Case study: Advantest Corporation
Advantest Corporation
Linking with MES (Manufacturing Execution System) data
Example of visualizing process progress
Kaizen effect
A progress meeting is held every morning to check progress by comparing the schedule and documents.
By combining production plans and performance information on the MES, you can always grasp the forecast and actual results of the manufacturing process.
To keep track of progress at factories far away, workers need to compare schedules point by point via phone or email.
Information is shared in real time, so it can be understood at a glance
The work of creating documents on-site alone takes more than an hour per day
Reports are generated automatically, so no labor is required
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Production Planning Department Manager Mr. Yu Nomura
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Production Planning Department Mr. Yasuyuki Takatoku
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Manager, Production Planning Department Mr. Mitsuteru Tajima
Advantest Corporation (hereinafter referred to as Advantest) is a company that manufactures "semiconductor test systems," devices used to check that semiconductors are operating properly.
The development of semiconductors is advancing rapidly with the spread of IT equipment, and the company's strength lies in its ability to provide the equipment necessary for testing them in a timely manner.
Yu Nomura, Director of the Production Planning Department
“Recently, the uses of semiconductors have been expanding in line with the progress of the world, including in automobile driving.
We believe it is important to respond to these semiconductor manufacturers in an accurate and timely manner."
In the semiconductor industry, the percentage of manufactured products that meet quality standards, known as "yield," has a major impact on manufacturers' costs. Advantest, which provides equipment to test yields, plays an important role for semiconductor manufacturers.
Visualizing work progress
Yasuyuki Takanori of the Production Planning Department said, "We use up to 10 or more types of forms to produce one model."
These reports were originally paper documents, but in order to improve the efficiency of production management, i-Reporter was introduced and the process of digitization was promoted.
However, one issue that arose during this process was that simply digitizing the documents themselves did not allow for immediate confirmation of work progress.
"Even if we entered the actual results into the ledger, we still had to make a judgment manually to see if they matched the schedule. For this reason, we previously had to gather together every morning for a 'progress meeting' to cross-check the schedule and ledger."
To visualize this work progress, it is necessary to create a system to link i-Reporter reports with data from the MES (manufacturing execution system).
The means to achieve this was the i-Repo Project.
Automatically obtain results for reports
When an order is received, the construction period and process are entered into the MES (Manufacturing Execution System). Each process has detailed tasks, each of which has a set schedule. This data on the MES can be input into i-Repo Project via WebAPI. Once this data is entered, i-Repo Project automatically generates i-Reporter forms tailored to the process.
At the manufacturing site, i-Reporter forms are checked using tablets and work results are entered. When the data is entered, the start and completion records, including when and who carried out the process, are also sent to the manufacturing execution system (MES).
Based on this information, the MES combines production plans and actual performance information, making it possible to constantly grasp the forecast and actual results of the manufacturing process.
In addition, the i-Repo Project makes it possible to visualize progress in real time using Gantt charts and other methods, allowing users to intuitively understand whether production is proceeding according to plan.
＼QDCの観点から品質改善に取り組むヒントを実例とともに紹介／
Zero man-hours
By establishing this system, it has become possible to visualize the progress of work, but Takanori says that this is not the only benefit of introducing the i-Repo Project.
"I also think that the i-Reporter report is generated as soon as an order is placed, which is a very useful feature.
Previously, it took more than an hour a day just to create the forms on-site, but now that forms are generated automatically, that time has been reduced to zero."
Furthermore, by introducing the i-Repo Project to subcontracted factories, progress management in remote locations has also become more efficient. Previously, to determine progress at remote factories, reports had to be received by phone or email and then compared point by point with the schedule, but now information is shared in real time through the i-Repo Project, so the progress can be seen at a glance by opening the i-Repo Project. Paper usage has also been reduced, leading to an estimated annual savings of around 20,000 sheets.
Towards new value creation
Mitsuteru Tajima, Manager, Production Planning Department
While progress management has become visible, huge amounts of work performance data generated during the process are beginning to accumulate daily.
