QUICCA utilization example
Visualize the efficiency of production equipment using OEE
Aggregation work is indispensable for evaluating the efficiency of production equipment, but what if a graph showing the increase in production volume compared to the previous month and a graph showing the decrease in yield compared to the previous month were displayed at the same time?
You're honestly not happy about this situation. As the number of summary graphs and tables increases, it may become difficult to comprehensively evaluate whether the production equipment is being used effectively. In this article, we will explain how to obtain OEE (Overall Equipment Effectiveness), which indicates the efficiency of production equipment comprehensively, using production plans and inspection records.
Do you have to spend a lot of time handling food contamination incidents?
In this article, we would like to discuss how to respond to complaints regarding foreign body contamination. Consumer feedback in which a product has been found to be contaminated is usually communicated to the manufacturer via a retailer. If there is a slight suspicion that the contamination actually occurred somewhere in the manufacturer's production process, its Quality Assurance Department will immediately begin an internal investigation. We would like to explain how long it takes to investigate "whether an inspection was carried out correctly" and "the cause of foreign body contamination," which needs to be reported to business partners, and propose how to reduce the time it takes.
How about starting with "visualization" to introduce IoT?
Food factories are now actively introducing IoT. The factors behind this shift include chronic labor shortages, aging workers, and a remarkable rise in material cost. The objectives of the introduction of IoT include improvement in production efficiency, preventive maintenance, information sharing, paperless work, and the acceleration of decision-making to utilize resources (manpower, equipment, and money) effectively. On the other hand, we often hear that companies that have introduced IoT systems with too many functions have not experienced the investment returns that they expected. In this document, we drastically narrow down the objectives and describe the effect of "visualization," which is the basis of IoT, on increasing motivation in production line employees.
Reducing raw materials through automated feedback to the upstream process
In Examples of utilizing QUICCA: VOL. 2, "QUICCA can reduce raw materials," we described that changing the settings of production equipment (we used the example of a hamburger patty forming machine for the description) while viewing a tablet screen can reduce raw materials waste. In this article, we would like to introduce an example of automatizing feedback to and adjustment of production equipment to reasonably minimize the amount of raw materials waste.
Increase productivity by reducing temporary line stops
It is important to think about cause and countermeasures if short time breakdowns occur frequently in the production line. If nothing done, it can lead to major problems such as the recall of products and the serious failure of equipment. For thinking about countermeasures, we will make it visualize for temporary line stops that are difficult to see quantitatively.
How about performing daily administrative work remotely?
With the epidemic of covid-19, companies who produce foods consuming at home, which are increasing in demand, continue to produce late-night and 24-hour production. In the meantime, managers who are responsible for production and quality continue to be busy every day. QUICCA can greatly reduce the workload of managers involved in the inspection process. The administrators will be freed from the cumbersome day-to-day operations and be able to work on improvements from a long-term perspective.
QUICCA can reduce raw materials
Statistics show that the average profit margin in the food industry is less than 3% in Japan. The food industry makes things that are essential for people to live, and it is not easily affected by economic fluctuations, but the business is less profitable compared to 10% in the machine tool industry and 6% in the electronic parts industry. Among foods, raw material costs account for a particularly high proportion, and products with a short shelf life, such as processed meat products and bread products, currently have a profit margin of around 2% even for top-class companies in the industry. Think about how you can reduce the waste of raw materials.
Would you like to promote paperless manufacturing?
QUICCA does not save the form itself, but saves the original data (date, time, worker, type, inspection result, etc.), extracts and calculates the one that meets the conditions, and outputs it in the specified format. In other words, no matter who operates QUICCA, the same result form can be reproduced on the computer screen at any time, so there is no need to print it on paper anymore. We will be freed from the hassle of printing and filing and will be able to focus on more creative work.