Manufacturing has an immense ability to generate Big Data. Every device, machine, and operator constantly generates data regarding its current state and process results. The variety and complexity of plant floor devices makes the task of connecting, retrieving, and analyzing this data a daunting task. Complicated systems can be created to automatically respond to changes on the shop floor in real-time. As a result, companies must invest heavily in systems and people to fully harness the capabilities of their equipment.

Until now.

Tutelar Technologies Inc., a Canadian based company, has developed a comprehensive plant floor system complete with Artificial Intelligence and Industrial Internet of Things. Using a standard browser-based framework of proven hardware and software tools, the company supplies total plant floor integration of equipment and manpower systems, creating a real-time, intelligent manufacturing system that delivers the highest levels of production and quality control. Tutelar’s system is quickly configured to deliver World Class results without requiring sophisticated programming, advanced technical knowledge, or extensive training.

Catering to solve the toughest manufacturing challenges, Tutelar’s Ujigami Product Directed Manufacturing System (PDMS) offers the fastest, most flexible software to not only deliver the best quality but also to minimize costs. “Ujigami knows how to produce each part in the correct sequence, on the correct machines and right operations. The solution ensures that each part arrives at the required machines at the appropriate time and then configures the machine for the manufacture of the part,” explains Edward Dickson, President, Tutelar Technologies.

Ujigami controls each step of the manufacturing process and monitors the results to ensure they meet specification. In case the process or production results fail to meet specifications, Ujigami automatically invokes predetermined business rules to contain and correct the problem. “Our product offers ease of use, intimate real-time device-level control, plant floor transparency, and universal access delivering Zero Defect manufacturing capabilities.” Ujigami allows authorized users to use their computer, tablet or smart phone to observe and control their manufacturing from anywhere across the globe.

“Building on the success of Ujigami PDMS, we have applied AI and IIoT methodologies to warehouse management and management reporting. Ujigami can now coordinate, control, and report on all manufacturing and warehouse operations from dock to dock,” Dickson says. Tutelar Technologies has been delivering IIoT functionality long before the term was coined. Although IIoT promises the future will be bright with the purchase of new equipment, manufacturers must also integrate legacy equipment to maximize overall performance. “Our software is truly device agnostic with the ability to control all plant-floor equipment, both new and old,” states Dickson.

As a case in point, a large multinational OEM uses the power and flexibility of Ujigami to train their employees on the techniques of World Class Manufacturing and the future of manufacturing. Ujigami was chosen due to its extensive capabilities and ease of configuration. “Students ranging from operators to Vice Presidents are taking Tutelar’s Ujigami PDMS capabilities back to the workplace to successfully implement millions of dollars of savings,” Dickson explains. He further highlights that even though machines are transforming rapidly, production systems are not keeping up. “Lean Manufacturing and Six Sigma are considered the ultimate in manufacturing. However, these methods originated over six decades ago—a time with no computers, no internet and little automation.” Dickson is on a journey to redefine the vision of manufacturing. A new vision that integrates the massive computing, data transfer, storage, and connectivity capabilities that are now available.