Date Published:Nov. 27. 2024
Line adjustment time for different bottle sizes was reduced by about half.
Automation Achieved for Over 20 Manual Adjustments.
Interviewed Representatives for This Case
Mr. I: Factory Director
Responsible for the overall design and operation management of the factory.
Mr. Y: Researcher, Miso and Soy Sauce Testing Laboratory
In charge of equipment installation and adjustment tasks on the packaging line
Responsible for the overall design and operation management of the factory.
Mr. Y: Researcher, Miso and Soy Sauce Testing Laboratory
In charge of equipment installation and adjustment tasks on the packaging line
Installation Locations and Equipment for Our Products
Installed on the line for soy sauce filling and packaging.
22 units installed on the line where soy sauce bottles flow, to adjust the width of the guide according to the bottle size.
22 units installed on the line where soy sauce bottles flow, to adjust the width of the guide according to the bottle size.
Product Introduced
What Were the Challenges Before Implementing Our Product?
We faced a challenge with manual width adjustments on the line in the soy sauce filling and packaging process, which required significant time and effort.Our company produces soy sauce in several bottle sizes, such as 500ml and 1L, and the line needed to be adjusted accordingly for each size.The guides supporting the bottles had to be manually loosened and tightened, requiring over 22 positional adjustments at the final implementation points before our solution was introduced.This adjustment process was needed once every three days, taking two people approximately one hour each time, making it a major issue.
How Did You Learn About Our Product?
We learned about it at a trade show.Initially, we were considering automating the process of opening and closing the handles of containers used to store soybeans when preparing miso, but it was not feasible due to torque issues.However, we saw a case study on the filling process featured on your website and thought it could be applied in a similar way, so we reached out to inquire and borrowed a demo unit to try it out first.
How Has Our Product Performed After Implementation?
After implementation, the adjustment time was reduced by half to about 30 minutes for two people, saving 5 hours of work time per month and approximately 60 hours per year.We initially introduced 18 units, but eventually increased to 22 units, including other adjustments beyond width adjustment.Additionally, since manual adjustments varied slightly depending on the person and required specific techniques for positioning, automation has enabled even new employees to maintain consistent quality.There have been no complaints from the site, and we feel that the staff recognize how much easier their work has become.
What Was the Decisive Factor for Implementing Our Product?
The main deciding factor was that we hadn’t seen any similar products that could solve this issue.While many products have alternatives, we have never encountered anything similar to the Auto-Positioning Units.We also use Nabeya Bi-tech’s V-pulley groove gauge to measure pulley wear, and we have been impressed by their unique approach and innovative solutions.
While we had a clear vision of what we wanted to achieve, we were slightly concerned about whether Nabeya Bi-tech’s Auto-Positioning Units could truly deliver.However, after reaching out to Nabeya Bi-tech, they provided a demo unit, which allowed us to verify its effectiveness before implementation, making it easier to proceed with consideration.Since adjustments and control of peripheral components were necessary, making an immediate purchase felt like a high hurdle, so being able to test it with a demo unit was a significant advantage.
We collaborated with an equipment company during the implementation process. When we passed the initial test, we had a strong feeling that “this will work,” which gave us the confidence to move forward with the implementation.
While we had a clear vision of what we wanted to achieve, we were slightly concerned about whether Nabeya Bi-tech’s Auto-Positioning Units could truly deliver.However, after reaching out to Nabeya Bi-tech, they provided a demo unit, which allowed us to verify its effectiveness before implementation, making it easier to proceed with consideration.Since adjustments and control of peripheral components were necessary, making an immediate purchase felt like a high hurdle, so being able to test it with a demo unit was a significant advantage.
We collaborated with an equipment company during the implementation process. When we passed the initial test, we had a strong feeling that “this will work,” which gave us the confidence to move forward with the implementation.
What Are Your Expectations for Nabeya Bi-tech in the Future?
YOKOYAMA MISO SHOYU ZYOZO TEN aims to create a workplace environment without restrictions based on gender or age and regularly holds sessions to listen to issues faced at the site.There are still many areas we’d like to improve, so we hope NBK continues to introduce more outstanding products that surprise us.
■ YOKOYAMA MISO SHOYU ZYOZO TEN
Founded in 1912, we are a company based in southern Kagoshima, manufacturing and selling "barley miso" and "sweet soy sauce."
https://kaneyo-soy.com/
For inquiries regarding this matter, please contact us here.
▼The Auto-Positioning Units featured in this case study can be found here.
Issue/case studies
Improved productivity/workability
Automation/robots/motorization
Food Machinery
FA Devices
Solution samples
FA solutions