Using the convenient functions provided by the CONPROSYS™ series, Komaki Factory has been busy implementing numerous initiatives based on “visualization.” At first, they started with the management of PCB production quantities on assembly lines. With this initiative, PCB production status is monitored in real time using CONTEC’s cloud server, enabling production plan progress to be ascertained and managed at a glance. Following the success of that initiative, other various visualization-based initiatives were started within the space of a single fiscal year, including power consumption monitoring on assembly lines, environment management based on temperature/humidity readings, management of the operation status of cell production, and the creation of online systems for static electricity checker measurement results, torque driver pre-work checks, and soldering iron tip temperature management. All these initiatives yielded vast amount of useful data and information, which could be analyzed and verified for findings capable of being used to achieve consistent enhancements in productivity.
In FY2018, three years after the start of such visualization-based initiatives, we decided to tackle the monitoring of power regeneration statuses of aging devices used in wireless power transfer systems. At Komaki Factory, power regeneration via aging devices is implemented as an environmental measure, designed not only to improve productivity but also to reduce CO₂ emissions while saving energy. The power regeneration capabilities obtained via this initiative yielded reusable energy totaling 2.4 million yen in value per year, a fact that would never have been known had we not monitored regeneration statuses and a true testament to the effects that can be realized through “visualization.”
With various “visualization-based” initiatives such as those above, data and information collected thereof can also be viewed wherever and whenever using an “Andon System.” Enabling factory managers and management, as well as on-site managers, workers, and other parties related to manufacturing, to check production statuses in real time has had a significant effect in ensuring production plans are achieved.
Future initiatives include combining CONPROSYS™ with infrared cameras, such as those used to measure employee body temperature during static electricity checks and achieve a higher level of health management. This new initiative is currently in its trial phase for implementation.