motors located before and after the displacement sensors. - The stepping motor operates when the measurement start button on the touch panel is pressed. - The stepping motor stops when the measurement is complete. *For more details, please refer to the PDF document or feel free to contact us.

• Electrical Equipment Testing

The "State Inspection Device" is a device that consolidates multiple testers into one to reduce processes and evaluate products. It switches circuits for each tester used, measures resistance with a digital multimeter, and determines surge waveforms with a surge tester. The inspection results are displayed using lamps installed on the device. Due to the background of wanting to consolidate processes because "measuring with multiple testers involves many setups and is inefficient," and "it is very dangerous to use high voltage, so we want to work safely," this device has been introduced. [Purpose of Introduction] ■ Reduce operational burden - We want to conduct multiple tests at once. ■ Work safely - We want to avoid touching high-voltage circuits. *For more details, please refer to the PDF document or feel free to contact us.

• Electrical Equipment Testing

The "Testing & Environmental Data Measurement System" centrally manages the different test equipment data and environmental data for each product in the field of product evaluation and testing. The centrally managed data is displayed in real-time or historically in graphs specified by the user. This system is implemented with the objectives of "wanting to accommodate multiple test devices without changing the basic structure," "wanting to manage and display test data and environmental data collectively," and "wanting to compare specified data (such as before and after adjustments) in addition to real-time and historical data." 【Benefits of Implementation】 ■ Simplified arrangements and procedures for measurement due to the switching of test devices and standardization of client screens. ■ The time required to learn individual measurement software has been minimized. ■ Previously, comparisons were made by printing past graphs, but now it is easier to understand performance changes as comparisons can be made on-screen. ■ It has become possible to print only the necessary data. *For more details, please refer to the PDF materials or feel free to contact us.

• Measurement and Inspection

This system is designed to perform setting transmission, automatic control, automatic measurement, computation processing, and report printing for air conditioner performance evaluation test facilities. According to operating conditions, it controls the testing equipment and collects and stores measurement data at regular intervals. It has been introduced with the aim of improving the efficiency of control and measurement during air conditioner performance evaluations, preventing operator errors during testing, and enhancing test quality through consistently stable testing. 【Implementation Effects】 ■ The efficiency of testing has improved as tests can be conducted in parallel. ■ Pre-registration of test settings has eliminated variability in testing by operators. ■ Reusing past test data has improved test quality. ■ Analysis of test results has become possible, contributing to improvements in testing operations. *For more details, please refer to the PDF document or feel free to contact us.

• Electrical Equipment Testing

This system is an "Electromagnetic Immunity Test System" that evaluates the electromagnetic resistance of test samples when exposed to electromagnetic fields. It irradiates electromagnetic noise at specified frequencies and test levels, allowing for the assessment of malfunctions or degradation of customer products. Additionally, by using the G-TEMCELL, testing can be conducted safely even without an anechoic chamber. The test frequency ranges from 100 kHz to 3 GHz as standard, and AM, FM, and pulse modulation can also be applied. 【Features】 ■ Improvement of operational efficiency - By managing data collectively, operational efficiency increases. - More efficient operation of expensive equipment. ■ Reduction of burden - Reduces the burden on operators and managers. - Safety interlock circuits help prevent accidents in advance. *For more details, please refer to the related links or feel free to contact us.

• Electrical Equipment Testing

This product is a testing device that uses a simulated load device to measure motor performance characteristics. A large-capacity servo motor is used to apply a simulated load to the test motor, measuring various data such as speed, torque, power, and temperature. By managing the data collectively, operational efficiency is improved, and with the automatic operation function, equipment can be operated efficiently, reducing the burden on operators and managers. Additionally, the establishment of various interlock circuits enables safe testing. [Purpose of Introduction] ■Reduction of Load - Minimize the burden on operators (such as the man-hours required for measurement and comparison) and create a system that does not depend on individual technical levels. - Aim to operate equipment efficiently. ■Reporting Function: Easily generate reports on motor performance. ■Safe Testing - Since it involves testing high-speed rotating bodies, we want to operate a device that is safe and accident-free. *For more details, please refer to the related links or feel free to contact us.

