CASE-004 MD SYSTEM for PD
A tablet on every press: production data straight from the shop floor
A production results collection system that links stamping data from planning to shipment and makes it visible in real time.
This is a summary of the case study. Full details are available on the Japanese page.
Challenges
Our stamping division grew quickly, and as part numbers and volumes increased, ad-hoc management no longer worked.
Each person kept their own management spreadsheets, so information depended on specific individuals.
Operators could not see production plans or results, making it hard to act on targets.
Production results were not available in real time, so problems were found late.
Managers spent time on paperwork, and stocktaking was slow and imprecise.
Our Approach: One flow from production to shipment
This project was carried out with the "DX Hands-on Support" program of the Hitachi Region Industrial Support Center (HITS), a public foundation. With advice from HITS DX coordinators and experts, our stamping, quality control and production control teams developed and rolled out the system in-house.
We also evaluated no-code / low-code tools, but chose to build the functions into MD SYSTEM, our in-house core system, to avoid learning costs, growing license fees, and the risk of keeping our production data on an external service.
11-inch tablets on all 14 presses
Each tablet shows the plan, actual count and progress for that press. Operators record start, count-up and inspection with large buttons, and lot numbers are assigned automatically.
Every stop is recorded
Any stop other than a count-up requires a reason code (material change, die maintenance, equipment fault, etc.), so we know which press stopped, why and for how long.
Shared on office monitors
Three 43-inch monitors show press status and daily/monthly results, and a 27-inch touch monitor in the meeting area gives instant access to production plans.
Key Features
Production planning
Production and equipment plans for each press.
Results collection
Operators register results on the tablet at the press.
Shipping inspection
Sample inspection and pass/fail judgment for each lot.
Packing & shipping
Passed lots are assigned to orders and shipped.
Visualization
Press status and results shown on monitors.
Lot traceability & inventory
Trace each lot from production through inspection to shipment; manage product and material stock.
Results
Higher output
Operators became strongly aware of plans and targets, and output has increased. When a press falls behind, other operators step in to help.
Faster response to problems
Production status is visible in the office, making it easier to gather information when trouble occurs.
Smoother quality control
Inspection progress and change points are visible in one list, and QC can prepare measurements by seeing what is running.
TECHNOLOGY
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