Factory IoT solutions
Actual data collection using IoT infrastructure
No results limit productivity improvement
Even if you create and execute a production plan based on standard hours, there is always a discrepancy between the standard hours and the actual work hours.
Is this how you collect performance data?
Isn’t this how performance management works?
Obtaining performance data is difficult in reality
There are various problems in obtaining valid “performance data”.
For example, even if the usage record information of “Machinery” can be obtained by PLC or SCADA, maybe it is true that it is almost impossible to collect the performance records of “Products (work in progress)” and “People (workers)”.
Furthermore, in some cases, detailed performance records are entered manually by workers, but there are cases where they forget to enter data or make mistakes, and the reliability is low.
As a result of the incomplete and inaccurate acquisition of “performance data”, there are limitations to the accuracy of production management (process, cost, quality, attendance, etc.).
IoT infrastructure automatically collects results
One of the major roles of IoT infrastructure (EXBeacon platform) is to obtain location information. Whether it is for “Products (work in progress)” or “People (workers),” if location information can be obtained, it can be processed skillfully to generate “performance data.” In this way, IoT infrastructure makes “performance” that was previously difficult to obtain in factories visible.
And IoT infrastructure can automatically collect performance data, so there is no risk of forgetting to collect it.
In addition, IoT infrastructure not only collects location information, but also various sensor information such as temperature, humidity, and vibration at the same time.
Utilizing location information using IoT infrastructure
By utilizing IoT infrastructure, for example, it is possible to easily and automatically grasp the stay time of workers or product work in progress.
The location is detected at a specific work location, and the time that the detection continues is constantly measured and considered as the stay time there.
Multipurpose use of acquired actual data
How data is processed
In IoT infrastructure, location information is obtained by attaching “tags” that emit radio waves to people and objects (products). The data coming from IoT infrastructure is raw data (machine data).
First, the raw data is converted into location information. At that time, both people and objects (products) are expressed with three pieces of information: “ID,” “time,” and “location.”
Next, a meaningful association is made between the location and work activities, and the simple location information is converted into meaningful data that is associated with “work activities.”
In addition, the data is processed to suit the purpose of use. The data generated based on location information in this way is diverse, including “Start/End time,” “Location/Stay detection,” “Actual time,” “Peak/off time,” and “Number of movements.”
Extension functions/System configuration
Integration with production management systems, etc.
The EXBeacon platform allows for integration with a variety of systems.
The external interfaces are as follows (Web/API, file output, IoTDB output). Performance data can also be manually downloaded through the dashboard.
System Configuration
In the case of a factory, the IoT DB not only collects real-space information collected by the EXBeacon platform, but also connects to external systems such as PLC (Machinery information) and accumulates various types of information within the factory.
The IoT DB becomes the reality of the Digital Twin and 1) provides on-site management information to MES and ERP as appropriate, 2) provides on-site support services at all times, and 3) analyzes the accumulated information using various analysis tools.
Extension function (Various sensing)
The EXBeacon platform uses BLE mesh network technology, so basically any sensor that meets the BLE advertising standard can be connected, and smartphones can also be used as sensors.
We have actually collaborated with multiple manufacturers and have a track record of connecting to many sensors. We can also prototype and develop special sensors that are not available for sale.
In this way, we can propose the optimal sensor to meet your company’s sensing needs, which are expected to evolve in the future.
Implementation examples, etc.
Grasping work progress using a work ledger
[Client] Toshiba Elevator and Building Systems Corporation
A work process management system for machine manufacturing in a large assembly factory. BLE tags are attached to the work ledger that moves with the work-in-progress group, and a receiver (EXBeacon) is attached to the ledger holder to grasp the work progress for each work area.
Detecting the location of work-in-progress and workers / MES integration
[Client] Major musical instrument manufacturer
Detects the presence or absence of work-in-progress at designated locations and performs detailed process management.
By collecting worker location information, the time required for each process is understood.
Linked with MES, it improves the accuracy of production management.
Pallet location detection using directional beacons
[Client] Major automobile manufacturer
Location management of “Metal pallets” within the factory.
Each pallet is tagged and a directional beacon is used to determine the boundary for more accurate location.
Progress monitoring using 1m positioning method
[Client] Major precision machinery manufacturer
Manufacturing process management in a precision machinery factory.
It will be used for process management by using pressure sensors to determine product placement and directional beacons to determine the presence or absence of work-in-progress and workers.
Automatically generate work results from collected location information
[Client] Major precision machinery manufacturer
Manufacturing process management in a precision machinery factory.
Used for process management by using pressure sensors to determine product placement and directional beacons to determine the presence or absence of work in progress and workers.
Location management of employees and work-in-progress using card-type tags
[Client] Nakamura Mhg. Co., Ltd
Location management of people and things at a parts manufacturing factory.
The location of work-in-progress is managed by attaching ultra-thin card-type tags to a clear file which holds paper work management chart in.
Not only is the current location of employees tracked, but the return-home rack is also used to manage those returning home at the same time.