• Electrical Equipment Testing

This system is designed to measure and evaluate the electrical characteristics of semiconductor products such as diodes and transistors by changing the temperature and humidity using a constant temperature chamber. It automates measurements and digitizes data by controlling semiconductor parameter analyzers, constant temperature chambers, and various wiring switches via GP-IB from a computer. The introduction of this system leads to improvements in operational efficiency and a reduction in workload. 【Benefits of Implementation】 ■ Improvement in Operational Efficiency - Automation increases operational efficiency (unmanned operation is possible after the test starts) - Expensive equipment can be operated more efficiently ■ Reduction in Workload - Energy savings are possible by quickly and automatically measuring a series of environmental controls - The time products are subjected to harsh environments can be minimized *For more details, please refer to the related links or feel free to contact us.

• Electrical Equipment Testing

This system is a position control system for a multi-axis stage used to inspect substrates, allowing control of a multi-axis controllable stage (turntable) from a PC to perform inspections and evaluations of various products. It features an automatic origin detection function during initialization, enabling easy operation for multi-axis position control by defining the home position and various other positions. By using various limit sensors in conjunction, it achieves more accurate position detection and various functions such as emergency stops outside the operating range. The applications are diverse when combined with other measurement system applications. 【Purpose of Implementation】 ■Reduction of operational burden - Enables processing of various tests collectively ■Realization with inexpensive equipment - Allows system construction using low-cost PC boards *For more details, please refer to the related links or feel free to contact us.

• Electrical Equipment Testing

The "Cable Shielding Effect Measurement System" is a system designed to evaluate the effectiveness of various shields. It automatically controls a spectrum analyzer and EMI clamp (test bench) from a computer to measure leakage from cables, comparing the measurement results of unshielded cables and multiple shielded cables. In addition to improving operational efficiency, it provides benefits such as reduced workload. 【Benefits of Implementation】 <Improvement of Operational Efficiency> ■ Increased operational efficiency by managing data collectively ■ More efficient operation of expensive equipment <Reduction of Workload> ■ Reduced burden on operators and managers *For more details, please refer to the related links or feel free to contact us.

• Electrical Equipment Testing

During the regular inspection (once a year), a full operation check was conducted. However, there were concerns about the valve sticking, and in fact, there was an instance where the valve could not operate, causing the safety valve to activate. When conducting the operational test, it was necessary to clean the piping due to backflow from the outside air. As a result, we are currently performing operational tests and cleaning work before operation, but we wanted to reduce downtime. This system can prevent sticking of valves that are normally closed and confirm their operation. By operating the valve just before the piping line slightly opens, we can prevent sticking while simultaneously checking whether the valve is in a state that allows it to operate. [Purpose of System Implementation] - To reduce cleaning work through operational tests and decrease downtime. - To prevent sticking by regularly operating the valve. - To identify any valve malfunctions before operation and take appropriate measures. *For more details, please refer to the PDF document or feel free to contact us.

• Security cameras and surveillance systems

Due to the inability to confirm the production achievement numbers on the production floor, the on-site workers were unable to grasp the delays in production, leading to instances where production was not completed within the target production time. Additionally, because abnormalities and failures in the production area could not be monitored in real-time, by the time issues were noticed, they had escalated into significant problems, resulting in wasted time and costs. This system enables real-time monitoring of the day's production progress by displaying the planned production numbers, actual production numbers, and their discrepancies on the production floor. [Purpose of Implementation] ■ Visualization of production achievement numbers and improvement of worker awareness - By recognizing the delays in production from the discrepancies between planned and actual production numbers, we aim to encourage improvements in work speed and complete production within the target production time. ■ Early detection of failures and abnormalities - We want to quickly respond to on-site troubles by monitoring abnormalities and failures occurring in the production area in real-time while remaining in the office. ■ Integration with higher-level systems - We aim to automatically receive data managed by higher-level systems for planned production numbers and incorporate it into the system without hassle in the office or production area. *For more details, please refer to the PDF document or feel free to contact us.

