English 日本語
English 日本語
Friendly to People and Strong in Quality
"D-PICS," short for Digital Production Indicate & Control System, was developed by Roland DG in 2000 as a user-friendly manufacturing support system that harnesses IoT to respond quickly and flexibly to everchanging customer requirements. It achieves this by sharing digital data like 3D design data throughout the entire company from product design to manufacturing, quality control, sales and services to cut development time, reduce costs and increase product quality. As part of these efforts, D-PICS was further enhanced by the manufacturing department to facilitate efficient high-mix, low-volume production.
The most distinctive feature of D-PICS is that operators involved in monozukuri can use it as a system for achieving high quality and efficiency while maximizing their own capabilities and individual talents to the fullest extent in the shortest time.
Digital data is available to support the operator in real time, which helps achieve reliable, high-quality manufacturing regardless of individual skill levels or varying degrees of attentiveness. At the same time, the system provides the operator with an environment in which they can focus on assembly with greater confidence which fosters a more exciting workplace atmosphere teeming with a high level of motivation and attention to detail and creating ideas for improvement.
Multiple digital kiosks called "Yatai"
connect to the server at the same time
to assist the operator with assembly
instructions and quality control
in real time.
Display progress by color
Administrator
Server
Digital YataiA
Digital YataiB
Digital YataiC
Administrator
Server
Digital YataiA
Digital YataiB
Digital YataiC
Administrator
Server
Digital YataiA
Digital YataiB
Digital YataiC
Digital Yatai is responsible for guiding the operator’s assembly procedures.
Digital operator instructions
Intuitive instructions are displayed with illustrations of the assembled model, together with assembly methods and procedures, required tools and jigs, parts, precautions, and other necessary information.
Component inventory control
Only the required number of components are supplied as they are needed.
Wireless electric driver
Torque and rotational time are controlled automatically, which allows for perfect assembly by simply using the indicated driver as instructed.
Wireless measuring instruments
Connecting a measuring instrument to D-PICS allows the condition setting of the instrument and the pass/fail judgment of the measured data to be acquired automatically. This eliminates mistakes caused by human error, while inspections performed during assembly result in a high level of quality without any follow-up work required.
CCD camera
Detects whether or not inspection tools are in their proper storage spaces, to prevent loss or misplaced items in the assembled product.
Moveable cart
A small, moveable cart enables changing the manufacturing plant layout easily to adapt to changing production requirements or conditions.
Remote control operation
Operations involving large products can be performed some distance away from the computer by using a remote control device to operate D-PICS remotely such as showing the next page of the instructions on the computer screen without the operator having to change positions.
Creating an environment where operators feel comfortable focusing on assembly work not only helps improve quality and work efficiency, but also boosts the motivation of operators as it makes work more rewarding for them. The reduction in effort required to learn work procedures also allows operators to explore their creativity such as finding new ways to improve operations.
Simultaneous development by adopting concurrent engineering methods
Parallel production of multi-product, flexible volume jobs
Swift, flexible response to sudden increases or decreases in production
Reduction of work-in-progress inventory
Shorter production lead time
Reduction in control time with increased quality
With the rapid advances being made to IoT and AI, digital data has become an increasingly critical tool for improving quality and efficiency in the manufacturing sector. Developing more competitive monozukuri methods requires not only harnessing such digital strengths, but also finding the best way to simultaneously maximize human capabilities including attention to detail and creativity.
What form should manufacturing take in this age where everything is connected via the internet? What is the proper response to take with changes in production styles in the age of globalization and with a greater sense of risk awareness? What is the best way to handle new working styles like telecommuting and methods with a higher priority on work-life balance?
Such challenges to present day demands and social environments are being faced not only by the manufacturing industry, but by a broad range of service sectors as well, including the fields of medical care and education. We are confident that D-PICS has the potential to provide an adaptable solution for many challenging environments. D-PICS is leading the charge for production and operational advancement.
Analysis