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Web The KAIZEN Handbook 2019 0604
Web The KAIZEN Handbook 2019 0604
www.patlite.com
CONTENTS
Automobile Manufacturing
Scenario 1 Automobile Manufacturing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Prevent sand overflowing from the hopper .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
33
Scenario 2 Food and Pharmaceutical.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Visualize Amount of Liquid in the Tank! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
34
Scenario 3 Logistics .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Create Uniform Visual Signals Throughout the Worksite .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
35
Visualize remaining amount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
Visualize the Stages of Equipment Maintenance Create a standardized, color-coded system for equipment status . . . . . . . . . . . . .
13 Logistics
Visualize Equipment Status in Unmanned Areas .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
Logistics
Visualize Robot Statuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21 UTM External Attack Monitoring Solution. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
Visualize the time required at each work step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22 Improve Notification of Emergency Information For Factory Security, Railway Command,Disaster Prevention and Emergency Services. . . . . . .
49
Remote monitoring reduces loss from stoppages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23 Industry or automobile-related manufacturing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
50
Takt Time for Manual Assembly Process .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24 Notice print output as soon as possible Confirm print output has been received. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
Visualize Takt Time with LA6 on AGV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25 Visualize Print Errors on Network Printers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
Visualize Takt Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26 Prevent Picking Errors with Pick-to-Light Implement NE Touch Sensor Beacons to simplify and enhance workflow . . . . . . . . . . . . . . . .
53
Regulating the Cell Assembly Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
Others
Signal From Cells Using an Andon Monitor .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
Smarter, More Efficient Scheduling. Visualize Meeting Room Schedules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54
Reduce Stress and Avoid Work Interruptions Indicate the busyness of current work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
Clear Indication, Simple Installation. Indicate meeting room status.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
56
Food and Pharmaceutical
Visualize Operation Panel Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Improve Predictive Maintenance Visualize lost productivity from reduction in speed .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32 List of Vocabulary.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
58
1 2
Scenario 1 Automobile Manufacturing
P re s s i n g
P9 Building Integrated Systems for Operation Management and Monitoring
P10 Easily Compile Operation Status of Old Equipment
P11 Automating a Handwritten Factory Daily Report
P12 Visualize Level of Cutting Oil Remaining in Tank
P13 Visualize the Stages of Equipment Maintenance
We l d i n g
P14 Visualize Equipment Status in Unmanned Areas
P15 Visualize / Analyze Stalled Robotics
Painting
P20 Visualize the Casting Process
P21 Visualize Robot Statuses
Body assembly
P22 Visualize the time required at each work step
P23 Remote monitoring reduces loss from stoppages
Te s t s a n d inspections P24 Takt Time for Manual Assembly Process
P25 Visualize Takt Time with LA6 on AGV
P16 Monitor issues remotely and in real-time P26 Visualize Takt Time
P17 Visualize Inspection Process Anomalies P27 Regulating the Cell Assembly Line
P18 Prevent Oversights During Inspection P28 Visualize Lost Time in Cell Production
P19 Mistake-free Inspection Process P29 IoT Screw Driver Measures Tightness of Screws
P30 Signal From Cells Using an Andon Monitor
3 4
Food and Pharmaceutical
Abnormal
Scenario 2 occurrence
Target 8600
Results 5560
Difference -3340
Ra w m
being tr aterials
ansport
ed
BUZZER
60
seconds
elapsed.
Energy, Energy C
onservation and Environment
P40 Make The Water Level Visible
an Reduce Checking Time
Security
P41 Maintaining Hygiene at Food Processing Site
5 6
Scenario 3 Logistics
M anagem en t office
P45 Remotely monitor server issues
P46 Broadcast Disaster Information to All Operators
P47 Reduce call wait times and backlogs
A rri v a l o f stock P48 UTM External Attack Monitoring Solution
P49 Improve Notification of Emergency Information
P42 Simple Request System P50 Industry or automobile-related manufacturing
11
10 20
30 40
50 12
0 10
20 30 40
50 13
0 10
20 30 40
50 14
0 10
20 30 40
50 15
0 10
20 30 40
50
Picking
P51 Notice print output as soon as possible
Confirm print output has been received
P52 Visualize Print Errors on Network Printers
P52 Prevent Picking Errors with Pick-to-Light
S t o ra g e of stock
P43 Air Conditioner Remote Alerts
S or ting
Shipment
P44 24-hour Network Camera Monitoring
7 8
Building Integrated Systems for Operation Easily Compile Operation Status of
Management and Monitoring Old Equipment
Automobile Manufacturing
Reduce Labor
Ethernet
LAN (LAN)
Return
Alarm
File(F) Edit(E) View(V) Favorites(A) Tools(T) Help(H)
Machine #2 stopped. Transmitter Operation information Cutting Processing Production Process Processing Painting Process Packaging Process Packing Process
Equipment No. 9 10 11 12 1 2 3 4 5
Unit 1
Unit 2
Unit 3
Log out
Before
•With older equipment, it is difficult to build an integrated operation management and monitoring system.
Normal Setup Alerm
•It would require remodeling the equipment so that it is compatible with the monitoring system, which is both costly and
time-consuming. Total the Trigger Time and Accumulated Time of each
Too old to support
Red switch
Logistics
IoT...
After ON Signal Tower with Find things to improve and
switch box HSST increase productivity!