• Security cameras and surveillance systems

Until now, the personnel responsible for equipment maintenance have been regularly touring each building within the factory. By aggregating data to a central PC via PLCs installed in each building, we can eliminate these regular inspections while monitoring the operational status of on-site equipment in real-time and significantly reducing the workload through automation of report generation. This system captures alarm signals from the PLCs distributed across various factory sites and monitors alarm occurrences at regular intervals on a PC. If an alarm is triggered, it promptly notifies the equipment maintenance personnel via internet email to their mobile phones. Additionally, alarms can be viewed on displays installed at the site. **Objectives of System Implementation** - **Reduction of Operational Load and Rapid Response** - We want to reduce the regular inspections by equipment maintenance personnel. - We want to respond quickly based on alarm information notified via email. - **Centralized Monitoring** - We want to centralize information distributed across various factories for real-time monitoring. - **Data Storage** - We want to record and display historical trends and automatically aggregate (and print) daily, monthly, and yearly reports. *For more details, please refer to the PDF document or feel free to contact us.*

• Security cameras and surveillance systems

In recent years, during emergencies such as abnormal weather, it is necessary to grasp the situation more quickly, and it is essential to accurately understand the situation on-site (dam site, river). However, there has been an issue with the aging of the existing system. This system is designed for remote monitoring of dams and rivers, acquiring various data from existing telemetry, displaying the data on a computer screen, and promptly notifying the responsible personnel via email or fax in the event of an alarm. Additionally, it can aggregate data and output reports as daily, monthly, and annual reports, and by installing surveillance cameras, it enables visual monitoring through images. 【Purpose of System Implementation】 ■ Improvement of Monitoring Accuracy - By confirming both data and images, it is possible to grasp the situation of dams and rivers more accurately. ■ Rapid Response in Emergencies - Sharing the same information between the site and the disaster prevention center allows for a quicker response during emergencies. *For more details, please refer to the PDF document or feel free to contact us.

• Monitoring and Control Equipment

Residents near the factory have occasionally lodged noise complaints, necessitating the prompt identification of the noise source to determine whether it originates from within the factory. Due to the vast area of the factory premises, we are considering the introduction of a system that allows for quick responses while keeping construction costs down. This system measures factory noise near the property boundary and transmits the data collected by the microphones to a central control room, enabling real-time assessment of the noise content and identification of the noise source. This will allow us to respond proactively before noise complaints are received. **Objectives of System Implementation** - To determine whether the noise complaints are from our facility. - If the noise is from our facility, to identify the source and assist in equipment maintenance. - To monitor noise levels while operating (adjusting operational plans for night and day to ensure environmentally friendly operations). - To utilize wireless LAN or similar solutions due to the long-distance wiring required for the internal network. *For more details, please refer to the PDF document or feel free to contact us.*

• Vibration and Sound Level Meter

We would like to introduce an information communication tool that delivers multimedia information to large monitors. Because information was conveyed using paper, it took time for the information to be communicated, and there was no method to convey large-scale advertisements or disaster occurrence information to many people at once. This system can automatically switch the information being delivered based on a time schedule. For example, it can be utilized as a tool for disseminating disaster information, displaying real-time information such as emergency earthquake alerts. 【Purpose of System Implementation】 <Information Dissemination> ■ We want to effectively utilize the visual effects of images and sounds for information communication. ■ We want to quickly display and switch materials. ■ We want to appropriately and efficiently disseminate information according to the time and location in public transportation, public spaces, commercial facilities, etc. ■ In times of urgent need, such as during a disaster, we want to ensure that emergency information can be confirmed immediately. *For more details, please refer to the PDF document or feel free to contact us.

