As manufacturers look to implement technologies such as IIoT, advanced robotics, big data, AI, cloud computing, and Industry 4.0, they are viewing the edge of another manufacturing renaissance. Once having been known for housing heavy machines and endless wires, shop floors are now starting to shed its confusing cluster of equipment for a finely-tuned and transparent machine network, where all moving parts communicate with each other wirelessly. However, to turn this aspiration into a reality, companies require additional human resources with new technical knowledge and capabilities. Unfortunately, the current scarcity of a compatible workforce in the manufacturing sector is deterring them from realizing the promised productivity and quality advances. To eliminate the need for skilled employees, Tutelar Technologies created software with the required know-how and capabilities built-in.

Tutelar offers device-level interfaces and comprehensive process and manufacturing control through their proprietary software—Ujigami, leveraging the abilities of a company’s existing workforce and equipment to deliver quality along with uninterrupted, productive uptime, for optimized performance. The Ujigami software suite can be quickly configured to achieve the desired results with rapid and sustainable ROI. “Ujigami provides next-generation capabilities for the manufacturing sector to help them achieve Industry 4.0 gains without the need of extensive skills development,” says Edward Dickson, President of Tutelar Technologies. The purpose-built shop floor software offers Product Directed Manufacturing capabilities, advanced mistake-proofing, dock-to-dock management, flexible manufacturing environment, fastest device level interfaces for plant floor equipment, and total solution ownership with a global reach.

These aspects, coupled with its ease of use and real-time control of any manufacturing environment helps manufacturers deliver products with zero defects. With Ujigami’s extensive device compatibility, the users can create new intelligent production environments – without the requirement to replace existing equipment. That being said, having considerable knowledge of process flow and control plan for each part, the software can control each machine and operations intuitively. Further, Ujigami leverages big data to drive the utilization of shop floor connectivity to automatically make effective business decisions and process corrections. As an added advantage, Ujigami’s architecture helps manufacturers bring their geographically distributed plants onto a single communication pane with real-time information sharing for greater transparency.

Today, many leading OEMs and tier-one manufacturers in North America are achieving the highest levels of manufacturing performance due to Tutelar’s leading-edge software. A recent case of the company’s success would be its collaboration with a large tier-one automotive supplier. The client was revamping their entire plant with automated guided vehicles (AGV) and automated storage and retrieval system (ASRS), along with collaborative operator interfaces, and real-time production coordination, control, and reporting. However, the supplier’s 20- year technology leap needed expert support to ensure success. With their comprehensive suite of manufacturing software, Tutelar helped them to reduce material stores significantly while increasing on-time delivery of the quality products. The overall equipment effectiveness (OEE) factors improved 13 per cent with better productivity and uptime metrics.

Currently, the company is helping many of its clients move their manufacturing business back to the U.S. to improve local product availability and profitability. For the months to come, Tutelar will continue focusing on applying active controls to both existing and new equipment opportunities. Besides, Dickson is confident about Tutelar’s ability in helping its clients harness innovations in the manufacturing sector. “Our team has a real manufacturing experience. Irrespective of what the problem is, what caused the issue, or when the problem occurs, our team of experienced professionals will dive in to help you find the root cause and create a sustainable solution that works,” concludes the President.