Email alarms Operation Management * Separate application software is required.
With the WD installed in workstations, Automatically calculate and summarize operation logs based on the signal tower’s color
supervisors away from the site receive email information (Red, Yellow, Green) using the WD-Z2 on the wireless network. Visualize
alerts when maintenance is required. overburden (Muri), waste (Muda), and inconsistency (Mura) in the manufacturing site.
Practical and economical solution for data acquisition and analysis, as well as identifying
production bottlenecks. Before
More Creating handwritten daily production reports can Signal Tower with
Use contact Just attach to
outputs for error
efficient be cumbersome, time-consuming, and inaccurate.
signal tower switch box
information Save log data
Wireless transfer Use the information, Use saved data Furthermore, our machinery is old and does not support HSST-3M2
operation status change the facility at new facilities!
Monitor operation modern protocols and devices to send this data over the
Monitor production
Email notification feature network.
Send information
from the Save as CSV data
transmitter on Transmitter Transmitter
the signal tower!
WDT-Z2 WDT-Z2
Others
After
To site Signal tower Transmitter Wireless
manager communication
LAN
Wireless transmission The WD System allows users to wirelessly
Utilize data
Secure
Receiver
acquire machine data remotely and in real-time,
Let’s check communication
it out! Over the Red: Abnormal stop WDR-LE-Z2
Yellow: Call the operator Green: Normal operation completely eliminating handwritten reports. The
Facility
collected data is accurate and can be used to determine
11 12 13 14 15
network name 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50
To facility
staff
Unit 1
issue severity for more effective predictive maintenance. Data analysis software is required separately
The WD and HSST can also be added to any machine,
Unit 2
Unit 3
9 10
Automating a Handwritten Factory Visualize Level of
Daily Report Cutting Oil Remaining in Tank
Automobile Manufacturing
Network your machinery regardless of brand or age
Before After
Receiver
Checking the amount of oil in the Visualize the oil level with LA6
underground tank is a burden... Signal Tower!
Automatic Records
Oil Level Meter
Transmitter Full
Transmitter A
Automatically Low
recorded data
ISSUE IMPROVEMENT
No missing entries Checking the oil level requires physically opening and • Meter display of the level of the cutting oil
checking the underground tank, wihch takes effort and • As the oil level is visible from a distance by the
time. number of segments, you can manage multipleunits
at once
Logistics
Before After
Operation reports are often handwritten and taken at the The WD System automatically records equipment
Improvement Using LA6 Signal Tower
end of the business day. Overnight, machines can stall operation information 24/7 allowing users to identify
which will not be reflected in the reports and then takes trends and pinpoint machine downtime for more SOLUTION • Use the LA6 Smart Mode (Pulse Trigger Type).
significant time to identify the lot of defective products, efficient predictive maintenance.
resulting in revenue loss. ① Detect the oil level with a water-level sensor and show the oil level with segments on the LA6
② You can see the status of multiple units
③ By visualizing the remaining oil levels per unit, you can prioritize maintenance
Wireless Data Communication System, WD-Z2 ■ Chronological order of equipment operations in a Gantt chart Extension
From notification signal tower to Red: Abnormal stop Yellow: Call the operator Green: Normal operation White: Main power supply ON • Connect a temperature sensor to make abnormaltemperature
recording signal tower. conditions more visible.
Others
Facility 11 12 13 14 15
name 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50
Unit 1
Display Pattern Example
Signal tower Transmitter Wireless
communication Unit 2
Example
Unit 3
Unit 4
Unit 5
Signal Tower
11 12
Visualize the Stages of Equipment Maintenance Visualize Equipment Status in Unmanned Areas
Automobile Manufacturing
Create a standardized, color-coded system for equipment status
PLC PLC
Wiring Machine 1 Machine 2 Machine 3
Before After
When workers leave the production site, they are not The NBM is able to convert I/O signals from robots to
Logistics
Normal Operation / Equipment Malfunction- Maintenance in notified when equipment issues occur. network commands, triggering the appropriate light
Maintenance Completed Maintenance Required Progress segment on the LA6-POE!
Others
Easy SNMP Send PING SOCKET Stationary Type with Direct
HTTP
Web v1, v2c email
function
RSH 24
Commu-
Command
Ethernet Clear Switch Mount
Setup nication
13 14
Visualize / Monitor issues remotely and
Analyze Stalled Robotics in real-time
Automobile Manufacturing
Factory
11 12 13 14 15
away!
Logistics
LED Flashing MP3 Voice
Also, operation analysis of robotics using accumulated data
Signal Light Annunciator Horn
In automated robotic processes, robots will stall without Workers away from the site may not notice when Equipment with Non-Voltage Contact Output
Industry • Manufacturing
anyone noticing for an extended period.The goal is to an issue arises with their equipment, which delays
eliminate manual checks to determine which robots Process • Robotic Cell Production corrective action, resulting in revenue loss. PATLITE
have stalled in the process. NBM-D88N NH Series LFH EHV
Usage
Others
After Device configuration After Interfaces discrete input/output signals between
Wireless Data Acquisition System WDR Receiver x 1 unit indication and control devices over Ethernet. Add a
By using the existing PATLITE signal towers on the The NBM is able to take signals from standard I/O variety of PATLITE signaling devices to a network
Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 20 units
control panels with the WD system, it is easy to make Administration software x 1
and network devices and send emails to remote staff, for real-time remote monitoring and/or data
a cost-effective wireless data acquisition system to alerting them of issues at the office and manufacturing acquisition.
improve your robotics operation management. 20 Robots site in real-time.