Takanori's manager, Tajima, says that Advantest's next goal is to analyze this data and use it to improve business processes, such as optimizing them.
"By using CIMTOPS' i-Repo Project and i-Reporter, we have finally built a foundation for digitizing and visualizing progress management. As the next step in visualization, we would like to move forward with efforts to utilize and analyze the accumulated data, and furthermore, to use that data to create new value for our business," he says.
Company Profile
Advantest Corporation
- Established:
- 1954
- Headquarters:
- Shin-Marunouchi Center Building, 1-6-2 Marunouchi, Chiyoda-ku, Tokyo 100-0005
- Business Description:
- Semiconductor and component test system business
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- Other manufacturing industries with 300-1,000 employees
・Measurement and recording of 20 locations can be done with the push of a button
・Thousands of paper documents can be digitized and centrally managed
- Significant reduction in inspection and recording time
・By adding ConMas IoT, data entry time was reduced from 5 minutes to 1 second (per entry)
The system is highly complete and the level of support, including the manual, is extremely high.
There are manuals for everything, and many things can be done in-house.-
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- Automobiles and transport equipment: 100-300 people
- Since data is entered using a tablet rather than paper, you can basically record data simply by tapping.
- Storage has become more convenient and the daily reports I need can now be viewed immediately.
・It was great that we were able to digitize the forms we had been using up until now with the same look and feel.
- The operation was simple and there was no confusion for the person entering the data.
· It is a very good improvement that we can now centrally manage various records kept by multiple departments.-
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- Iron and metal: 20-50 people
Originally from Excel. Endless possibilities for use.
First, create a template in Excel. Add attributes to the input cells.
Once uploaded to the server, you can set it up using the dedicated software. Once that's done, test it and if there are no problems, publish it.
So, there is no need to program anything up to this point.
The more items you have to enter, the more difficult it becomes to set up, but once you get used to it, it's no problem at all.
Some Excel functions can be used, but not all.
Depending on the settings, the possibilities for use are endless and it is a very easy-to-use app.-
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- Food for 300-1000 people
・It is easier to read than handwritten records, reducing the burden on administrators to check records.
- With paper, two steps were required - recording, then checking against a standard and making a decision - but with paper, the decision can be left to a formula.
- Early detection of deviations reduces losses and leads to more stable quality.
-It's also great that the information sent to the server can be checked remotely in real time.
- Photos can be taken and added to the record on the spot, and a timestamp can be automatically added, lowering the hurdle for taking records that can serve as objective evidence.
▼Name of digitized field report
Foreign object detector operation confirmation record
Health check etc.-
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- Cars and bicycles Over 1,000 people
i-Reporter is easy to use in the field
- Approval route settings are simple and easy to use
⇒You can set it up to a certain extent by feel, without having to read the instruction manual carefully ⇒It is less dependent on the individual
・Work on site becomes easier (voice from the field)
⇒You can take photos of the actual item and report any abnormalities on the spot.
It has been extremely helpful in accumulating and managing evidence required for on-site work.
By introducing i-Reporter, we were able to standardize reports, make management easier, and simplify approval requests and approval procedures, as well as the accumulation and recall/linking of information, reducing work time by approximately 50%.-
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- Other manufacturing industries with 100-300 employees
The fact that you can use Excel functions such as if statements makes it easy for Excel users to adopt, and I also think the import function is easy to use; you first create the format in Excel, then write the functions in Excel and then just import the data.
We feel that it is extremely beneficial to be able to create reports for process management and product management and link them to Motionboard to perform BI analysis.-
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- General machinery: 1,000+
Previously, factory quality check sheets were handwritten on paper, but now we can input data onto an iPad, register the data in a database, and electronically approve the documents, allowing for paperless storage.
Information for each product can also be imported from the higher-level system and reflected on the checklist on the iPad.
There are comprehensive manuals and support available, so I think you can achieve digitization if you have a certain level of skill.
・Processing process
Assembly process
・Operation process
・Shipping process
・Create daily reports for each process
We are introducing it into our business.-
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- General machinery: 1,000+
The operation feels the same as a smartphone app, so you can use it without any hesitation.
