This is an IoT package specialized for the manufacturing industry. We provide a consistent proposal from sensors to communication and software, making it easy to implement at a low cost.
● IoT Solutions Specialized for Manufacturing Factories "Factory Guardian" is an IoT package developed to improve production efficiency and quality in the manufacturing industry. Its design is based on research conducted on manufacturing factories, allowing for immediate use in enhancing productivity. The PCs and devices used are from Advantech, a leading manufacturer with extensive experience in the industrial IoT field. ● Easy Implementation with a Package Even without skills or know-how related to IoT, implementation can be achieved through simple consulting, significantly reducing the effort and time required for system construction. The software is provided pre-loaded on the gateway machine. ● Simple System Configuration This system allows for nearly centralized management of manufacturing machines with different models and specifications through a straightforward mechanism. By adopting edge computing, it can simply respond to system configuration and security measures by processing information from PLCs and sensors within the PC. ● Operation with Low Running Costs In edge computing, there is no need to send large amounts of data to the cloud, allowing for operation at appropriate costs even when using cloud services.
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basic information
● Sensors, etc. After consulting, we will propose solutions that are suitable for the factory. ● System (Software) It is built on the basis of edge computing. Since it processes and manages information from PLCs and sensors within the PC, implementing security measures is easy. Additionally, it does not transmit large amounts of data to the cloud, allowing for operation at appropriate communication costs. The system is developed by Japan Rad Co., Ltd., which has been active as a system integrator since 1971. (Hardware) We use devices from Advantech, a manufacturer of industrial PCs, which are suitable for tough factory environments. ● Output Information Production quantity, production progress, operating rate, number of abnormal occurrences, operating status by equipment (andon), real-time abnormal reporting, abnormal history, analysis of operating status by time, analysis of non-operating factors by time, production pitch, and the above will be displayed as needed in graphs and tables for the entire factory, each line, each piece of equipment, each month, each day, etc.
Price information
Approximately 3 million yen – The price varies depending on the scale of the system.
Price range
P6
Delivery Time
※About 3 to 4 months after receiving the order.
Applications/Examples of results
The packaged IoT solutions, ranging from sensors to software, for the manufacturing industry have finally begun to be launched in the market. In the future, many implementations are expected to be considered due to the advantages of easy adoption. Our company, Yamashina, is engaged in the metal products business (screw manufacturing), and we will utilize this "Factory Guardian" to IoT-enable a total of 100 manufacturing machines of different models across two lines in our factory by April 2018. (Demonstration has been completed.)
Detailed information
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The operating status of factory equipment is displayed in color-coded format. Production planned numbers, production actual numbers, production progress, operating rates, number of anomalies, and the status of anomalies are all displayed in a centralized manner.
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Production Real-Time Monitor It displays the current production plan numbers and actual numbers, production progress, operational status such as stop, standby, and operation, as well as the breakdown of reasons for inactivity.
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Operational Information Analysis Operational information such as stops, standby, and operation is displayed in a time series format, such as by day. At the same time, a breakdown of non-operational reasons (reasons for stopping) is also displayed.
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Production progress analysis (monthly) The planned production quantity and actual results will be displayed.
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Production pitch analysis It compares the production quantity per minute with the reference value and displays it in a graph.
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Company information
Established in 1917, during the dawn of mass production of screws in Japan, the company succeeded in producing the first domestic cross-recessed screws in 1949 and cooperated with the government to localize tapping screws in 1954. The company holds data on over 200,000 types of screws and bolts, enabling the high-quality manufacturing of various shaped products. Recently, it has focused on investing in research and development, working on tapping bolts with a diameter of 6mm or more, high-strength aluminum bolts, tapping screws for thin steel plates, and tapping screws for CFRP, which will support the next generation. The company is committed to innovative technological development without being bogged down by history.