Interface Converter
NBM-D88N
15 16
Visualize Inspection Prevent Oversights
Process Anomalies During Inspection
Automobile Manufacturing
Are you rushing visual inspections?
Missed the anomaly threshold value in the inspection process? Inspection line
Logistics
MP3 Playback Network Monitoring Signal Tower
NH-FV Series
Inspections are carried out on the production line before
Pros/Cons
PROBLEM distribution. To quickly reach their daily targets, workers may
●
●
●
●
rush inspections. Rushed inspections result in oversights and ● ●
Improve
Others
Play
88 dB Sound resonates
After Sound notification Once all the segments are blue, the
worker can end the inspection. Then
With its compact housing, the unique With audio notification, you can
The NH-FV is able to accept commands from the horn structure achieves sound pressure communicate information with proceed to the next product.
terminal and provides visual and audible alerts to ensure of 88 dB or more (at 1 meter). messages that tell you, "What and how
that's a problem," and combine with
the operator is aware of the threshold anomalies. input conditions.
17 18
Mistake-free Inspection Visualize the Casting
Process Process
Automobile Manufacturing
Example system
Before After
Red FAIL Cast manufacturing equipment Signal Tower LA6 Solution
USB-controlled signal tower Signal Tower indicates completion. As time elapses, the tower displays different patterns
according to its progress. When casting is complete,
LR6-USB
Green PASS the tower will flash blue.
Works with USB bus power
*USB Cable sold separately
USB connection
Logistics
Reduce the workload for staff on site
• Must continually go back to machine to check its status.
PROBLEM
• Unwanted downtime if machine is unattended when work is complete.
Before Industry / Equipment Overview
During the inspection process, Pass and Fail New feature!
Industry • Manufacturing
notifications on the screen are sometimes overlooked, Using the LA6 Signal Tower, make the elapsed time visible until complete
resulting in error. Process • Inspection Process
• With the application software EDITOR Benefits Signal Tower
SOLUTION
For Signal Tower, customize the Visualize elapsed time until casting is LA6
display pattern and time of each work complete.
Others
process. Easy to see the process of Understand the situation even from a
After Device configuration
equipment even from a distance. distance.
USB-controlled signal tower LR6-USB x 1 unit
By adding the LR6-USB, the visual and audible alerts Increase EFFICIENCY !
indicate Pass or Fail, adding another notification layer to Download the editing software here: All lights
flashing
Example
further prevent oversight and errors. www.patlite.com/la6/app.html
Extension
• Use tower to display information from the operation panel.
• Integrate with sensors to display tank fluid levels.
20 min 30 min 40 min 50 min Complete
19 20
Visualize Robot Statuses Visualize the time required
at each work step
Automobile Manufacturing
Do increases in work-in-process inventory create bottlenecks?
Before After
Use LA6-POE to make elapsed time visible and to notify managers.
Example
Factory Flashing lights
and audible
alarm
5 minutes elapsed
In the robot motion display, the signal light or pilot Visibility is greatly improved by programming all five WIP Inventory
light was the only indication that the power was on. light segments of the LA6 a single color. Contact LAN
output
Understanding the status of the device can be done
• Detect with a sensor, and show
from a distance without having to approach the the elapsed time since completion of
previous process.
control monitor.
Sensor • Use mirroring function to display
the status in the office
Logistics
Remote monitoring of robot operation status and safety improvements
⃝ With fewer workers on site, the need for clearer visual information as well
Display Pattern Example Signal Tower
as safety lighting increases. Visualize signal tower information from various locations LA6-POE
When light
is on
When light
is off
LA6-5DSNWB-POE (Stationary)
LA6-5DTNWB-POE (Direct Mount)
Problem at
the factory!
New feature! Improvements Using LA6 Signal Tower Command
Easy wiring with PoE
communication Freely set up the Luminous Color
Rich expressions, high visibility https://www.patlite.com/product/
detail0000000651.html
21 color display using multi-color LED. Display various status conditions in a variety of colors.
Maximum 8 locations
[Orange: Servo power ON, White: Teaching, Green: Automatic run] By emitting the same color Office
on all five light segments, visibility is increased.
Others
Stationary Type with Direct
Clear Switch Mount
Count up from when problem occurred to show the elapsed time
Manufacturing
Using the LA6 timer function, count up every 5 minutes from when the problem occurred. site A
21 22
Remote monitoring reduces loss Takt Time for Manual
from stoppages Assembly Process
Automobile Manufacturing
Callout Notification System 10 second 30+ second
delay delay
Work Time up Overdue
Takt time 100 seconds
Operative Operative Operative complete
100 sec 50 sec 0 sec
Switch
Network
ON
Alarm!
Green Yellow Red Problem with Line C. Cart Lock Cart Lock
Check immediately.
Logistics
Work flow
Retrofit existing equipment easily. Remotely monitor contact information over the network.