Regarding the conventional in-factory checklist,
The usual process was to fill out paper on site → collect it → approve it with a stamp → collect it → file and store it at the quality control center → scan it and save it as a PDF when the storage period expired, and then dispose of it, but now all of these processes can be done paperlessly.
It is now possible to view files from the PC on your desk without having to go and search for them.
In addition, data compilation and analysis previously required the input of paper checklist information into Excel each time, but now it is possible to extract the information from a database.-
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- Software/SI: 20-50 people
・Easy to use as a native app. The UI is easy to understand.
・Can be used offline.
- You can digitize the Excel forms you have been using by simply importing them into the design tool and making a few edits.
- Label function makes it easy to classify.
-Easy to introduce as the first step towards going paperless.
- Printing and stamping work is eliminated, reducing costs.
Prevents loss of documents and mistakes when filling them out.-
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- Electrical and Electronic Equipment: 1,000+
By digitizing documents such as inspection sheets and progress charts, we were able to achieve a paperless system. In addition, because the documents can be created on an Excel base, there was little resistance from the field staff during the transition, and the digitization went smoothly.
It is used for on-site inspections, etc. It eliminates the need for paper management, leading to reduced man-hours and costs. In addition, by converting the data into digital data, it can also be used for tabulation and performance analysis.-
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- Electrical and Electronic Equipment 100-300 people
It is not only easy to digitize Excel files, but also to use the data for secondary purposes. Even if you are not familiar with systems, you can digitize paper documents with intuitive operations.
In the manufacturing process, many paper forms were attached to the product, but by digitizing them, we were able to reduce paper resources and, even with the movement of products between departments, we were able to refer to the forms from anywhere, which was good. In the future, we would like to actively promote secondary use of the acquired data.
Don't be overconfident that spending money to introduce a system will immediately bring about improvements, but rather use it in an innovative way to maximize the benefits.-
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- Automobiles and transport equipment: 100-300 people
- Using QR codes can reduce the hassle of inputting information
・Report formats can be created from Excel files
・It was introduced with the aim of reducing the time it takes to input and compile information written on paper at the work site.
・We have not yet been able to use it to tally data, but we no longer have issues with data being handwritten and illegible.
▼Name of digitized field report
Daily operation report-
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- Plastic products
・It was possible to set up and operate the system without making major changes to the paper forms.
· By participating in a hands-on seminar prior to implementation, the barrier to construction was low, and we were able to get the system up and running in a short period of time.
・It is mainly used for recording production at manufacturing sites, and input from iPads was easily accepted.
・By linking data with the upper core system, it contributes greatly to reducing input errors and paper
・Production status can now be seen at a glance thanks to display on the BI tool-
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- Electrical and electronic equipment: 300-1000 people
By digitizing the checklist, we have achieved a paperless system. It also reduces the need for storage space and transportation to the storage space.
The input check function made it possible to reduce human error.
The document management function makes it possible to search smoothly when needed.
With paper-based management, the longer the storage period, the more time it took to secure storage space and search, which made it less efficient. With digitalization, there were more benefits, such as reducing storage space, reducing costs, and shortening search times.-
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- General machinery: 1,000+
It has become an essential tool for promoting digitalization.
・Low coding allows even newbies with no programming skills to start development right away
・Master import integration from core systems, integration with other systems, data analysis systems, etc.
- A product that frequently adds new functions and will continue to have a wider range of uses in the future
・Equipment inspection checks were previously done on paper, but by digitizing them, issues such as searchability, reducing the amount of paper storage space, and detecting abnormalities were resolved.-
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- General machinery 20-50 people
・The workflow is simple but quite usable. In our case, the workflow is just "Person in charge" ⇒ "Investigation" ⇒ "Approval", so the workflow can be easily realized by only setting the authority and email address. In addition to approval, the workflow for change requests and change notifications can also be easily set up with just the above settings.
