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Ujigami: Digitalizing The Plant Floor For Next-Gen Manufacturing
The rapid technological progress in the manufacturing industry is closely tied to the integration of AI- enabled devices and equipment into the production process. This shift towards Industry 4.0 can require significant investments that empower manufacturers to engage in real-time monitoring, facilitate predictive maintenance, and implement adaptive production processes. However, to generate optimum value from the manufacturing domain, each device must connect to an intelligent central system that controls the production of every part. Simple, low cost connectivity and control is the core idea behind Ujigami software.
"We realized that companies in the manufacturing domain required a user-friendly control system that is easy to use, reduces the time spent on learning the system, and increases flexibility and problem-solving options," says Edward Dickson, President of Ujigami.
Today, nearly three decades later, Tutelar Technologies remains the prominent player in the manufacturing industry, consistently delivering optimal results for its manufacturing and distribution clients. Its purpose-built, turn-key plant floor software system enables global OEMs Tier-1 and Tier-2 manufacturing companies to realize advanced manufacturing capabilities while addressing process inefficiencies, preventing bottlenecks, and achieving stringent quality control.
The Ujigami suite of software products creates a comprehensive dock-to-dock next-generation manufacturing environment, including the Ujigami Product Directed Manufacturing System (PDMS), Ujigami Warehouse Management System (WMS), and the Ujiboard World Class Manufacturing (WCM) software. Ujigami harnesses the latest in artificial intelligence and machine learning technology to establish seamless connectivity across machines and devices, streamlining the manufacturing processes on the plant floor.
With this real-time control system, every component aligns perfectly, each process executes flawlessly, and all products meet the highest quality standards.
Making Intelligent Manufacturing Accessible to All
Typical present-day plant-floor systems require technical resources with extensive knowledge and experience in programming to install and maintain the system. This high technical resource requirement creates another barrier due to the already short supply of skilled employees. With Ujigami’s easy-to-configure architecture and built- in machine interfaces, the need for these specialized experts is greatly reduced.
The Ujigami browser interface provides a familiar experience to ensure users do not require prior training or experience for configuring, operating, and accessing the extensive capabilities of the system.
Through its comprehensive collection of manufacturing process control tools and plug-and-play machine interfaces, Ujigami provides equipment connectivity and manufacturing intelligence to the plant floor team, streamlining operations into a user-friendly process and reducing the need for micromanagement of workforce and operations. Existing and new equipment assets are quickly integrated without the need for in-house programmers. This capability provided by Ujigami allows an organization to achieve higher quality products and production performance with minimal new investment.
Ujigami offers intelligent manufacturing solutions that are accessible to everyone, regardless of their technical background. It is designed as a comprehensive solution for controlling, monitoring, managing, and improving productivity and quality in manufacturing plants.
"Industry 4.0, characterized by increasing automation, informed data, and the use of smart factories, was previously the realm of the large companies However, the availability of cost- effective devices with highly intelligent manufacturing systems like Ujigami has made it accessible to every manufacturer," says Dickson.
Driving Manufacturing Innovation
What sets Ujigami apart is its ability to seamlessly connect all legacy and new machines on a plant floor. Legacy equipment can be upgraded with digital-to-analog bridges and connected to Ujigami, enabling users to manage recipes, operator certification, and machine output to ensure adherence to specifications. It also prevents recurring manufacturing issues and continuously optimizes processes, resulting in zero defects.
Ujigami is also known for offering a structured manufacturing environment flexible enough to provide manufacturers with a roadmap for improvements while allowing on-the-spot process adjustments.
Through its comprehensive collection of manufacturing process control tools and plug-and-play machine interfaces, Ujigami provides equipment connectivity and manufacturing intelligence to the plant floor team, streamlining operations into a user-friendly process and reducing the need for micromanagement of workforce and operations. Existing and new equipment assets are quickly integrated without the need for in-house programmers. This capability provided by Ujigami allows an organization to achieve higher quality products and production performance with minimal new investment.
Ujigami offers intelligent manufacturing solutions that are accessible to everyone, regardless of their technical background. It is designed as a comprehensive solution for controlling, monitoring, managing, and improving productivity and quality in manufacturing plants.
"Industry 4.0, characterized by increasing automation, informed data, and the use of smart factories, was previously the realm of the large companies However, the availability of cost- effective devices with highly intelligent manufacturing systems like Ujigami has made it accessible to every manufacturer," says Dickson.
Driving Manufacturing Innovation
What sets Ujigami apart is its ability to seamlessly connect all legacy and new machines on a plant floor. Legacy equipment can be upgraded with digital-to-analog bridges and connected to Ujigami, enabling users to manage recipes, operator certification, and machine output to ensure adherence to specifications. It also prevents recurring manufacturing issues and continuously optimizes processes, resulting in zero defects.
In contrast to traditional MES systems focused primarily on data collection and reporting, Ujigami's software can be easily configured to control and monitor the entire manufacturing process. It integrates data from various sources, including real-time sensors and equipment, analyzes this information, and swiftly eliminates inefficiencies like machine failures, quality issues, and production schedule problems. Coupled with Ujigami's advanced analytics tools, such as statistical process controls and predictive modeling, clients gain a holistic view of their manufacturing process and can make data-driven decisions.