Before ● 21 different colors
Assembly line at a major car manufacturer
● Flashing mode
As assembly work is done by hand, work speed may ● Easy set up from a PC
fluctuate. At times, a worker may not be able to keep up
with the main assembly line and other workers may not ● Easy to change Takt time by
be fully aware of the situation or the assembly pacing. changing input signal
Network Monitoring Signal
Others
Signal Tower
Tower - NH Series LA6
After
Signal Tower ⇔ LAN
Install a signal tower showing the work progress. By
• Compatible with a wide making delays clearer, awareness at the work site is
Interface Converter NBM-D88N LAN ⇔ Relay range of protocols such as improved, and supply delays are reduced.
SMTP, SNMP, RSH
• Get contact inputs → Control network monitoring
• Notify receipt of TRAP and The cart travels on rails, and requires a button to send it
signal tower over Ethernet
commands from NBM with to the next process. As the button is pressed, the signal
• With email notification feature, you can report to
visual and audible alerts tower is automatically reset.
supervisors in charge, even at night
23 24
Visualize Takt Time with Visualize Takt Time
LA6 on AGV
Automobile Manufacturing
LA6 visualizes Takt time A production line utilizing AGV (automated guided vehicles). Set a Fixed Pace with the LA6 Signal Tower
The LA6 mounted on the AGV displays the work time for each Sub Line
assembly process.
Assembly line for outdoor equipment
Manage progress of the sub line
Exceeded
Takt time
Sub Line
Alert
Yellow light!
Supply parts from the sub
Start work
Yellow light is on! line just in time for assembly
Better hurry! Green light! on the main line, reducing
Make workers aware of the Takt time, to keep pace with assembly speed.
Reduce lost time caused by AGV stops.
Awareness Keep pace Reduce lost time
Signal Tower time loss
Picking and assembling parts on the sub line to the main line
Logistics
• Register 15 types of takt time patterns
• Pulse input at the start of production starts the takt count
• Pulse input at the end of production resets the count Improve quality and productivity by pacing the work.
Display Pattern Example • Currently, our main line and sub line are running separately, although
PROBLEM
the main line is dependent on the sub line for parts. When the sub line is
Example: Production takt time = 10 seconds
After input at start of production, the display changes to show the passing of time When takt time exceeds a certain threshold, not keeping up with the main line, it can cause errors and/or delays in the
lights flash and audible alarm sounds production while also affecting subsequent processes.
Others
lights
Using visual presentations, information that was hidden is now visible. Increase EFFICIENCY !
Signal Tower LA6
Audible
• Install a program on the signal tower to set the display patterns and colors.
alarm
• Set or change the Takt time even without a control program device
Elapsed Time 1 sec 2 sec 3 sec 4 sec 5 sec 6 sec 7 sec 8 sec 9 sec 10 sec (personal computer required)
• IP65 protection rating with integrated globe
• Display as much information as a production analysis board.
Registered display patterns change as time elapses
25 26
Regulating the Cell Visualize Lost Time in Cell
Assembly Line Production
Automobile Manufacturing
Collect Working Time and Visualize the Bottlenecks Example system
Hands free by using Automatic collection
foot switch with proximity sensor
Getting
parts
WDR Workbench
Receiver
Logistics
Sensor 15.6%
↓
visualize the bottleneck and clarify where balancing is Wireless Data Communication System WDR Receiver x 1 unit workers leaving their work area. The
Wireless Data Communication System WDT Transmitter x 1 unit collected information can be analyzed
required. to make necessary improvements 8.3%
With WD-LR transmitters, you can have 1 receiver and up to and increase productivity. 7.3% reduction!
30 transmitters in a single cell.
Step 2 The main focus at the factory is the assembly of many Industry • Manufacturing
Step 3
types of small quantity parts in cell stalls. Managers are
unable to see time loss resulting from workers leaving Process • Cell Assembly Line
Step 4
their work area to pick parts or perform other duties.
Step 5 1 2 3 4 5 6 7 ← Total production
Others
Ideal
Step 1
Step 2
After
Step 3 By installing a sensor at the workbench of the cell stall
Step 4 to collect the simple data of when the worker is in
the stall (working) and when the worker is away (not
Step 5 1 2 3 4 5 6 7 8 ← Total production
working), we were able to make improvements in just 1
month without adding a burden for collecting this data.
Lost time adds up and
reduces productivity
By visualizing the work time of all processes, you can
increase overall efficiency by evenly distributing workload. by 12.5%
27 28
IoT Screw Driver Measures Signal From Cells Using
Tightness of Screws an Andon Monitor
Automobile Manufacturing
System example Example system
WDT-LR-Z2
Transmitter Andon Monitor
Missing parts
Cell
1 2 3 4 5 Check quality of work
00:00 00:00 00:15 00:00 00:00
Elapsed
LAN Time 6 7 8 9 10 Jig issue
00:00 00:00 00:00 00:07 00:00
WDR Receiver 11 12 13 14 15
Possible to
• Example CSV data Electric screwdriver label Start Increase Torque Reverse Not used Check on a tablet!
Electric screwdriver
0: OFF, 1: ON
• WD can collect the start, increase torque, and reverse signals only.
Logistics
Caution (WD cannot collect the stop signals from the electric screwdriver.)
• An electric screwdriver signal cannot turn on an LED lamp of the LR series.
Signal Tower with All button operations are recorded – such as ON: Attention, OFF: resume work – so they can
switch box HSST
be the basis for improvement data such as frequency of occurrence and response time.
