Supporting Planned Quality Production Through “Always-On” Manufacturing Lines
Case Study - Manufacturing Operations Optimization
Installed Base Worldwide90,000+ units
Service Locations 21 countries / 160 + locations
The Customer’s Challenge
Labor shortages, rising costs, and geopolitical risks are making it increasingly difficult for manufacturers to maintain planned production of high-quality products. Companies need the ability to detect early signs of unplanned downtime and quality issues while ensuring rapid recovery and consistent quality across global operations.
Our Approach and Solution
Realizing the Autonomous Factory Through Intelligent Management of the “5M” Factors
5M:huMan/Machine/Material/Method/Measurement
Systems That Support Stable Equipment Operations:
Minimizing operational variability from production preparation through startup by leveraging high-rigidity machine frames, maintainability, and offline setup capabilities, helping establish a stable production foundation.
Software That Optimizes Entire Production Lines:
Leveraging automation and data-driven intelligence based on 5M data to reduce production variability, improve overall equipment efficiency, and minimize downtime losses.
Lifecycle Services That Support Continuous Operations:
Supporting stable equipment operations through preventive maintenance, remote support, and upgrades while maximizing lifecycle value.
Benefits*1 and Business Impact
Zero Equipment Downtime During New Product Introductions
NPM-DGS enables all data preparation to be completed offline, eliminating equipment downtime caused by data adjustments on production machines. This helps keep production lines running without interruption.
Approx. 70% Reduction in Equipment Stoppages
An automatic pickup error recovery function (software license) reduces error-related stoppages and lowers the number of equipment stoppages for target components, helping restore operations quickly when issues occur.
33.3% Monthly Reduction in Feeder-Related Quality Losses
Feeder OPEX and monitoring maintenance services detect early signs of deterioration and reduce feeder-related quality losses, enabling proactive action before problems lead to production interruptions.
*1:The stated implementation benefits are estimates provided by the customer. Actual results may vary depending on conditions and operating environments.
Contributions to Sustainability*2
Extending Equipment Life and Maximizing Resource Utilization
Maximizing the lifecycle value of existing equipment through longer service life, enhanced maintenance, and improved utilization.
30+ Year-Old Models Still in Operation (India)
Extending equipment life through upgrades and preventive maintenance.
*2:The described contributions are based on individual customer case studies and may vary depending on conditions and operating environments. Similar results are not guaranteed for all implementations.