In recent times, machines and devices on the plant floor are becoming significantly more intelligent and capable of communicating across a standard Ethernet connection. This creates an opportunity for manufacturers to leverage those devices into a completely integrated environment that provides real-time manufacturing knowledge and control. As a result, they are able to control the required output— significantly improving productivity and reducing waste. In theory, this promises great advances! However, the reality is that creating and adopting such robust solutions alongside standards like “lean” and “Industry 4.0” for manufacturing has been slow and is still many years away from adding significant value.

Shortage of technical resources aside, there is a need for plant floor data and control and seamless device connectivity. What manufacturers need today is easy to use, device-agnostic, intelligent software that can make decisions in real-time. It must be able to contain the knowledge of how to produce each part and then control the machines and operators to make sure parts are built to their unique specifications. But, does such software exist?

To that, Edward Dickson, President and CEO of Tutelar Technologies, says, resoundingly, “Yes, there is!”

Nearly three decades ago, even before current buzzwords like IIoT and AI were coined, Dickson had a vision for an advanced manufacturing environment. He realized the need for an intelligent, connected plant and began work on the Ujigami software.

At its core, the Ujigami suite of software products creates a comprehensive dockto-dock Next Generation manufacturing environment. Ujigami provides nextgeneration capabilities - those promised by IIOT, Industry 4.0, AI, and more - without the need for extensive programming and customization.

The software solution includes the Ujigami Product Directed Manufacturing System (PDMS), Ujigami Warehouse Management System (WMS), and the Ujiboard World Class Manufacturing (WCM.) As such, it emerges as the real-time control system that can direct, detect, correct and control all processes during the manufacturing of individual parts instantaneously, as they are being manufactured.

The Ujigami PDMS acts like a GPS, guiding parts through the appropriate machines and operators and making accurate and proactive decisions for every part being produced. First, it calculates the best route for manufacturing each individual part. Then each part is tracked through the manufacturing process to ensure quality output, continually making decisions based on real-time feedback. However, the PDMS does so much more than a traditional GPS.

“Since the system not only monitors each machine but also controls it, the PDMS can ensure that every machine is set up correctly and produce results that meet specification. Imagine the power of a GPS that ensures the driver makes no wrong turns, follows all traffic rules, and arrives at their destination on time. We are seeing this capability developing in self-driving cars. Our Product Directed Manufacturing System brings this capability to parts being produced in our factories,” says Dickson.

Unlike traditional shop-floor systems that limit themselves to simple reporting functions, Ujigami ensures accurate process execution and safeguards machines and operators from making incorrect decisions during production.