Others
Industry / Equipment Overview operations and the order for multiple screwdrivers Device configuration
(Electric screwdrivers are identified by registering
Industry • Manufacturing their names with the WD transmitter's MAC address)
After Wireless Data Acquisition System WDR Receiver x 1 unit
Signal Tower with switch box HSST-3M2 x 20 units
3. Automatically record loosen screw operations The manually-controlled HSST allows assembly workers Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 20 units
Process • Cell stall (with the reverse and start signals) to send requests to the Andon monitor so managers can Administration software x 1
4. Compile all the electric screwdriver operations at the determine priority and reduce lost time.
Device configuration
facility (with the WD unit's csv log file) For 20 Cell Stalls
Wireless Data Acquisition System WDR Receiver x 1 unit
Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 5 units
LR Series Body Unit x 5
5 Electric screwdrivers
29 30
Visualize Operation Panel Improve Predictive Maintenance
Information
Automobile Manufacturing
Reduce Labor Visualize lost productivity from reduction in speed
With the LA6 Signal Tower, visualize panel information from a distance Processing equipment with cycle
time of 60 seconds
Exceeds cycle time by 10 seconds
Out of
Productivity down approximately 8%
Line 1 material!
Exceeds cycle time by 10 seconds
Equipment can be checked for Productivity down approximately 16%
abnormalities at a glance from By visualizing the extra time that has elapsed,
a distance, without needing to you will not miss any required maintenance.
Abnormal 12 sec 24 sec 36 sec 48 sec 60 sec 61 sec 62 sec 63 sec 64 sec 65 sec 66 sec
Line 2 stop
Exceeded
Line 3 cycle time
Emergency Situation
Operate at standard cycle time Visualize extra time
Logistics
Visualize the timing of maintenance: Cycle time for processing equipment is 60 seconds.
A yellow light is lit for every second over the standard cycle time. When the standard cycle
time is exceeded by 6 seconds or more, all the lights on the signal tower change to red.
Others
After Device configuration
LA6
31 32
Prevent sand overflowing from the Visualize Amount of Liquid
hopper in the Tank!
Automobile Manufacturing
Visualize tank status with minimal configuration
Make the amount of sand in the hopper visible!
No PLC
Relay output
Electrode holder
CAUTION
Level Sensor SAFE
Electrode
LA6 displays the remaining
amount of sand in the hopper.
Logistics
Wastewater tank change in correspondence with status.
PROBLEM • When the level of sand in the hopper is not monitored, it could cause overflowing.
Product Configuration
1. With minimal equipment configuration, the LA6 clearly displays thefluid
With new Signal Tower functions, create an intuitive display levels. No need to utilize complicated PLC controls.
• When used with a sensor, the signal tower can indicate different statuses
SOLUTION 2. Tower-type display for clear visibility even from a distance.
based onuser-specified display pattens using colors, number of segments, Improve
Others
and flashing lights.
3. The signal tower can be set up for both water supply and drainage.
• You can customize the display pattern with configuration software.
Easy set up from a computer.
Download the application here (free): www.patlite.com/la6/app.html
Increase EFFICIENCY !
1 2 3 4
MODE MODE MODE MODE
33 34
Create Uniform Visual Signals Throughout Visualize amount of remaining fluid
the Worksite
Automobile Manufacturing
Before After Before After
Factory A Factory B Factory A Factory B Visualize Using LA6 Signal Tower
Critical Critical Critical Critical Casting Site
error error error error
Detect the level of liquid aluminum in the tank with
Consistent
Tank with Liquid Aluminum
sensors. Use LA6 to display the level.
Logistics
Make consistent status displays on all Signal Towers in the worksite Improvements Using LA6 Signal Tower
SOLUTION
• With the application software EDITOR For Signal Tower, set up various Display Pattern Example
displays for errors. Signal Tower
In the level meter display, show the remaining amount of material.
Others
• Even after installation, you can change signal colors using the application. LA6
35 36
Visualize the elapsed time from when the Visualize Work Progress
problem occurred
Automobile Manufacturing
Before After Before After
Alarm LA6 to visualize each process LA6 to visualize each process
Current status is unknown...
Only 1 red light
• The LA6 Signal Tower displays different light patterns Tank with Liquid Aluminum • Color code processes
and audible alarms. Additionally, one segment lights • Flashing light/audible when there is an error
up every 10 minutes, until the alarm is restored.
Error
• If 1 hour elapses, all the lights flash in sky blue.
All lights
flashing Process 1 2 3 5
Example
ISSUE IMPROVEMENT
To check the progress of the current process, the Each process is assigned a color, and the segments
operator must get close to the equipment. indicates the progress, with flashing lights and audible
With a small number of people, productivity is alarms when an error occurs, makes it possible to
10 min 20 min 30 min 40 min 50 min 1 hour
affected by delays in checking. check even from a distance to enable a fast response.
Logistics
Make maintenance time visible Improvements Using LA6 Signal Tower
• Long equipment maintenance time lowers operation rate. • Solved with LA6 Smart Mode (Time Trigger Type).
PROBLEM SOLUTION
① Assign a color for each process. Know the working process right away
• Difficult to manually record the time elapsed after alarm goes off.
② When work is started, the progress is made visible by the number of segments
③ When an error occurs, alert with flashing light + audible alarms
SOLUTION: LA6 Signal Tower
• After an alarm goes off, signal tower increases one tier every 10 minutes until the
SOLUTION problem is resolved.
• Easy installation; no programming required to activate timer display.
