The KAIZEN Handbook
60Pages

~Solutions for Factory Improvement~

Improve Predictive Maintenance Visualize lost productivity from reduction in speed

Prevent Picking Errors with Pick-to-Light Implement NE Touch Sensor Beacons to simplify am

Automobile Manufacturing Building Integrated Systems for Operation Management and Monitoring Easily Compile Operation Status of Old Equipment Automating a Handwritten Factory Daily Report Visualize Level of Cutting Oil Remaining in Tank Visualize the Stages of Equipment Maintenance Visualize Equipment Status in Unmanned Areas Visualize / Analyze Stalled Robotics Monitor issues remotely and in real-time Visualize Inspection Process Anomalies Prevent Oversights During Inspection Mistake-free Inspection Process

Visualize the Casting Process Visualize Robot Statuses Visualize the time required at each work step Remote monitoring reduces loss from stoppages Takt Time for Manual Assembly Process Visualize Takt Time with LA6 on AGV Visualize Takt Time Regulating the Cell Assembly Line Visualize Lost Time in Cell Production IoT Screw Driver Measures Tightness of Screws Signal From Cells Using an Andon Monitor 4

Visualize Operation Panel Information Improve Predictive Maintenance Prevent sand overflowing from the hopper Visualize Amount of Liquid in the Tank! Create Uniform Visual Signals Throughout the Worksite Visualize remaining amount Ra w m being tr aterials ansport ed BUZZER

Abnormal occurrence Target Results Difference Visualize the elapsed time from when the problem occurred Visualize Work Progress Equipment Operation Management over LAN seconds elapsed. Energy, Energy C onservation and Environment P40 Make The Water Level Visible an Reduce Checking Time Maintaining Hygiene at Food Processing Site

Simple Request System 10 20 Air Conditioner Remote Alerts 24-hour Network Camera Monitoring

Remotely monitor server issues Broadcast Disaster Information to All Operators Reduce call wait times and backlogs UTM External Attack Monitoring Solution Improve Notification of Emergency Information Industry or automobile-related manufacturing Notice print output as soon as possible Confirm print output has been received Visualize Print Errors on Network Printers Prevent Picking Errors with Pick-to-Light

Building Integrated Systems for Operation Management and Monitoring Report equipment errors via email Wirelessly send operation information Signal tower + WD Mail server Email notification feature Wireless transmission LAN Return to the site! Auto-compile operation logs Machine #2 stopped. Check immediately. To operators away from equipment. Before With older equipment, it is difficult to build an integrated operation management and monitoring system. ・ It ・ would require remodeling the equipment so that it is compatible with the monitoring system, which is both costly and time-consuming....

Stop (problem) → ● button Change step → ● button Return to normal ● button The performance status of each unit can be recorded - No need for daily reports. Automobile Manufacturing Easily Compile Operation Status of Old Equipment Reduce Labor Unit 1 stopped (equipment failure) Production information File(F) Edit(E) View(V) Favorites(A) Tools(T) Help(H) Production Information Management System Operation information Actual information Process management Equipment monitoring Alarm histroty Production Process Processing Painting Process PackagingProcess Packing Process Production Process Unit 1...

Automating a Handwritten Factory Daily Report Network your machinery regardless of brand or age Receiver Automatic Records Transmitter A Manually recorded data Automatically recorded data Operation reports are often handwritten and taken at the end of the business day. Overnight, machines can stall which will not be reflected in the reports and then takes significant time to identify the lot of defective products, resulting in revenue loss. The WD System automatically records equipment operation information 24/7 allowing users to identify trends and pinpoint machine downtime for more...

Automobile Manufacturing Visualize Level of Cutting Oil Remaining in Tank Before Checking the amount of oil in the underground tank is a burden... Visualize the oil level with LA6 Signal Tower! Oil Level Meter Food and Pharmaceutical Checking the oil level requires physically opening and checking the underground tank, wihch takes effort and time. ● Meter display of the level of the cutting oil ● As the oil level is visible from a distance by the number of segments, you can manage multiple units at once Improvement Using LA6 Signal Tower SOLUTION ● Use the LA6 Smart Mode (Pulse Trigger...

Visualize the Stages of Equipment Maintenance Create a standardized, color-coded system for equipment status Normal Operation Equipment Malfunction Status Confirmation Tap touch button to confirm status and start maintenance Blue light indicates maintenance in progress Normal Operation / Maintenance Completed Touching the NE Sends Information to PLC PLC changes the NE light color Equipment MalfunctionMaintenance Required Even when there are signal towers to alert operators when equipment is down or needs maintenance, there are no indicators that tell operators whether the issue is being...

Identify the equipment by segments on the LA6-POE Problem with machine 1! By dividing the channels into the NBM, you can identify which machine has a problem. Example: CH1 - Machine 1, CH2 - Machine 2 and so on . mSignal Tower LA6-POE Series u Before After When workers leave the production site, they are not The NBM is able to convert I/O signals from robots to notified when equipment issues occur. network commands, triggering the appropriate light Accessory: AC Adaptor * Use for exporting logs and settings (cannot control with USB connection) • 8 digital input contacts and 8 digital output...

Example system Robot Operation Andon Elapsed Time ' Separate application software is required. Gantt Chart System Robot 3 is still stalled I have to go right away! Also, operation analysis of robotics using accumulated data Before In automated robotic processes, robots will stall without anyone noticing for an extended period. The goal is to eliminate manual checks to determine which robots have stalled in the process. Industry / Equipment Overview [ Industry^ • Manufacturing [ Process^ • Robotic Cell Production After By using the existing PATLITE signal towers on the control panels with...