Expanding “Visualization” Through IoT Demonstrations at Our Own Factory
- Customer
- Contec Komaki Factory
- Industry
- Manufacturing
- Contec products
- CONPROSYS Industrial IoT
- Goals
- Enhanced customer service, Quality improvement, Cost savings
Since 2015 Contec has tested CONPROSYS at its Komaki factory, adding Andon displays, torque driver checks and aging-test monitoring. Regenerated energy alone is worth 2.4 million yen a year.
Overview
Since 2015 Contec has tested its CONPROSYS industrial IoT series at its main Komaki factory, one of its global production bases, to bring more forms of visualization to its operations. The factory also serves as a showroom for customers interested in CONPROSYS.
Challenge
In 2015 Komaki was behind in IoT visualization. The aim was to improve quality, cost and delivery in a plant producing many products in small lots, while building case studies for customers and partners through repeated testing and product refinement.
Solution
Komaki uses CONPROSYS data transmission (including 3G models where wiring is impractical), CDS2 Cloud Data Service 2, VTC Visual Task Control for browser-based signal processing and alarms, signal I/O modules and a Modbus master that collects data from up to 30 devices without programming. Applications include:
- PCB production counts from line phototubes, compared with plans in the cloud
- Temperature, humidity and heat stress monitoring for work areas and storage cabinets
- Cell production monitoring of operating time, ratios and output
- A low-cost Andon system on large monitors, from cell to management level
- Torque driver checks linked to work instructions, packaged as Contec’s Alpha Series
- Aging device temperature monitoring for traceability
- Arrival checks with static discharge and infrared body temperature
- Online soldering iron tip temperature management
Results
The team started with easy wins and expanded within one fiscal year, building a large data set that supports steady productivity gains. Since FY2018, monitoring power regeneration from aging devices for wireless power transfer systems has produced reusable energy worth 2.4 million yen per year. The Andon system helps the factory meet production plans.
Hattori Kazunori, Production Engineering Department manager, said starting with low-hanging fruit matters and that large, complex systems are unnecessary.
Contec products used
Originally published by Contec Co., Ltd. at contec.com.