Improve Display Pattern Example
Others
• Use editing software to change display time, display, color (21) and pattern (15). Flashing lights
1 2 3 4
MODE MODE MODE MODE
audible
Elapsed 10 min 30 min 50 min 10 min 30 min 50 min 10 min 30 min 50 min 10 min 30 min Error
Time
LA6
37 38
Equipment Operation Management Make The Water Level Visible and Reduce
over LAN Checking Time
Automobile Manufacturing
System example
Before After
PoE HUB
Chemicals
Production information
Signal Tower.
Operation information CuttingProcessing Production Process Processing Painting Process PackagingProcess Packing Process
Equipment monitoring
Alarm histroty
Energy consumption
Water level is visible!
Simple set up of display patterns (color, elapsed time) for input
Unit 1
Where is
signals
Unit 2
the water
Use Case
overflow?
Drain tank reaches irregular level → all segments of tower light
Log out
Logistics
Alarm Alarm Alarm
LA6
Display Pattern Example
Others
After Device configuration Increase EFFICIENCY !
LA6-5DTNWB-POE
By switching signal towers to LA6-POE, you are able Wastewater ②
to collect operation data over the LAN infrastructure. 30 minutes elapsed
Because the LA6 supports PoE, it does not require a
power supply.
audible
39 40
Maintaining Hygiene at Food Simple Request System
Processing Site
Automobile Manufacturing
Example system
Before After
The opening and closing of doors allow for intrusion Warehouse A Warehouse B
of contaminants such as dust and insects.
LA6 Signal Tower Solution
Because contamination could be fatal in a food LA6 displays the amount of time doors are left open.
processing center, we want to ensure that we are not Flashing when the doors are opening, and for the Network Monitoring Signal Tower
letting exterior contaminants inside. amount of time they remain open, there is a change in NH-FV Series
However, the door may accidentally be left open the colors and number of segments.
when carrying items in or when multiple people pass Please supply parts
through. Benefits
Logistics
Warehouse A notifies Warehouse B when the parts will be supplied.
• Use the LA6 to visualize the amount of time the door is left open. Signal Tower
SOLUTION
• Easy time-keeping so workers can concentrate on their daily tasks. LA6
• The LA6 notifies workers right away when there are hazards such as the door notfully
Others
closed or if something is caught in the door.
After Device configuration
NH-FV Series x 2 units
The NH-FV gives visual indication of when and what
Display Pattern Example supplies are being requested. Wait time for parts is
Extension
reduced, and productivity increases.
• Connect a temperature sensor to make abnormal
temperature conditions more visible.
41 42
Air Conditioner Remote 24-hour Network Camera Monitoring
Alerts
Automobile Manufacturing
Automatic Camera Restart
Example system
Temperature / humidity sensor
with alarm output function 365 day operation Freeze
Temperature
/humidity error!
LAN
Ping monitoring of
network camera
LAN
PoE
ON/OFF
Camera restarted
Command
monitoring ports on
PoE HUB
Network Monitoring
Signal Tower
NH-FV Series Send Command
Electronic component warehouse temperature Notified by email alert
and humidity management
Logistics
Temperature Range 60-85℉ (15.6-29.4℃) Alerts when temperature
Email sent to notify NH-FV Series
Humidity Range 30 - 75%
or humidity is beyond Flashing Red
normal levels the manager. Remote Power Supply Controller
Voice essage
Others
Play
88 dB Sound resonates
After Device configuration After Sound notification
NH-FV Series x 1 unit With its compact housing, the unique With audible alerts, you can play
The NH-FV Network Monitoring Signal Tower alerts site When the network camera freezes, the remote power horn structure achieves sound pressure messages that tell you "what and how
managers via visual, audible and email alerts when there controller used to monitor the port automatically of 88 dB or more (at 1 meter). that's a problem"
are irregularities in temperature or humidity. restarts the camera. The PATLITE NH-FV series uses
ping monitoring and in the event the camera cannot
recover automatically, the NH-FV alerts via visual, ■ Actively get the equipment status
Network Monitoring Signal Tower audible, and email notifications. With this sort of In addition to PING monitoring, the NH Signal Towers are equipped with an
NH-FV Series configuration you can use network cameras with SNMP monitoring function. It actively obtains MIB information from supported
confidence. SNMP network devices and is able to notify personnel with visual, audible and/or
email alerts when changes occur.
43 44
Remotely monitor server issues Broadcast Disaster Information to
All Operators
Automobile Manufacturing
Emergency Situation
Logistics
Before Device configuration Before Device configuration
There are servers and network systems in place, but SERVER ・ NAS ・ UPS ・ PATLITE NH-FV Series Need to respond immediately to disaster alerts such as Terminal for receiving information, Administrator PC,
no operators that can constantly monitor the operation early earthquake warnings, however this information PATLITE - NH-FV Series, Amplifier / Speakers
status of the equipment. Therefore, there is a delay in cannot be transmitted right away from administration
noticing and addressing equipment issues. Usage computers. Usage
The Network Monitoring Signal Tower uses the ping By connecting the disaster information delivery system
monitoring function or SNMP for servers, NAS, and UPS with either socket communication or SNMP, status can be
Others
to notify the status of network equipment via visual, indicated via visual, audible and email notification.
