Even after a year into the unprecedented COVID-19 pandemic, manufacturers across the globe are struggling with a continuous sense of loss and uncertainty. Given the unpredictability of consumer demand, economic instability, and dramatic fluctuations in supply chains, the future seems to be unsettling, to say the least. Manufacturers are today tasked with a mission to determine ways to not only adapt to the new normal but develop a strategic and coherent approach to sustain in the days to come. The market volatility, however, has now brought to the fore a new question: would the tried and tested methodologies of lean manufacturing still be relevant and deliver results as they did in the past?
Surprisingly, the answer is yes. From its origins in the Toyota Production System, the “lean” modus operandi evolved with time to offer companies the ideal set of tools and skills to navigate this fluctuating environment. In fact, many experts believe that the disruptions caused by the pandemic call for a complete overhaul of the sector. As such, companies must consider adopting lean principles, tools, and digital operations as it emphasizes on enhancing productivity, improving agility, and eliminating unnecessary waste. Given that Industry 4.0 has introduced greater automation, increased the availability and access to data and metrics, and enabled better communication, lean manufacturing would help companies fine-tune workflows driven by a customer-centric orientation. It would also provide them with the skill set required to operate with resources in a strategic way that would ensure success.

Guided by the principles of 6 Sigma and Lean Manufacturing, Tutelar Technologies strives to help clients achieve just that. The company provides a complete solution to control, monitor, manage, and improve the productivity and quality of a manufacturing facility. Their comprehensive software systems drive immediate results to your bottom line - quickly reducing costs associated with inefficient production, poor quality, and missed deliveries. Tutelar Technologies’ flagship product, the Ujigami Product Directed Manufacturing System (PDMS), is equipped with Next-generation Artificial Intelligence, built-in Industry 4.0 capabilities, and integrated IIoT.

“Its unique product directed manufacturing methodology, combined with industry leading connectivity and real-time active controls, drives Zero Defects and ensures your plant always operates at peak performance. No other plant floor system has the speed, capabilities and ease-of-use of Ujigami,” prides Edward Dickson, President, Tutelar Technologies.

No other plant floor system has the speed, capabilities and ease-of-use of Ujigami

At its core, the Ujigami PDMS delivers all of the features and benefits to make manufacturing operations a success. The software is a comprehensive, fully-loaded MES encompassing operator, inspection, automated, test, and repair stations with interactive graphical work instructions, operator certification, quality alerts, scheduling, labeling, inbound and outbound sequencing, etc. To help ensure quality, the Ujigami PDMS’s active Product and Process Mistake-Proofing technology controls and tracks the quality of each serialized assembly through the entire production process to ensure the product is properly manufactured with zero defects prior to shipping. Also, there is an advanced, browser-based production and quality reporting tool that provides up-to-the-second status information highlighting production and quality concerns before they affect shipping schedules. It can easily Integrate with plant floor hardware, supporting all types of real-time sensors and equipment, including pick-to-light, part presence, and color detection, scanners, printers, fastening controllers, PLCs, conveyors, robots, and measurement devices. This ability means the system immediately identifies errors in material/people/process and then controls the corrective actions to ensure the proper containment and repair. Ujigami also includes Scheduling and Material Control functions with advanced features to enhance the traditional MES functionality (e.g., automatic line-side material replenishment).

What makes Ujigami a truly one-of-its-kind software is its ability to easily make changes and enhance the system for line balancing and continuous product, process, and quality Improvement. Production issues can be identified and quickly corrected anywhere a browser-enabled device is available. Ujigami operates continuously with minimal computing resources without requiring ongoing maintenance or programming. “Ujigami performs in your plant like the intelligence running a self-driving car. You just need to get in, tell it where you want to go, and the car does the rest. Similarly, Ujigami is configured with the business rules and intelligence of how to build a product and the system does the rest. It leverages AI and IIOT to deliver a next generation manufacturing environment that continuously produces parts that meet or exceed specification,” says Dickson.

Truly, at a time when manufacturers struggle to manage on-site resources given the increasing concern around contracting the virus, Ujigami makes a world of difference by enabling clients to not only do more with less but ensure overall success. Most recently, Briggs and Stratton deployed the advanced Ujigami PDMS system to reshore engine manufacturing to the United States and build engines of the highest quality at the lowest cost, “We find ourselves particularly well suited and poised for the manufacturing environment. Ujigami’s framework is very suited to be able to review, support, and share information in a distributed nature. Going forward, we will continue to listen to our customers for the capabilities they are looking for,” concludes Dickson.