Industry 4.0
Operational
Management
System for Factory
Using Internet of
things (IOT)
What You Want on the Factory Floor
Make routine operations quicker and easier
- Create daily and monthly reports with ease
- Make equipment** checks less labor-intensive
- Go paperless for all kinds of data
Monitor operations remotely
- Be notified of alarms even when away from the factory
- Reduce total duration of brief stoppages
- Spend less time standing over equipment**
Analyze operational results
- Do more with regularly collected data
- Identify reasons for different operating rates across lines
- Aggregate operational/ production results more easily
Why our system ?
Our software that runs on computers locally (Server PCs and IOT devices) It supports Connection, Collection, and Visualization throughout the factory
- Reduced downtime (monitor operations)
- Optimized operations (understand operating rates)
- Improved production capacity (analyze operating times)
- Increased production planning accuracy (leverage operational/production results)
- Traceability (analyze causes of alarms and defective parts)
- Go paperless for data collection
- Preventive maintenance (analyze device data)
What our Industry 4.0 system do ?
monitoring
Prepare a diagram of the factory floor and place icons to visualize the operational status of the whole factory
monitoring
Equipment monitoring
Click an icon to display operational status or alarms for groups or individual pieces of equipment
results
- Operational results by group as a graph
- Detailed analysis of operational status of every device
- Output, number of production schedules, and completion rates as a graph
monitoring
Signal monitoring
- Display signal status in real time
- Display can be based on preset threshold values
history
- Display signal changes in collected data as a graph
- Data can be output in CSVformat
Overview monitoring
Prepare a diagram of the factory floor and place icons to visualize the operational status of the whole factory
Equipment monitoring
Click an icon to display operational status or alarms for groups or individual pieces of equipment
Operational results
- Operational results by group as a graph
- Detailed analysis of operational status of every device
- Output, number of production schedules, and completion rates as a graph
Signal monitoring
- Display signal status in real time
- Display can be based on preset threshold values
Signal history
- Display signal changes in collected data as a graph
- Data can be output in CSVformat
Steel
On worksites in the steel industry, many different materials are used in continuous processes. If manufacturing conditions are not set properly, the risk of producing defective targets increases. Consequently, manufacturing conditions must be managed continuously and the introduction of IoT is becoming an essential technology.
- Management of Billet Temperature and Preheating Heater
Measure the actual heating temperature of all billet materials before hot forging, check the degree of similarity with the target value, and record the result.
Connect to IoT
Recording the temperature data enables quick investigation and countermeasures when a quality problem arises in a subsequent process.
The data can be sorted by product type, which allows easy extraction of optimum conditions for each product.
- Flow Management of Mold Release Agent
Manage the amount of mold release agent used. The amount used has an effect on the input of raw material and waste fluid treatment, so it is an important management item.
Connect to IoT
Flow management is required at many different points in a large facility, so it is difficult to record the data manually. Networking of equipment allows easy data confirmation to achieve efficient flow management.
- Checking the Gap Between Rollers
Continuously measure the gap between the work rollers, which determines the plate thickness accuracy and flatness. These values can be displayed in the central control room for recording.
Connect to IoT
The continuous monitoring of numerical data allows counter measures against errors to be taken in real time to minimize downtime.
- Steel Sheet Width Management During Rolling
Continuously check that the steel sheet width is within tolerance and record the result.
Connect to IoT
Centralized management including other data such as X-ray thickness measurement, profile measurement, and defect detection allows easy process improvement of the entire rolling process. When an error occurs in a measurement system, it is indicated in real time so downtime can be minimized.
- Height Control of a Steel Sheet
Check the sagging of steel sheets to adjust the mandrel rotation automatically. This prevents top mark flaws caused by slipping.
Connect to IoT
The optimum amount of sagging varies depending on the product type. Automatic feedback of these values during product type changeovers will save time spent changing settings.
Managing the measured values and other data from the equipment on the same platform is useful for management of the whole behavior.
