Contributing to smartification of factories! IoT solution for visualizing operation rates & realizing effective downtime reduction

23/05/2022

PATLITE (THAILAND) CO., LTD.

Since Industry 4.0 (Fourth Industrial Revolution), smart factories have been attracting worldwide attention. Utilizing digital data in factories and continuously improving quality and productivity = "IoTization of factories", but there are still only few places that can utilize effectively at manufacturing sites in Thailand. In order to improve on-site productivity, it is essential to accurately recognize and review the current operation rate and how much waste there is. In this article, we will introduce our recommended solution for reducing equipment downtime in manufacturing factories that can achieve these goals.

Reduce downtime by visualizing operation rate ⇒ Improve factory profitability

There are three main phases to becoming a smart factory.
① Install signal towers (signal lights) in appropriate places
② Visualize the acquired data (conversion of information into data)
③ Reduce downtime as much as possible ⇒ How quickly can workers recognize abnormality?

We offer the solutions necessary to solve these processes step by step. By visualizing on-site operation rates and utilizing the information obtained to kaizen (improve) the manufacturing process, we can achieve efficient "downtime reduction.

Reduce downtime by visualizing operation rate

One of the most common problems faced by our customers is ‘the difficulty of constantly monitoring the operation status’. Even operating status administrators cannot always monitor monitors and signal lights. They may be in a remote location, or may be occupied with other tasks.

Most of the main causes of downtime are not serious machine failures, but can be resolved with a little daily effort. In other words, notifying the person in charge at the moment when the equipment stops and rushing to the site as soon as possible will lead to reduction of downtime.

Grasp the operating status of machines in real time

WD system configuration diagram

▲ WD system configuration diagram

A solution that can visualize the on-site operation rate by combining the wireless data communication system WD Solution developed by our company and SEESET WATCH®︎ developed by Thai software development company Zenalyse Co., Ltd. is more efficient with smart watches that inform the operating status more efficiently.

The advantage of smart watches is that they are "resistant to noise in the factory" and "easy to check during work.” Even in noisy workplaces where workers wear earplugs, the vibration of a smart watch will always be noticed. During on-site work, wearable devices that can be checked by simply looking down are more suitable than email notifications.

SEESET WATCH

▲ SEESET WATCH®︎, a smart watch that can notify of abnormalities in real time.　

SEESET WATCH

▲ In conjunction with the signal light, notify the operator of the abnormality by vibration.

* SEESET WATCH®︎ is an additional optional feature of SEESET. The installation requires the SEESET software.
　SEESET WATCH®︎ is a software that runs on Android.An Android smart watch is required to use it.

[Procedure for smartification of a factory]
1. Visualize machine operation information by installing indicator lights (signal towers).
　　⇒ Unify the meaning of colors throughout the factory and install them so that they can be seen from the aisle
2. Collect operation status from each machine.
　　⇒ Information can be collected using common indicator lights (signal towers) even if the machines are of different models or manufacturers.
3. Reduce downtime
　　⇒ To reduce downtime, it is necessary to have a system that can instantly notify information.
　　　Notification within the office...use network signal towers
　　　Notification to individuals…use smart watch

It is suitable for all industries, including machine manufacturing factories, auto parts factories, and printing factories. You can start with one unit on a trial basis and expand the range of utilization after confirming the effectiveness.

If you are interested in smartification of factory, or if you have any issues such as visualization of factory operation status, facility operation rate, or productivity improvement, please contact us using the form below.

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