What is OKUMA's Dream Site ? A factory of the future, where advanced automation technology and skilled craftsmanship are interwoven!

21/06/2021

OKUMA TECHNO (THAILAND) LTD.

OKUMA, a comprehensive machine tool manufacturer, proposes a high-efficiency production factory, the "OKUMA Smart Factory".

We will introduce three of OKUMA's own factories as "Dream Site (Japan)," as a demonstration model maximizing the use of the cutting-edge IoT technologies and products that make up the Smart Factory and optimizes production.

A fusion of cutting-edge technology and skilled craftsmanship A Dream Site (DS) that realized mass customization

The Dream Site (hereafter DS) is a factory of the future where advanced automation technology and skilled craftsmanship are interwoven.OKUMA's world-class, cutting-edge technology and the skilled craftsmanship cultivated over more than 120 years have been combined to achieve high-quality, high-efficiency machine tool production. This is known as mass customization because it enables productivity comparable to that of mass production even for custom-made products.

◾️ Self-contained integrated production

Control the processing and logistics of the entire factory based on a production plan that makes full use of IoT. The entire process from material input to parts processing, assembly, inspection, and shipping is carried out in an integrated manner, enabling speedy production of a wide range of machine tools.

◾️Clean & energy-saving factory environment

The parts processing area is always kept clean by the automatic chip collection system. In addition, by using solar power and geothermal heat, energy costs have been reduced by about 30%.

◾️Advanced automation

We have built a fully automated system by employing a number of smart machines, robots, automated transport systems, etc. equipped with our own control devices, and have achieved continuous automated operation 24 hours a day, 7 days a week.

◾️Front Loading

Program creation, operation simulation, etc. are prepared in advance on a PC. In order to maximize the operating rate, we carry out thorough front loading to minimize on-site processing preparation and improve production efficiency.

◾️Optimization of the entire factory

The IoT-based "progress and operation monitoring" and "management system" provide centralized management of all information. In addition, we analyze and improve the accumulated data to further improve the operation rate and shorten the lead time.

Through these efforts, OKUMA has established DS as a model plant for demonstrating mass customization.

The latest IoT factory built by collaborative creation with Hitachi Dream Site2 (DS2), an advanced model for high-efficiency production

In DS2, OKUMA and Hitachi are working on a collaborative creation to build an advanced model of high-efficiency production that supports mass customization.

※Collaborative creation: Jointly creating innovation and sharing results

◾️Background of collaborative creation

Hitachi has advanced solutions for optimizing not only machines but also production lines, factories, logistics, etc. By combining these with our know-how, two concepts for optimizing DS2 production planning were born.

◾️Collaborative creation concept ①: Evolving production visualization

By simultaneously monitoring and visualizing the "progress of production" and "operation status of equipment," that were shown separately in the conventional system, the cause of production delay can be determined by dynamically analyzing patterns from the history to make predictions. This has made it possible to take swift measures for production optimization.

◾️Collaborative creation concept ②: Optimize and speed up the factory control cycle

Work IDs are attached to all machined parts to accurately grasp their positions and instruct parts to be transported timely with accuracy in hours and minutes. In the future, we aim to create a system that can always automatically generate the optimum schedule in any situation by making full use of simulation technology that can be automatically learned by AI.

Production optimization know-how gained daily with DS2. OKUMA will continue to provide these as "Manufacturing Service Solutions" to our customers.

Smart factory with further evolution Dream Site3 (DS3) for integrated production of machining centers

Based on the know-how gained from DS1 and DS2, DS3 was completed in 2019 at Okuma's Kani Factory.

In addition to the adoption of the latest smart machines such as “LB3000EXII ARMROID” and “MULTUS U4000 LASER EX”, DS3 is also evolving its automation and unmanned technology through the use of IoT and advanced utilization of robots and FMS (Flexible Manufacturing System).

OKUMA's smart factory "Dream Site" will maximize the capabilities of your factory to achieve the world's highest level of mass customization.

If you are interested in implementing factory automation / optimization solutions in Thailand, please contact us using the form below.

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