Would you like to see the hard-to-imagine IoT in action at an actual usage site (a screw factory)?
The IoT package system "Factory Guardian" is an IoT system developed based on a model of a screw manufacturing factory and is sold by Yamashina. In response to customer concerns such as, "Even if we talk about IoT in factories, there are no actual products, and it's hard to understand," Yamashina is holding tours of the IoT system "Factory Guardian," which is operational in its own factory. We believe that the methods for acquiring information from actual devices, wiring, communication, PC systems, and how to display data obtained from information will serve as a reference for the introduction of IoT in manufacturing factories. To solve such challenges… ● We are considering the introduction of an IoT system in our factory but want to see something that is actually operational. ● We want to hear firsthand accounts of the challenges before implementation and the benefits after implementation. Please feel free to consider visiting our IoT system. *For details, please refer to the PDF or contact us. *We may decline visits from individuals in the screw industry for the "Factory Guardian" tour.
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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, time-based operating status analysis, time-based non-operating factor analysis, 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, aimed at the manufacturing industry have finally begun to be introduced to the market. In the future, many implementations are expected to be considered due to the advantages of easy adoption. Additionally, our company, Yamashina, is engaged in the metal products business (screw manufacturing) and 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 conducted).
Detailed information
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The operation 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 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 stops, standby, and operation, as well as a breakdown of reasons for inactivity.
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Operational Information Analysis Operational information such as stop, standby, and operation is displayed in a time series format, such as by day. At the same time, a breakdown of non-operational (reasons for stopping) is also displayed.
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Production Progress Analysis (Monthly) The planned production numbers 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.