• Digital Signage

As a measure to address electricity demand during the summer, it has been decided to urgently install power generation equipment and to establish a monitoring system for the power generation facilities that has printing capabilities for operational data collection, daily reports, monthly reports, and various other reports. This system will collect data on the operational status of the power generation equipment, power generation data (generation, transmission, reception, fuel, etc.), environmental data (NOx, SO2, O2 equivalent values, etc.), and alarm signals (fire alarms, faults, upper and lower limits, etc.), and will provide real-time data display and trend visualization. Additionally, the collected data will be stored, and various reports such as daily reports, monthly reports, and trend reports will be generated. Furthermore, by utilizing the internet, remote monitoring will be possible. [Objectives of System Implementation] ■ To grasp the operational status, alarms, and measurement values of the equipment in real-time ■ To print daily reports, monthly reports, and trend reports ■ To display collected data trends ■ To enable remote monitoring from the office *For more details, please refer to the PDF document or feel free to contact us.

• Security cameras and surveillance systems

When operators retrieve the designated workpieces, there are instances where they may mistakenly take a workpiece that looks very similar in shape and color for visual confirmation. Additionally, barcodes and QR codes can be significantly affected by heat and dirt during processes like painting, making it difficult to read when affixed to the back of the workpiece. Therefore, we have adopted RFID tags. This system utilizes RFID technology for production management. In each stage of the production line, we perform production instructions and verifications using RFID tags attached to the workpieces (such as products), and upon completion of verification, we record the work performance of the target workpiece. This allows for the confirmation of production status and achievements for each workpiece or process. [Purpose of System Implementation] ■ Prevention of Human Errors - Prevent human errors such as missed checks and verification mistakes. ■ Collection of Production Achievements - Utilize recorded achievement data during verifications at each stage for traceability. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

We would like to introduce the traceability system for products and parts in the assembly process. Although a traceability system had already been implemented, the use of handheld readers by operators to scan barcodes led to issues with the effort required and human errors. In this system, all equipment, products, and parts are interconnected, allowing for automatic scanning of product and part barcodes without human intervention, and recording of traceability information (such as scan date and time, and ID). Since it is linked with the equipment, it is possible to notify alarms for mistakes in assembly procedures and prevent defective products from flowing into subsequent processes. [Purpose of System Implementation] ■ Reduce the workload for operators ■ Eliminate human errors ■ Improve production speed *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

Managing multiple processes independently has made it difficult to have an overall understanding, and each operator has been proceeding based on their own judgment, resulting in a lack of consistency in work and inspection records. Additionally, since work results and inspection records were managed on paper, the reliability of the data was low, and there were instances of missing entries. This system centralizes the management of work and inspection records across multiple processes in a production environment, achieving traceability of operations. Inputting work and inspection records for each process can be done using client PCs, handheld terminals, tablets, or other devices based on usage conditions. 【Purpose of System Implementation】 ■ Visualization of the Factory - We want to centrally manage the data of work achievements and inspection records for each process. - We want to check the progress of work in each process from the office without going to the site. ■ Improvement of Quality - By standardizing work and inspection records for each process and eliminating operator judgment in operations, we aim to eradicate work omissions. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

The "Equipment Operation Management System" centrally manages parts and product information, as well as work history, in the assembly process of a factory. By recording and managing work information and parts/product information in real-time from assembly instructions to work, inspection, and completion, it allows for extraction and inquiry from various perspectives such as products, lots, production dates, and parts, visualizing traceability information in the production process. This enables rapid response in the event of product issues. We respond to the need to easily identify products or lots produced around the same time when product defects occur by ensuring traceability of products, parts, and work. 【Purpose of Implementation】 ■ Quickly and easily track past data on who did what work using which parts and what the results were. ■ Accurately grasp the progress and status of products and output. ■ Automatically determine parts items and installation positions from part identification codes. ■ Reduce the workload during data entry. ■ Eliminate work mistakes such as incorrect part installations to prevent quality loss. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