Industry 4.0., Characterized By Increasing Automation, Informed Data And The Employment Of Smart Factories Had Always Been The Realm Of Large Companies. However, Over The Last Decade, With The Availability Of Low- Cost Devices With Highly Intelligent Manufacturing Systems Like Ujigami, At A Reasonable Cost, Has Made It Accessible To Every Manufacturer
Ujigami is also known for offering a structured manufacturing environment flexible enough to provide manufacturers with a roadmap for improvements while allowing on-the-spot process adjustments.
To further support customers, Tutelar Technologies provides a team of skilled technicians that act as an extension to the client’s team. With expertise in real-world manufacturing and software implementation, the team helps clients quickly solve production challenges.
Scripting Stories of Excellence
"The ultimate goal of a smart factory is fully automated operation, running a factory with minimal human intervention. Until a few years ago, this seemed almost impossible. Now, with new technology like AI vision and Ujigami, we have reduced and eliminated dependency on humans, even for supervision and coordination," says Dickson.
A testament to Ujigami's manufacturing intelligence prowess is its collaboration with a leading global Tier-I automotive supplier facing a critical challenge at one of their manufacturing plants. They aimed to enhance the performance of their predominantly manually operated injection molding work cells. Recognizing the need for digital transformation, they turned to Tutelar Technologies. The primary objective was to establish connectivity and control over a complex array of injection molding machines and auxiliary equipment, ensuring machine parameter accuracy, proper setup of auxiliary equipment, material and colorant selection and verification, operator elimination, and ongoing control and monitoring of machine outputs to maintain product quality and consistency.
By engaging with Tutelar Technologies, the client significantly reduced downtime, increased productivity, and made significant strides toward achieving zero defects. Ujigami's integration with the client's ERP system facilitated real-time production reporting, enhancing inventory management and supplier releases.
The project's success underscores Ujigami's transformative potential in manufacturing, showcasing the possibilities for increased efficiency, precision, and connectivity across production processes.
Shaping the Future of Manufacturing Excellence
Never one to rest on its laurels, the company serves customers in 185 countries, with support teams continually developing new features and integrations that elevate the performance of their organizations.
“Manufacturing Can Be A High Stress Environment, Where Managers Worry About Things Going Wrong. Ujigami Removes The Stress By Seeing Everything And Controlling The Results”
In that vein, Tutelar Technologies has added a flexible management-level reporting system where KPIs and standards can be defined to provide an even richer experience for the end-users to visualize their plant more clearly. Users can also access and see their plant's performance from anywhere in the world, giving tremendous transparency into the work on the plant floor.
"Manufacturing can be a high-stress environment, where managers worry about things going wrong. Ujigami removes the stress by overseeing everything and controlling the results," says Dickson.
Over the years, Ujigami has been a boon for engineers, supervisors, managers, and executives striving to achieve operational excellence. Ujigami is fully aware of all changes within the facility and ensures operators and machines respond accordingly.
Scripting Stories of Excellence
"The ultimate goal of a smart factory is fully automated operation, running a factory with minimal human intervention. Until a few years ago, this seemed almost impossible. Now, with new technology like AI vision and Ujigami, we have reduced and eliminated dependency on humans, even for supervision and coordination," says Dickson.
A testament to Ujigami's manufacturing intelligence prowess is its collaboration with a leading global Tier-I automotive supplier facing a critical challenge at one of their manufacturing plants. They aimed to enhance the performance of their predominantly manually operated injection molding work cells. Recognizing the need for digital transformation, they turned to Tutelar Technologies. The primary objective was to establish connectivity and control over a complex array of injection molding machines and auxiliary equipment, ensuring machine parameter accuracy, proper setup of auxiliary equipment, material and colorant selection and verification, operator elimination, and ongoing control and monitoring of machine outputs to maintain product quality and consistency.
By engaging with Tutelar Technologies, the client significantly reduced downtime, increased productivity, and made significant strides toward achieving zero defects. Ujigami's integration with the client's ERP system facilitated real-time production reporting, enhancing inventory management and supplier releases.
The project's success underscores Ujigami's transformative potential in manufacturing, showcasing the possibilities for increased efficiency, precision, and connectivity across production processes.
Shaping the Future of Manufacturing Excellence
Never one to rest on its laurels, the company serves customers in 185 countries, with support teams continually developing new features and integrations that elevate the performance of their organizations.
“Manufacturing Can Be A High Stress Environment, Where Managers Worry About Things Going Wrong. Ujigami Removes The Stress By Seeing Everything And Controlling The Results”
In that vein, Tutelar Technologies has added a flexible management-level reporting system where KPIs and standards can be defined to provide an even richer experience for the end-users to visualize their plant more clearly. Users can also access and see their plant's performance from anywhere in the world, giving tremendous transparency into the work on the plant floor.
"Manufacturing can be a high-stress environment, where managers worry about things going wrong. Ujigami removes the stress by overseeing everything and controlling the results," says Dickson.
Over the years, Ujigami has been a boon for engineers, supervisors, managers, and executives striving to achieve operational excellence. Ujigami is fully aware of all changes within the facility and ensures operators and machines respond accordingly.
