Manufacturers of all sizes have realized the benefits of implementing an MES on their plant floor to augment their operations. However, today most MES systems are simply data collection hubs. These simplified solutions do not provide the necessary analytics and active controls required to drive exceptional performance. This is where Tutelar Technologies comes in. For over three decades, Tutelar Technologies offers its Ujigami software suite that leverages next-gen AI, Industry 4.0 capabilities, and IIoT to provide real-time active controls while ensuring optimum performance. The company’s Ujigami software suite goes beyond a basic MES to provide the speed and advanced capabilities for high-level manufacturing. At the same time, the software ensures zero defects in production. “Our Ujigami software can be easily configured with integrated controls to offer high level mistake proofing to enhance productivity and lower costs,” says Edward Dickson, President of Tutelar Technologies.

Tutelar offers manufacturing intelligence that not only provides insights but actual intelligence and real-time decision making. Typically, an MES collects results from machines and provides them to end users for decisions. The advanced Ujigami Product Directed Manufacturing System collects and analyzes data in real time to ensure the results meet specifications and make decisions automatically. “There is a lot of data coming out of manufacturing plants everyday and it is almost impossible for a human to keep up with it and make decisions in a timely manner; Ujigami takes away this burden from manufacturers and assumes the role of decision maker on the floor in real time,” says Dickson. Ujigami ensures that the right things are happening at all times. It acts as the best supervisor operating 24 hours a day, overseeing and helping every operator on the floor. Simultaneously, the software decides and tells machines how to operate, without human interference.

Dickson compares the transition from a normal MES to Ujigami with moving from paper maps to GPS. For many years users have used maps with few improvements, but GPS has revolutionized navigation by permitting the user to simply enter the destination and letting the GPS calculate the best route.

Our Ujigami can be easily configured with all the controls to offer high level mistake proofing to enhance productivity and lower costs

In case a wrong turn is taken, the GPS immediately recalculates an alternative route. Similarly, Ujigami breaks new ground for manufacturing by providing real time intelligence on the plant floor to calculate the correct path for each part as it is being produced, and continuously monitoring its progress to ensure it is made to specification, on time. However, Ujigami is much better than a GPS, as Ujigami can actually control devices and machines whereas a GPS has no control over the vehicle.

Dickson illustrates an example of a mid-tier automotive parts supplier that had to ensure they produced molded assemblies in specific customer sequence. Due to process constraints, molding requires batch production based upon various material combinations, tools and colors. Ujigami receives customer demand to calculate production orders and schedules for injection molding, prior to storing the molded components in an ASRS. The moulded components are produced approximately eight hours prior to the requirements of final assembly. Ujigami releases the parts from the ASRS for delivery by AGV as and when needed for final sequenced production. All of this is done seamlessly, requiring no human intervention.

With manufacturing intelligence at its core, Ujigami continues to empower manufacturers to rapidly produce defect-free goods. As the COVID-19 pandemic is pushing manufacturers to find new methods of production, Ujigami helps manufacturing companies take control of their plants. Ujigami creates an intelligent manufacturing environment that drives the highest performance in quality, productivity, and delivery. “Although the pandemic has thrown new challenges at manufacturers, Ujigami provides an essential toolset to overcome those and excel within the new requirements,” he adds.