An IoT package for factories called "Factory Guardian" that can be implemented for around 4 million yen.
Factory guard
IoT that can be used on-site for researching manufacturing factories! Constantly collecting and visualizing machine operation information! For analyzing production efficiency and reasons for downtime.
Using IoT, we want to continuously collect and visualize operational information from factory machinery to analyze production efficiency, investigate reasons for downtime, and improve quality. But how can we achieve this... "Factory Guardian" addresses these challenges. "Factory Guardian" is an IoT package developed through research on manufacturing factories. It offers a comprehensive proposal of necessary equipment and specifications in a package, making it easy to implement even without expertise in system construction. Since it is a packaged system, there is no need for the costs associated with custom-made solutions, allowing for very affordable implementation and significantly reducing the effort and costs of IoT adoption. Do you have any of the following challenges? - I want to easily implement IoT to improve production efficiency and quality, but I lack the know-how... - I've heard that implementing IoT incurs significant costs, making it out of reach... - I need a reliable solution; it must be an IoT system suitable for manufacturing, not just a cheap option... - I want a system that fits my factory's needs... ↓ ↓ ↓ "Factory Guardian" from Yamashina solves all of the above. *For more details, please refer to the PDF or contact us.
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basic information
● Sensors, etc. After consulting, we will propose solutions that fit your 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, security measures can be easily implemented. 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 Inc., which has been active as a system integrator since 1971. ● System (Hardware) We use devices from Advantech, a manufacturer of industrial PCs. These are suitable for use in tough factory environments. ● Output Information Production quantity, production progress, operating rate, number of abnormal occurrences, operating status by equipment (andon), real-time abnormal reports, 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 equipment, each month, each day, etc.
Price information
The price varies depending on the scale of the system.
Delivery Time
※Approximately 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, it is expected that many implementations will be considered due to the advantages of easy adoption. Additionally, 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 varying ages 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 abnormalities, and the status of abnormalities are all displayed in a unified 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 stops, standby, and operation, as well as a breakdown of reasons for inactivity.
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Operational Information Analysis Operational information such as stops, standby, and operation will be displayed in a time series format, such as by day. At the same time, a breakdown of non-operational status (reasons for stopping) will also be 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 number 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.