Sato Launches 'IritoDe® Process Management' for Real-Time Manufacturing Visualization via RFID

Sato Launches 'IritoDe® Process Management' for Real-Time Manufacturing Visualization via RFID

Sato Corporation has announced the release of 'IritoDe® Process Management,' a new solution designed to visualize manufacturing processes and digitize work records at production sites.

This solution utilizes RFID technology to capture information such as work initiation/completion, operator details, and component data. By visualizing process progress and history in real-time, it contributes to increased efficiency and improved quality in manufacturing environments.

### Development Background

Process management is essential in manufacturing to optimize quality, costs, and delivery times. Appropriately tracking and analyzing the order of processes, progress, and work-in-progress inventory facilitates productivity improvements and standardization.

However, in many manufacturing sites, process progress and actual operations are not sufficiently visualized, making it difficult to monitor situations in real-time. Particularly where manual input is relied upon, data discrepancies and delays occur, hindering accurate status assessment and analysis.

Recent challenges, including rising resource prices and changes in raw material procurement, demand flexibility for production fluctuations and high-mix, low-volume production. In make-to-order manufacturing, fixed processes are lacking, making it difficult to grasp labor hours and costs, which acts as a barrier to optimal production planning. Furthermore, severe labor shortages necessitate new systems that balance labor-saving with productivity improvements.

Against this backdrop, Sato has developed and launched this RFID-based process management system to enable appropriate performance management, accurate record-keeping, and visualization of manufacturing processes, facilitating data-driven analysis and operational standardization.

### Overview of IritoDe® Process Management

'IritoDe® Process Management' automatically collects and stores work performance data in manufacturing processes using RFID, enabling site visualization and data utilization. By integrating with production management systems and the existing 'IritoDe®' shipping/receiving and inventory management system, it enables end-to-end management from components to finished products.

By utilizing RFID-tagged work instructions or employee ID cards, operators can automatically record the start and completion of tasks simply by scanning the tags, allowing for data collection without increasing the burden on the frontline.

It supports a wide range of production styles, from mass production to make-to-order, and is applicable to assembly manufacturing (discrete manufacturing), electrical/electronic component assembly, and lines centered on manual tasks.

### Key Features

1. Real-Time Visualization of Process Progress Automatically records work start/completion to grasp progress per process in real-time. Early detection of delays or bottlenecks allows for rapid response.

2. Automatic Accumulation of Work History and Inspection Data Centrally manages work history, inspection results, and component information for traceability. This contributes to advanced quality control and faster defect handling.

3. Facilitating Site Improvement through Data Analysis Analyzes accumulated performance data for standardized work hours and cost tracking. Supports productivity improvement through an accelerated improvement cycle.

4. Simple and Accurate Data Acquisition via RFID Unlike barcodes, RFID can be read by 'scanning' (waving). This reduces input labor and prevents human error.

5. Flexible Operation and Short-Term Implementation Standard packages can be implemented in as short as two months. Sato also offers customization based on site operation needs and provides optimal operational proposals utilizing 'on-site expertise.'

### Future Outlook

Sato will continue to expand support for tablet terminals and Android devices while enhancing input methods and analysis functions. The company aims to accelerate the deployment of this solution as a key driver for digital transformation, labor saving, and advanced on-site management in the manufacturing industry, where labor shortages are becoming increasingly severe.