[Improvement case study] Production efficiency is improved by using IoT at factories! Realized 'visualization' of operating rate by introducing signal tower × data communication system

31/08/2020

PATLITE (THAILAND) CO., LTD.

As the top manufacturer of rotating beacons, the PATLITE Group is expanding globally and developing products that meet the local needs of each country.

In recent years, "manufacturing" work sites in Thailand are required to cope with high-mix low-volume production. In the case of multi-product production of many types of products, the process and processing details differ depending on the type of product, which causes increases in losses and defects. In the case of small-quantity production, setup changes will be more frequent and lots and sizes will differ for each product type, leading to poor productivity. However, the trend toward high-mix low-volume production is steadily increasing and coping with the needs at the work site is essential.

Then, "How to improve productivity in the future. In order to solve the problem, PATLITE (Thailand) will propose a solution to the Thai production sites and introduce an example of the implementation.

Improvement Case Vol.1: PATLITE's IoT solution -Printing Company-

Voice of Customer　― CPC Decal Co., Ltd. ―

Wish to "visualize" the operating status of printing presses and improve production efficiency

: IoT solution PATLITE

Before introduction

It took time to collect paper data, and it was difficult to see the goal for efficiency.

● Check the operating status machine by machine
●Record on paper by hand
●Aggregate paper data to manage the overall status
●There was a time lag before the results were calculated, and it lacked accuracy.
●Problems with efficiency were difficult to grasp, and it did not lead to the operator's motivation to improve.

Wireless data communication system enables real-time aggregation

IoT solution PATLITE

Introduced wireless data communication system
It is a system that collects data directly from signal beacons, aggregates equipment utilization data, and "visualizes" equipment utilization rates and loss rates. By understanding the operating status of equipment accurately, we improve the loss rate and contribute to an increase in production.

■ Equipment and systems required for installation
・ Install the tricolor signal beacon and transmitter/receiver (AirGRID) for wireless data communication
・ Building a system that combines the equipment operation monitoring system "i-Brain"
⇒ Aggregate and monitor operating status in real-time
⇒ Store daily operating status as data

The ability of IoT makes it easy to prepare future production and improvement plans!

It takes time to aggregate the operating status in the factory using paper data, and the problem cannot be grasped in real time. With the IoT system, the status inside the factory can be grasped in real time, and the improvement points that were not visible with the paper data can be revealed. In addition, by utilizing the data accumulated in the software, it is useful for creating daily production plans and concrete improvement plans.

IoT solution PATLITE

After introduction

The current situation and goals have been clarified, and the environment has become easier for operators to be aware of production efficiency.

●Automatic recording of accurate actual operating status instead of handwritten daily reports for each machine
●A system that can immediately respond to troubles such as work delays and machine breakdowns
●Improvement points that were not visible in the paper data became clear
●It became possible to grasp accurate data for each machine at the weekly meeting, and it became possible to correct problems immediately.
●Posting weekly data on the spot increased motivation of the work site and improved productivity.
●By comparing with past data, more specific goals can be set.

IoT solution PATLITE

A scene from the weekly meeting

IoT solution PATLITE

Posted production efficiency for each machine every week at the work site

― Voice of customers ―

CPC DECAL

After the installation of the system, we check the progress from time to time and have a system ready to respond to any troubles. The data of the average utilization rate gathered is posted in the factory on a weekly and monthly basis so that the operators themselves can check the utilization rate of the machine they oversee. I think this leads to the awareness of productivity improvement and problem solving. In the future, we are considering installing it on yet another model, and plan to introduce a system that can link with the data of the existing printing presses.

CPC DECAL

―Company profile of CPC DECAL CO., LTD.―
Printing offset, silk screen, etc. Proposal and production of novelty goods that utilize special printing technology.

If you are looking for information display equipment to help improve production sites in Thailand, such as the rotating beacon "PATLITE®", signal beacon, and IoT utilization, please contact us through the inquiry form.

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