Ujigami
Integrating and Controlling All Manufacturing Processes

A manufacturing facility where every aspect of production, ranging from processing raw materials to assembling finished products, is well-connected and optimized may sound like a pipedream. Smart manufacturing software with their device agnostic communications protocols and built-in artificial intelligence are turning this dream into reality.

Ujigami has emerged as the preferred solution for this reason. The purpose-built, turn-key plant floor software system enables global OEMs and Tier- 1 manufacturing companies to realize advanced manufacturing capabilities. It allows clients to address process inefficiencies, prevent bottlenecks, and achieve stringent quality control.

Ujigami can seamlessly communicate with, and control, all devices and equipment on the plant floor. It does not matter which hardware manufacturer or vintage, Ujigami can be deployed to achieve the manufacturing integration and performance goals. More importantly, companies can obtain industry 4.0 connectivity without relying upon any specific communications standard.

“Most manufacturing execution systems that are available in the market are limited to data collection,” says president Edward Dickson. “Ujigami goes well beyond simple data collection to ensure every single part is built to specification. It’s like a self-driving car for manufacturers.”

The software solution’s distinctive features are connectivity, speed and ease of use. Manufacturers typically implement multiple systems to fulfill different functions. But to make these systems work together, they need to act as software integrators—usually with less than optimal results. With Ujigami, manufacturers are relieved from this daunting task. Its flexibility and intuitive interface enable clients to achieve their goals of reducing turnaround time and improving manufacturing efficiency.

As a case study, a leading automotive tier-one manufacturer specializing in drive shafts designed a new manufacturing process. The client required a plant floor system that would coordinate and control all processes from fabricating raw material, through welding, press operations, outside paint application, assembly, final verification testing, packout and labeling. The new process relies upon a mixture of manual and robotic/automated workcells. These workcells are fed on demand by AGVs with an automated storage and retrieval system (ASRS) buffering bulk manufactured components prior to build-in-sequence final assemblies. The new methodology significantly reduces both manpower and inventory requirements.

The manufacturer needed a solution that could coordinate and control the entire workflow – both between workcells and the individual steps within each workcell. The goal is to drive all manufacturing from customer demand, only building required quantities and delivering materials to the designated work cells by AGVs. Verification of process results to ensure strict adherence to specifications and traceability of the as-built condition is mandatory to meet OEM requirements.

The client decided to implement Ujigami as their master scheduler, sequencer, process controller, data collection and storage system bringing outstanding outcomes.

A key benefit is the significant reduction in programming complexities, including robotic, test, and PLC programming. This resulted in a shorter machine build time and less downtime. They also minimized capital requirements by reducing the number of purchased AGVs. The direct savings of almost $1 million was significantly greater than the cost of the Ujigami system. Ongoing savings and cost avoidance continues to improve the positive ROI.

Ujigami has become the first choice for many manufacturers who are achieving operational excellence. Especially with today’s human resource constraints and the manufacturing world looking toward industry 4.0 for direction, the tools and functionalities Ujigami delivers are the gold standard in the industry.