After audible and/or email alerts. After
When a server issue occurs, you can immediately notify When a natural disaster alert is received, the NH-FV
the operator with visual, audible and/or email alerts. notifies administrators immediately with visual and
Even without an operator responsible for constantly audible alerts to ensure prompt response to emergency
monitoring the systems, this notification method situations.
ensures a quick response for any problems.
Network Monitoring Signal Tower Network Monitoring Signal Tower
NH-FV Series NH-FV Series
45 46
Reduce call wait times and backlogs UTM External Attack Monitoring
Solution
Automobile Manufacturing
Call center Office
Display the status of the call center Alert for unauthorized operation or an external attack
Server detects
unauthorized
operation!
TRAP Unauthorized access
transmission! detected!
Security
Server
Logistics
Normal operation Call waiting Dropped calls
Green light on Amber light on + audible alarm Flashing Red + audible alarm
There are periods where callers experience unusually Call center system PATLITE Unified Threat Management (UTM) has been UTM・Security Server PATLITE
long call wait times due to call volume spikes, unusually NH-FV Series implemented to prevent unauthorized access, filter NH-FV Series
long calls or insufficient operator resources at the call emails, and counter Web threats, but we are unaware of
centers. Usage any immediate threats. Usage
By connecting the call center system with either socket By connecting the UTM or security server with either
communication or SNMP, status can be indicated via socket communication or SNMP, status can be indicated
Others
visual, audible and email notification. via visual, audible andemail notification.
After After
By indicating operator's call status with the NH-FV, Detect an external attack with UTM, and use the NH-FV
administrators are able to monitor the situation remotely series to notify administrators immediately. By noticing
and in real-time, allowing them to route calls to another as early as possible, you can take measures to improve
call center, mitigating long wait times for multiple call the safety of servers that handle personal information.
center locations.
Network Monitoring Signal Tower Network Monitoring Signal Tower
NH-FV Series NH-FV Series
47 48
Improve Notification of Emergency Information Industry or automobile-related
For Factory Security, Railway Command,Disaster Prevention and
manufacturing
Automobile Manufacturing
Emergency Services
Machine 1
operation is
Camera is down almost done.
HUB
TRAP monitoring
TRAP monitoring
Send RSH
command
Office
Mirror status of LA6-POE master over LAN connection
Logistics
Remote notification of core equipment operation cycle time
● Monitoring network equipment for signs of life ① Synchronize Signal Tower LA6
Before (PING monitoring of 24 nodes) Before LA6 master control via PLC I/O contacts
It is critical that IT staff is able to monitor the increasing ● Get status of all the network equipment Make visible the operation cycle and changeover time. ② Connect LA6 slaves via LAN lines
number of devices on the network and be notified (You can register 20 MIB for SNMP compatible Build a centralized monitoring display center and make Synchronize display with mirroring
immediately when and where an issue is occurring. quipment) that site responsible for multiple remote facilities.
Others
After Device configuration After Device configuration
In additional to visual alert functions, the NH-FV can The LA6 conveniently integrates into your facilities'
also play user-specified voice message alerts to specify existing LAN infrastructure. Operators are able to mirror
where the issue is coming from instead of coding status from the LA6-POE master over the network to the
Network Monitoring Signal Tower Signal Tower
multiple locations with lights or sounds. LA6-POE slave in the office.
NH-FV Series Leveraging the existing LAN connection minimizes time LA6-5DTNWB-POE x 2 units
and wiring costs.
49 50
Notice print output as soon as possible Visualize Print Errors
Confirm print output has been received on Network Printers
Automobile Manufacturing
Improve Efficiency Starting with Printing Example system
Distribution depot
Out of paper...
Printer server
Out of paper.
Print Print
confirmed started
Network Monitoring Signal Tower Receive print command...
Immediately
NH-FV Series emits visual and
audible alerts
Network Monitoring Signal Tower Printing.
NH-FV Series
Push button when
Logistics
2
print confirmed
*For NH-FV setup, either check with the printer manufacturer or contact us.
By using the NH-FV Series print monitoring and audible Industry Overview
Before notification features, you can remotely notify printing Before
I do not notice when my colleague sends me a print job instructions. At sites where work is initiated by instructions output by Industry • Manufacturing
to my printer from his remote office. a printer, sometimes no one notices when the printer is
My colleague has no way to tell if and when I have out of paper, there is a paper jam, or other printer issues
received his printed documents. that could delay work.
Others
After Device configuration After Device configuration
51 52
Prevent Picking Errors with Pick-to-Light Smarter, More Efficient Scheduling.
Implement NE Touch Sensor Beacons to simplify and Visualize Meeting Room Schedules
Automobile Manufacturing
enhance workflow
Logistics
As parts are picked from bins, operators simply
touch the sensor located on the top of the NE to turn room changes to red via contact
off the light, allowing operators to accurately keep output from the NBM.
track of the parts and reduce picking errors.
Others
After After
Wall Mount Bracket
Implementing a pick-to-light system with NE signal NE-002D
By implementing a visual meeting room indicator Signal Beacon
beacons simplifies the part picking process and system, meetings became more efficient and reduced NE-M1ANN-M
prevents human error. Furthermore, the NE features a Mounting example delays in the meeting room schedule which improved
compact size for installation in tight spaces. Mounting Bracket productivity.
T85130016-F1
Wall Mount Bracket
Mounting Screw NE-002D
T81800030-F1
53 54
Reduce Stress and Avoid Work Interruptions Clear Indication, Simple Installation.