Data sampled on a PC can be embedded into a QR code (QR codes are automatically created in Excel), and when creating design verification documents, the data can be read and broken down into multiple clusters, allowing data to be entered all at once without the need for manual input. This is proving to be a powerful tool in improving work efficiency.-
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- Other manufacturing industries with over 1,000 employees
He is active as a data logger advancing digital transformation on-site.
Although we are working to collect on-site information using IoT devices, there are still many tasks that can only be recorded by humans.
By preparing a unified data collection form using i-Reporter, it is possible to link to the integrated data warehouse and operate it without any hassle. Even if the number of items to be collected increases, it is only necessary to modify the form.
By using a unified form to collect on-site data, which was previously dependent on individual staff, it is now easy to respond to sudden changes in data collection needs.
This makes management much easier when collecting similar data at multiple locations.-
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- Facilities (Construction/Architecture) 100-300 people
・It's very easy to create reports, and there is ample support available.
- When entering values, it is possible to set a threshold value to prevent missing entries.
・Excel forms can be easily created, and there are many ways to input numbers, text, and photos. Photos and drawings can be placed at the same time, which is helpful for making presentations to customers.
- It is very easy to use as it is possible to use the conventional Excel format as is.
- Previously, all forms were paper-based, and we had to spend extra time and effort sorting and searching through the huge amount of documents, but now it has helped us reduce expenses and improve work efficiency.-
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- Plastic products 100-300 people
・You can digitize data in the familiar Excel form format.
・All form data, including re-editing history, is automatically stored in the database.
・It is now possible to instantly search and tally up data that was previously impossible to tally up on paper (e.g., date, day of the week, period, person in charge, machine, product, color, etc.)
- Edit history is accurately recorded, so you can accurately check who made the changes and what they were.
・Reduced data collection time (7 hours for monthly reports, data creation only, reduced to 5 minutes)
・As long as the data is available, data can be compiled instantly, so clients rarely have to wait.-
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- Plastic products 100-300 people
If you just want to tally up data, it can be done not only in a database, but also by processing CSV data in batches or macros, which can be set to be output when the report is completed and saved.
Although it was difficult to create the entire data collection process from scratch as I had no experience, the benefits of computerizing the system were enormous.
I'll never go back to handwritten reports.-
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- Transportation 300-1000 passengers
・You can digitize the data by continuing to use the Excel you are currently using.
・Excel functions and formulas can be maintained almost as they are
- You can receive email notifications based on the content you enter.
Previously, reporting work required printing out a blank Excel form, placing it in a binder, writing the form by hand on the paper at the site and taking a photo with a smartphone, then entering the clean copy into Excel once back in the office, then connecting the smartphone and pasting the photo into the Excel file. This can now be done on an iPad.
▼Name of digitized field report
Safety Patrol Check Sheet-
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- Electrical and Electronic Equipment 100-300 people
· When digitizing paper operational formats, it was possible to create Excel-based forms even without specialist knowledge.
- Data can be collected and downloaded as a CSV file, and photos can be downloaded at the same time, making it very easy to use.
-It can be used on both the iPad and a PC, so you can fill out documents on-site using the iPad, and then add details or long text later on using the PC.
(We were able to digitize in-process defects and pre-shipment inspection records from paper to data, but the concrete numerical results of the implementation will depend on how we operate from now on.)-
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- Other manufacturing operations: 300-1,000 employees
・You can input data from any device
・DX can be promoted without changing the existing document layout
-You can create your own master
- Data is saved in CSV format on a cloud server, making it possible to link with in-house systems.
- Multiple reports can be created with one template form
・Improved input rate
・Reduce input time
・The efficiency of administrative work has been improved by changing from manual input of paper to input into the in-house system, to inputting data into the system only through i-Reporter.
・Differentiation from competitors-
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- Other manufacturing industries with over 1,000 employees
Daily quality characteristic data and other data that was previously managed on paper has now been digitized and can be referenced at any time, which is extremely helpful in terms of quality control. template form can also be created on an Excel base, so once you get used to it, it's easy to create them.
