Roland DG

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The Power of Creativity

D-PICS: A User-friendly Manufacturing Support System Harnessing IoT

Friendly to People and Strong in Quality

Concept

"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.

Production scene with D-PICS 1 Production scene with D-PICS 2 Production scene with D-PICS 3 Production scene with D-PICS 4

System

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.

Operation status

monitor monitor closeup Display progress by color Operator Administrator
Server Server Wireless commnunication
  • Wireless commnunication On-schedule Digital Yatai Operator Digital YataiA
  • Wireless commnunication On-schedule Digital Yatai Operator Digital YataiB
  • Wireless commnunication Slower progress Digital Yatai Operator Digital YataiC

Analysis 

Quality control

Quality control

Monitor Operator Administrator
Server Server Wireless commnunication
  • Wireless commnunication Automatic
    inspections
    Digital Yatai Operator Digital YataiA
  • Wireless commnunication Automatic control of
    measuring instruments
    Digital Yatai Operator Digital YataiB
  • Wireless commnunication Automatic control of
    products
    Digital Yatai Operator Digital YataiC

Operation status

Analysis

Analysis

Analysis Work log / Operator hours / Nonadjusted ratio / Process capability Operator Administrator
Server Server Wireless commnunication
  • Wireless commnunication Log data 1 6.23596717495…
    2 9.32137852511…
    3 7.90245762845…
    Digital Yatai Operator Digital YataiA
  • Wireless commnunication Log data OK [1010]StartOKb
    OK [1040]StartOK
    NG [70]Start in…
    Digital Yatai Operator Digital YataiB
  • Wireless commnunication Log data [1010]StartOK[250]
    [1040]StartOK[230]
    [70]Start input…
    Digital Yatai Operator Digital YataiC

Quality control

Operation status

Digital Yatai

Digital Yatai is responsible for guiding the operator’s assembly procedures.

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Created Value

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.

D-PICS was developed to assist manufacturing operations and
has been shown to deliver a wide range of advantages to production sites.

  • Image for Simultaneous development by adopting concurrent engineering methods Simultaneous development by adopting concurrent engineering methods
  • Image for Parallel production of multi-product, flexible volume jobs Parallel production of multi-product, flexible volume jobs
  • Image for Swift, flexible response to sudden increases or decreases in production Swift, flexible response to sudden increases or decreases in production
  • Image for Reduction of work-in-progress inventory Reduction of work-in-progress inventory
  • Image for Shorter production lead time Shorter production lead time
  • Image for Reduction in control time with increased quality Reduction in control time with increased quality

D-PICS

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.

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