In raw material inventory management, the use of paper for physical management led to data inconsistencies due to operator input errors, and the long distance between the manufacturing site and the office resulted in delays and time consumption for data registration and viewing. The high temperatures and dust in the manufacturing environment made it difficult to manage with conventional fixed PCs. The "Mobile Device Inventory Management System" allows for inventory management of raw materials, products, and intermediate goods using mobile devices in the manufacturing site. Operators can read in and out information using mobile devices equipped with barcode readers, updating inventory information on the remote inventory management server in real-time from the site. [Purpose of Implementation] - To utilize mobile devices for registering and viewing inventory information while remaining on the manufacturing site. - To always have the latest inventory status based on real-time changes in product in and out information. - To eliminate wiring, allowing operators to move freely around the manufacturing site while performing their tasks. *For more details, please refer to the PDF document or feel free to contact us.

• Inventory Management System

The equipment that requires manual operation is numerous, and workers have been burdened by the need to travel back and forth to the site. Additionally, there have been operational mistakes by inexperienced workers during manual operations, as well as variations in quality due to reliance on the experience and judgment of the workers. The "Reaction Kettle Control System" automatically blends raw materials processed in the reaction kettle according to specified formulas and transfers them to the reaction kettle. It can automate a series of controls from heating to drying within the reaction kettle, automatically transferring the reaction products to the product tank and switching to a different tank when the transfer destination is full. The entire process is managed under lot control, and after the final process is completed, a performance file is created. The process management room centrally manages this and can also allow for remote manual operation as needed. [Purpose of Implementation] ■ Centralized Monitoring and Operation We want to reduce the burden of traveling to the site by remotely operating on-site equipment from the process management room. ■ Stabilization of Quality We want to automatically calculate blending amounts to prevent operational mistakes and stabilize product quality. ■ Automation of Records We want to eliminate the creation of records by workers and automatically collect accurate data to improve operations. *For more details, please refer to the PDF document or feel free to contact us.

• Automatic Control Equipment

Due to the lack of centralized management of production data, it was difficult to grasp the situation in the cell production site, and because work was being carried out based on paper work instructions, there were frequent instances of forgotten tasks and mistakes. This was the background for the introduction. The "Cell Production Management System" manages production information for each process such as picking, assembly, inspection, and shipping in real-time at the cell production site, while also enabling real-time management of products for traceability. Additionally, by displaying work instructions linked to actual tasks, it is possible to eliminate work mistakes and prevent the outflow of defective products. [Purpose of Introduction] ■ Visualization of the cell production site - Accurately grasp the progress and status of products and output - Quickly track who did what and when ■ Quality improvement: Prevent quality loss by eliminating work mistakes and increasing yield ■ Reduction of worker burden: Reduce the burden on workers and aim to shorten production time *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

This system uses electronic scales for raw material weighing, confirmation weighing during input, weighing of samples for analysis, and output weighing, creating weighing record sheets. A tablet PC is adopted as the weighing terminal, and by utilizing Bluetooth communication to connect various devices in an M2M manner, it enables output of reports from the electronic scale to the printer without human intervention. The wireless system configuration allows for space-saving, making it suitable for various customer environments. In the introduction, there was a background of wanting to "replace the existing electronic scales with a weighing system" and "create a configuration that allows for flexible changes to the indoor layout rather than a fixed layout." 【Purpose of Introduction】 ■ Space-saving Effectively utilize indoor space without securing a dedicated area for the weighing terminal. ■ Freedom in indoor layout Ensure that the placement of devices is not restricted by connection to communication cables. ■ Simplification of operations during weighing tasks Enable printing of weighing record sheets without screen operation on the weighing terminal. *For more details, please refer to the PDF document or feel free to contact us.