Indicate the busyness of current work Indicate meeting room status
Automobile Manufacturing
Unavailable Available; unoccupied In use Available
N type T type
Logistics
Upper Bracket Wall Mount Bracket Pole Pole (threaded)
NE-001D NE-002D POLE22-N POLE22-T In use Available Touch to switch color Mounting example
Before Before
In a time-sensitive work environment such as call In a large facility with multiple meeting rooms, it is
centers and broadcasting stations, it can be difficult unclear which rooms are in use and which ones are
to respond to a coworker's request when working on vacant. It was an inefficient process to have to check Signal Beacons
NE-M1ATB-M
another task. Interruptions in employee's busy work each room to confirm its vacancy, and important
flow causes delays, errors, and further stress. meetings were often disrupted by this.
Others
Upper Bracket Pole (threaded)
After After NE-001D POLE22-T
100mm
The NE Signal Beacons is installed on the employee's The NE Signal Beacons are implemented in a color-
desk, allowing them to toggle indication between red NE-M1ATB-M coded system with red signaling "in use" and green
for "busy" and green for "available" with a single touch signaling "available," enabling quick and clear
button. This avoids time-sensitive work from being Signal Beacons indications, even from a distance. Furthermore, it can be Mounting Bracket Mounting Screw
T85130016-F1 T81800030-F1
interrupted, and coworkers can clearly see when it is an connected using a single M12 cable, making installation
appropriate time to have a discussion. quick and easy.
55 56
Vo c a b ular y
Vocabulary Explanation Vocabulary Explanation
The rate at which one unit of a product must be produced in order to meet the customer's demand.
Stands for "Internet of Things", an industry term describing the interrelationship of devices connected to the
IoT Takt time is the quantity of products requested by a customer, in relation to the total time it takes to produce
internet, which collect and share data. Takt Time
those items.
Takt time = Total Time Available for Production / Average Daily Customer Demand
Stands for "Machine-to-Machine" and refers to technology that enables the exchange of data between networked
M2M
machines, without requiring human assistance. Refers to the average time required to complete production of one unit.
Cycle Time (C/T) When cycle time > takt time, it creates a shortage
When cycle time < takt time, it creates a surplus
Stands for Eliminate, Combine, Rearrange, and Simplify.
They are a set of processes that aim to carry out a procedure in a disciplined and effective way.
Refers to the ability to trace all pocesses of the production of an item, from the procurement of raw materials,
Eliminate: Identify processes that can be eliminated. Traceability
ECRS production, consumption, all the way until disposal.
Combine: if work cannot be eliminated, try to combine them.
Rearrange: Rearrange resources to optimize work efficiency.
Simplify: Simplify processes and make continued efforts for long-term improvement. Refers to the worldwide spread of a new disease.
Pandemic Pandemic countermeasures are actions taken by the country or an organization to eliminate the pandemic
disease.
Stands for "Power of Ethernet" and describes a system where both data and power are supplied to a machine
PoE
using a single Ethernet cable. Refers to the percentage of time that is actually used to perform productive work, in relation to the total
Utilization
available time.
Rate
It can be used to measure operational efficiency, as well as how well capital investment is being managed.
Stands for Total Productive Maintenance, which refers to a stategy for equipment maintenance in efforts to
TPM
optimize production efficiency.
Refers to the percentage of total time that an equipment is properly functioning during the time it is required for
Operational production.
Availability Of course, an operational availability rate of 100% is ideal. However, events such as maintenance, cleaning, and
The 7 Wastes Seven wastes (or Muda) that hinder production productivity. resolving machine errors can reduce the operational availability rate.
of Lean
Overproduction, Excess inventory, Excess motion, Defects, Over-processing, Waiting, and Transporting.
Manufacturing
Refers to the percentage of total time that an equipment is properly functioning when it is required for
Predictive production.
Refers to the digitalization and automation of logistic processes, as well as the interaction of people, machines, Maintenance Of course, an operational availability rate of 100% is ideal. However, events such as maintenance, cleaning, and
Logistics 4.0 and products within the digitally-networked system. resolving machine errors can lower the operational availability rate.
Examples include: AGVs, Drones, parts picking robots.
Refers to techniques using machine-monitoring devices that track the machine's status while in operation, to
Small Lot detect and address signs of error before they result in failure.
Refers to the management of a company and its suppliers, from the raw components and services all the way to
Supply Chain Production Unlike conventional methods of equipment maintenance that address equipment issues after they occur,
delivery to the consumer.
predictive maintenance aims to realize signs of potential issues, and resolve them before they occur.
Refers to inefficiencies that occur in a production system. Production Refers to a production technique where the rate of production remains constant, regardless of the fluctuation in
Bottleneck
The term is derived from the apprearance of a bottle: wide at the base, but narrow towards the top. Leveling demand over time.
Labor reduction can be achieved by improving operational procedures and implementing equipment that can
A status-display system in a production area that alerts managers of machine or process errors in real-time, so Labor and replace human labor.
Andon that the issue can be addressed right away. Manpower
Manpower reduction can be achieved by optimizing work efficiency and reducing any unnecessary or redundant
Reduction
It originated from Toyota's production system.
work.
57 58
Please use your products with ease from the time of purchase to after-support
through PATLITE’s global network.
EUROPEAN HQ CHINA
(GERMANY)
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Head Office
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