Because trends in quality control data can be extracted all at once, we were able to immediately see what trends had preceded the current problem.-
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- Facilities (construction/architecture) 1000 or more people
・The control numbers were previously entered manually, which was prone to errors and was time-consuming, but by converting the control numbers into barcodes and scanning them, it became possible to enter them instantly. This prevented input errors and reduced the time required.
-Mandatory input function prevented omissions.
- The date and time can be managed more accurately thanks to the automatic input function.
- Now, documents can be submitted without having to travel to distant departments, saving a lot of time.
Problems solved and specific effects
・Prevent typos and save time
・Prevention of omissions
- Improved accuracy of date and time input-
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- Electrical and Electronic Equipment 20-50 people
When the system was first introduced, it was used to digitize checklists and other documents that had previously been used on paper at the production site, but it was discovered that i-Reporter reports could be created without worrying about the number of pages.
It is easy to flip pages, so even if the number of pages in a document increases, it can be used without any discomfort.
- With paper forms, it was necessary to use the minimum number of check items and text necessary to fit on a single page.
- Since it is also possible to use photos, etc., the system can be used as both a procedure manual and a checklist, making it easy to use the checklist even when the person in charge is not present.-
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- Other manufacturing industries with over 1,000 employees
- Easy form design
-Various functions to meet on-site needs
・Ease of using data
・Forms can be developed without special IT skills
・Detailed functions required for on-site work are implemented in an easy-to-use format
・Data is stored in an easy-to-process format, making it easy to link with other systems
・Paperless on-site operations
・Data aggregation problem
- Secure management of photo data
· The transition was efficient because the traditional Excel forms could be digitized as they were.
-By going paperless, we were able to collect all the data in one place.-
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- General machinery 20-50 people
- ISO9000-related Excel reports can be transferred directly to i-Reporter, making it easy to go paperless.
· Because it was in the same Excel format as before, it was quickly accepted on-site.
- Review and approval workflow settings can be set up as standard functionality.
- Easily set up email notifications for reviews, approval requests, etc.
- If you convert measurement data from another measuring device into a QR code in Excel, you can simply read it into i-Reporter and the measurement values will be entered, eliminating the need for transcription.
・The time required to input various reports has been reduced. Data can also be shared.-
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- Automobiles and transport equipment: 100-300 people
By switching from inputting data on paper to using i-Reporter, it became possible to utilize the data, reducing the effort required for searching and increasing the scope of data utilization.
The task of transcribing data from paper has been reduced, and secondary use of the data has become possible.
In addition, by using it for lot management, it became possible to manage the progress of the lot, eliminating the trouble of having to search for the actual item.
▼Name of digitized field report
Lot control sheet-
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- Construction, Minerals, Metals: Over 1000 people
・Report design can be freely configured.
-An app is available and security measures are easy to implement as it does not require the use of a browser.
· Even though the factory does not have a network, by installing an app on a SIM-free tablet, it is now possible to exchange electronic data entered on-site with electronic information on a PC on the in-house network.
We believe that it will prove beneficial as a key tool in the movement towards achieving a paperless society.
・Paperless/printing hassle/on-site distribution hassle, etc.
▼Name of digitized field report
Pre-work checklist-
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- Food for 300-1000 people
Since daily reports differ depending on the products manufactured in the factory, they can be created to suit each daily report, and the use of selective input and simple functions reduces the workload.
In addition, we were able to use the database to register and retrieve data, and create inventory management for work-in-progress and maintenance and inspection management in line with our operations.
The previous transcription work was converted into electronic documents, which allowed for database integration and reduced duplicate work.
At one factory, 50% of daily reports have already been digitized, making it possible to achieve things that were not possible with paper, such as inventory management of work-in-progress.
▼ Digitized on-site documents
Maintenance slips and reports
Inventory Management Daily Report
Daily attendance management report-
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- General machinery: 100-300 people
This is a major first step in going paperless within the company.
- Screen design can be done in Excel, making it easy to modify the screen layout of input forms.