• Measurement and Analysis Equipment

The system automatically sorts the destination of products in the manufacturing site. Based on data from inspection equipment systems in the previous process and higher-level systems, it determines whether products are good or defective according to predetermined conditions and automatically decides the sorting destination on the manufacturing line. By quickly and accurately processing the sorting of products into good and defective categories, it can contribute to improving manufacturing efficiency and reducing manufacturing costs for customers. Previously, the inspection data for products, the determination of good and defective items, and the sorting operations were performed manually, which was time-consuming and became a bottleneck in the manufacturing process. The results for each product were recorded on paper, and the higher-level system was updated later through manual input. [Purpose of Implementation] - Reduction of human error and workload - Automation of the determination process to speed up the manufacturing site - Prevention of defective products from flowing into subsequent processes - Real-time updating of the determination results in the higher-level system for immediate tracking of defective product counts *For more details, please refer to the PDF document or feel free to contact us.*

• Manufacturing Equipment

The operation and recording of failures by equipment personnel, as well as the aggregation by process managers, made it difficult to grasp the real-time operational status, resulting in various records and aggregations depending on the equipment. The "Equipment Operation Management System" is a system that collects the operational status from approximately 400 pieces of equipment in a line production method and performs unified operation management. Additionally, it uses MELSEC CC-LINK as the equipment local network to collect and manage all operational statuses—from the conveyor belt to processing, coating, firing ovens, and inspection machines—based on the same criteria. Furthermore, the client's operational status can be displayed in a browser and output to Excel, eliminating the need for dedicated computers. [Purpose of System Implementation] <Unified Management of All Equipment> ■ We want to manage the operation of all equipment (approximately 400 units). ■ We want to understand losses due to failures in preceding and subsequent processes and delays in replenishment. ■ We want to manage product flow through real-time status monitoring. *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

Until now, the management of manufacturing performance data has been conducted independently for each process, and as it was not centrally managed, it has been difficult to grasp the overall manufacturing situation, including inventory, yield, and defect conditions. Therefore, there was a need to centrally manage manufacturing performance data across multiple processes. In the "Process Management System," operators register the manufacturing performance of each process on the operation screen, and based on the registered manufacturing performance data, inventory information and yield information are output in report form. It enables product traceability by lot and product number, and transfers manufacturing performance and inventory data to higher-level systems. 【Purpose of System Implementation】 <Factory Visualization> ■ Want to understand inventory and yield conditions ■ Want to centralize the management of manufacturing performance data that is currently independent for each process ■ Want to manage product traceability at the lot and product number level *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

The "Manufacturing Management System" receives manufacturing instructions from the host, issues directives to the manufacturing line, collects information from the manufacturing line, and performs status monitoring and alarm monitoring. The manufacturing line primarily communicates data through a master PLC, which conducts management processing. It retrieves manufacturing performance data from the manufacturing line and sends the performance data to the host. With the implementation, the workload has been reduced by receiving manufacturing instruction data from higher-level systems, operations have been standardized to minimize errors, and the operational status during manufacturing can now be monitored in real-time. 【Purpose of System Implementation】 <Improving Operational Efficiency> ■ Integration with Higher-Level Systems: Reduces registration tasks and errors through manufacturing instructions and performance handover. ■ Understanding Manufacturing Status: Real-time awareness of the manufacturing line's status. *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

The "Container Automated Transport Management System" is a system that manages production instructions, transport management, container bin management, and shelf management. It provides From-To instructions for transport equipment in the processes of raw material input, blending, raw material supply, product receipt, cleaning and drying, and product bagging, using automated warehouses as raw material warehouses, intermediate warehouses, and product warehouses. The design facilitates easy recovery from transport troubles, and the implementation achieves a reduction in recovery time during troubles through the visualization of equipment and device information. 【Purpose of System Implementation】 ■ Visualization - Real-time confirmation of the operation and abnormal conditions of manufacturing equipment and transport devices. ■ 24-hour Operation Support - By using general-purpose OS computers, transport management, transport control, shelf management, and container management are performed via PLC. - Data on the PLC side is backed up from CPU1 to CPU2, and regular backups are also performed on general-purpose PCs. *For more details, please refer to the PDF materials or feel free to contact us.

