Going beyond ‘Visualization’ in manufacturing with ‘D-QiTs’

D-QiTs Kaizen IoT Solution

With the advancement of IoT technology, “Visualization” has become commonplace in the manufacturing industry. The critical question that each organization must ask is, “What should we do next?” The first step is to identify the problems, then pinpoint the real issues, and finally find ways to improve and resolve them. However, in reality, many companies are unable to reach the final step.

Visualization of problems

The first step in implementing visualization is collecting on-site data and understanding the situation in real-time. At this stage, IoT devices can be used to monitor machine status and production data, as well as to quickly detect anomalies and issues. However, many companies gather data but fail to use it effectively, preventing them from moving on to the next step.

Identify problems and implement corrective measures

The next step is to concretely identify problems from the data obtained through visualization and implement corrective measures or Kaizen. In this phase, the key concept is “Jidoka,” or autonomous control. Here, Jidoka not only refers to the automated operation of machines or systems but also includes a framework where humans can intervene when necessary. Before aiming for complete automation, it is crucial to improve tasks that require human intervention in essential situations. For instance, understanding the current problems accurately is necessary to connect with real solutions.

Build a sustainable culture of Kaizen using D-QiTs

D-QiTs (Dx Quick Kaizen Tools) is a Kaizen IoT package developed by DENSO Asia. It visualizes the true issues in the production process, analyzes problems, proposes solutions, and helps you build a continuous and sustainable Kaizen (Improvement) culture. D-QiTs visualizes three critical data points for Kaizen activities.

1. Output

Comparing the production plan with actual results and displaying them in a graph
Comparing the production plan with actual results and displaying them in a graph

Data is collected from the machines installed on the production line and displayed on a dashboard in real-time. This allows for immediate detection of anomalies. Additionally, it enables the comparison of production plans and actual results in real-time, making it easy to identify any gaps. iCONEXT also supports the visualization (creating a dashboard) of data beyond the default settings.

2. Cycle Time

The cycle time of each production line is displayed in a graph, allowing you to identify where the bottlenecks are.

Displaying the cycle time of each production line
Displaying the cycle time of each production line
Displaying the processes that are bottlenecks
Displaying the processes that are bottlenecks

3. Video

Users can immediately verify and respond to anomalies on the graph, as it is linked to on-site camera footage.

If an anomaly occurs, it can be checked through the video
If an anomaly occurs, you can check it through the video

Identifying OEE (Overall Equipment Effectiveness) and losses, and providing next-step advice

You can calculate OEE within the production line from the data and identify production losses. Additionally, we provide advice on prioritizing and optimizing by reducing these losses. Our package includes guidance and support for Kaizen activities by experts from DENSO International Asia, who have extensive experience in Thailand. This program uses D-QiTs data to support the transition to Lean manufacturing and ultimately automate production control.

Checking OEE and identifying losses, as well as proposing improvements by experts from DENSO Asia
Checking OEE and identifying losses, as well as proposing improvements by experts from DENSO Asia

Click here to download D-QiTs Kaizen IoT

iCONEXT supports visualization using DENSO IoT Data Share and provides IT support and system consulting services. If you are interested in D-QiTs, please feel free to contact us at thaisales@iconext.co.th or click our Inquiry Form.

Image: Freepik

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