- Some Excel formulas can also be used, making it convenient to incorporate functional logic into the input content.
- Being able to develop it ourselves has led to improved IT literacy within the company.
・Used to manage the performance of on-site workers in factories, achieving a paperless system
・Reduce the time required to record results (reduce labor costs) and reduce recording errors
⇒ The investment costs were expected to be recovered about one year after implementation.-
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- Other manufacturing industries with 300-1,000 employees
・It is created from Excel format, so you can use the Excel format you are currently using. Easy to get started.
Utilizing single and multiple selection options to select from options and setting prohibited characters improved the variation in spelling, leading to more efficient data collection.
・Gateway integration allows you to do things that are not included in the standard features (such as creating graphs from entered data and performing unsupported function calculations).
· Data such as standard values, unit prices, and machine numbers can be easily pulled from the master, expanding the range of uses, such as displaying standard values for each product and calculating losses.-
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- Food for 300-1000 people
Reduce paper forms and system input work at manufacturing sites
・By using Python script integration, the degree of freedom has increased dramatically. Detailed validation checks and PostgreSQL references within Python are possible, so we have been able to go beyond electronic forms and reach the level of a dynamic application.
・Manufacturing instructions have been digitized. Previously, production results were written on paper and entered into the system one by one by hand, but now the data is reflected in the system from iPads, reducing labor costs and eliminating the need for paper.
▼ Digitized on-site documents
Manufacturing Instructions-
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- Automobiles and transport equipment: 100-300 people
I decided to use this product because it does not require programming languages and allows you to create web forms even without specialized skills. The free seminar at the time of introduction was thorough, and even I, who had no prior knowledge, was able to introduce it successfully. It allows you to go paperless with checklists and daily work reports that were previously written by hand, and makes them visible in real time, and is at a price range that even small and medium-sized enterprises can afford, so I'm glad I was able to introduce it.
Data and records that could only be viewed by going to the site can now be viewed from remote locations, allowing us to take action more quickly.-
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- Other manufacturing industries with 100-300 employees
A versatile product that is easy to implement for Excel users
・A place where you can create report layouts in Excel
- Excel functions can be used as is (only some of them)
・Forms that were originally printed from Excel can now be made dataless.
- Easy to use because it is familiar
In addition to going paperless and integrating Excel, which was previously on the server, the integration with MotionBoard has made it possible to carry out real-time analysis.
▼Name of digitized field report
Product Management
Process Management
Inspection Management
Equipment Management-
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- Automobiles and Transportation Equipment Over 1,000 people
ConMasGateway and API functions are excellent
What I find attractive about i-Reporter is that the information entered is digitized and can be linked to external systems.
There are some tasks that require human judgment (such as inspections) that are difficult to automate, so we would like to make full use of this technology.
The work of checking for errors and omissions, as well as the task of calculating information by comparing each piece of paper, was eliminated. → Labor costs reduced by approximately 480 hours per month
▼ Digitized on-site documents
Checklist
Quality control report-
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- Beverages, tobacco, and feed: 300-1,000 people
Problems solved and specific effects
There were no more calculation errors.
-Until now, I had been filling out the form to apply for overtime hours by hand, but even though I was careful, I was making calculation errors.
I contacted the support website and was instructed on how to set up automatic calculations. After I started using i-Repo, the calculation errors disappeared and the checker's work time was significantly reduced.
▼Name of digitized field report
Micropipette accuracy check table
Overtime application form-
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- Electrical and Electronic Equipment 20-50 people
no-code report app development with satisfactory support
- Report designs can be created in Excel, so ideas can be shared at the requirements definition stage and adjusted designs can be implemented as is.
- Various input methods can be implemented without no-code, making report development quick.
-Complex judgments and controls can be easily achieved by combining Excel formulas and network functions.
・When I have a problem, I can contact the support website and they will even consider a solution. It has helped me many times.
▼ Digitized on-site documents
Security Inspection Questionnaire
Construction documents
Quotation-
The above reviews are quoted from ITreview.（https://www.itreview.jp/products/i-reporter/reviews)
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