• ERP (core system)

There have been operational errors where unacceptable raw materials were received during the raw material arrival process. When issues arise with the raw materials, the extraction of the products used is conducted on a paper basis, which takes time. The "Raw Material Weighing Management System" is a system that centrally manages master data, arrival instructions, order information, and arrival/weighing results in a database. Based on the arrival instructions, the raw material receiving process is carried out, and barcode labels for the received raw materials are issued at the individual packaging unit level. After selecting the weighing raw materials and orders, the raw material barcode is scanned, the weighing process is performed, and a barcode label for the weighed product is issued. The arrival and weighing result information is then summarized on a daily basis and handed over to the upper level. [Purpose of System Implementation] <Cost Reduction, Business Efficiency> ■ Integration with Upper-Level Systems: Reducing registration and maintenance work ■ Manufacturing Responsibility System: Operational restrictions through the setting of work permissions ■ Lot Traceability: Tracing raw materials from upstream processes of received raw materials and downstream processes of weighing raw materials *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

Until now, we managed the manufacturing conditions for each product on paper, and every time we changed the product to be produced, operators manually input the manufacturing conditions one by one into the control device. Additionally, due to the large number of manufacturing condition items, there were instances of setting errors in the control device. The "Product Management System" manages different manufacturing conditions such as batch size, temperature, and time in a database based on the combination of equipment and product, allowing for easy downloading to the control device with simple operations. With the introduction of this system, the task of setting manufacturing conditions in the control device has become easier, eliminating setting errors. 【Purpose of System Implementation】 ■ Centralized Management of Operating Conditions - Centrally manage the manufacturing conditions to be downloaded to the control device for long-term storage. ■ Efficiency Improvement - Reduce the time required to set manufacturing conditions in the control device. *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

The "Defective Count Management System" is a system for managing the number of defective products that occur on the manufacturing line. Until now, the number of good and defective products on the manufacturing floor has been managed entirely on paper, which has resulted in lengthy analysis when a large number of defects occur, placing a significant burden on site managers. This system has various aggregation and output functions, allowing users to input on-site data and link it to the number of good and defective products, facilitating the analysis of the causes of defects. Additionally, it includes a simple process progress management function utilizing the input of good and defective product counts. [Features] - Input the number of good and defective products, which were previously managed on paper, via a terminal on-site. - Link various measurement data collected on-site to product data. - Allow site managers to easily check the progress status from a PC. - Aggregate and output the inputted number of good and defective products, as well as on-site data. *For more details, please refer to the PDF document or feel free to contact us.

• ERP (core system)

The "Temperature Control Efficiency System" is a system that utilizes measurement data from thermal cameras in conjunction with image monitoring for alarms and control. It is implemented for the purpose of monitoring multiple areas with thermal cameras, as it is difficult to install thermometers in several locations. The benefits of implementation include the ability to "infer mixing unevenness inside the tank from the surface temperature of the tank." 【Effects of Implementation】 ■ The ability to infer mixing unevenness inside the tank from the surface temperature of the tank. ■ By comparing the average, maximum, and minimum values of the internal thermometer and surface temperature, unnecessary cooling (shower) cycles were reduced. ■ By connecting a separate computer, thermal images can also be monitored, making the temperature distribution clear at a glance. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

The "Human Detection Interlock System" installs human sensors and surveillance cameras in areas prohibited for entry during operation and in equipment with high noise levels, establishing interlock and monitoring functions during operation. It is implemented with the objectives of "wanting to ensure the safety of workers," "wanting to strengthen the safety awareness and rule compliance of operators," and "wanting to effectively utilize existing digital information such as video and sensor signals in the operation and monitoring room." 【Effects of Implementation】 ■ Eliminates sudden operation starts (near-miss incidents) from the operation and monitoring room during on-site work. ■ Allows for confirmation of the presence of people (on-site workers) from the operation room, making safety verification methods easier. ■ By installing human detection devices, on-site workers develop a stronger awareness of the "monitoring area," reducing unnecessary entry. ■ Combined with camera functions, it provides a double-check through visual observation and detection. *For more details, please refer to the PDF document or feel free to contact us.

• Security cameras and surveillance systems

The "Wearable Wireless Notification System" uses a wearable device (watch-type) to issue alarm notifications and individual calls to on-site personnel. As a result of implementing this system, it has become possible to be aware of alarm activations even when away from the monitoring room, and by adopting a specific low-power consumption, we have been able to reduce running costs. Furthermore, the re-notification function eliminates the possibility of forgetting notifications, even if confirmation is not received within a certain time frame or if it is not confirmed in the monitoring room. 【Purpose of System Implementation】 ■ To reduce unnecessary external buzzer sounds and notify the appropriate personnel based on the type of alarm ■ To facilitate operations with a small number of people during nighttime and other times ■ To eliminate troublesome wiring work by adopting a wireless system ■ To prevent forgetting to respond by considering re-notification *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

The "On-site Confirmation Authentication System" is a system that displays check items and random authentication codes on an operation monitoring display. The control system recognizes the on-site check as complete only after the authentication code is entered. This system has been implemented with the objectives of "preventing the formalization of checks, which had been simplified to just a simple click," "while improvements in equipment are necessary in the future, we want to strengthen checks immediately," and "ensuring that important equipment is visibly marked for on-site verification." 【Background for System Implementation】 ■ Until now, checks were simplified to just clicking "OK" on the check items. ■ We want to introduce answer signals to each device, but there are many manual valves, making immediate implementation financially challenging. ■ We want to enhance workers' awareness regarding their tasks. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

The "Image Poka-Yoke System" is a system designed to assist in distinguishing differences in product color and the installation status of optional parts by alternately displaying images of standard products and production products in a diverse and multi-option manufacturing environment. By alternating the images of standard and production products, it becomes easier to check for excess or shortage of options and to verify colors. 【Purpose of System Implementation】 ■ Easy checking of differences from standard products - We want to implement a system that allows anyone, regardless of experience, to visually identify differences. ■ Easy adaptation to new products - We want to eliminate labor-intensive tasks such as teaching and adjustments. ■ Preservation of history - We want to reliably keep logs of visual inspections and product images. *For more details, please refer to the PDF document or feel free to contact us.

• Process Control System

The "Simple Security System" provides basic security functions for control panels. By holding an IC card for each worker up to the control panel, it manages permission for switch operations. (Unauthorized switches will not be activated even if operated.) Unlocking records are saved in the IC card reader and can be viewed on a PC or similar device. 【Purpose of System Implementation】 ■ To eliminate the need for key-based unlocking and locking operations for control panels for switch operations, reducing the loss of keys and the management of lending. ■ To automatically keep simple unlocking records. ■ To utilize the IC cards that each worker already has (without incurring additional costs). *For more details, please refer to the PDF document or feel free to contact us.

• Facility Management System

The "in-house broadcasting system" is a system that combines DCS and voice conversion packages, using broadcasting equipment interruption. It outputs registered voice messages (details of abnormalities and countermeasures) in response to alarms or event messages generated by the registered CENTUM DCS. Additionally, it suppresses unnecessary noise by interrupting the broadcasting equipment only during message output. This system enables a reduction in the workload of operators in the control room and ensures reliable information dissemination over a wide area. 【Purpose of System Implementation】 ■Increase in Work Efficiency - We want to eliminate the hassle of operators having to contact relevant parties in remote locations every time an alarm occurs. ■Clarification of Information - By quickly sharing abnormal conditions within the building, we aim to appropriately allocate personnel and reduce the occurrence of defective products. *For more details, please refer to the PDF materials or feel free to contact us.

• Facility Management System