Challenge: Limitations of routine maintenance and the need for IoT

Drink servers in family restaurants and karaoke shops, and coffee/water servers in cafes, operate by refilling the remaining amount at the appropriate time so that customers can pour themselves a drink at any time.

In many stores, replenishing stock is done by checking the remaining stock at regular intervals. This method is also called TBM (Time Based Maintenance). If the check cycle is longer, the operational burden is reduced, but customers cannot be served the beverage they need, resulting in a decrease in customer satisfaction. However, if the check cycle is shortened, the operational burden increases, which places a burden on employees in the midst of a labor shortage.

Inventory levels change depending on external factors such as weather, surrounding events, and business partner operations, so it is extremely difficult to replenish inventory at an optimal cycle. In Japan, which has entered an era of population decline, labor shortages are an issue in all industries. Utilizing digital technology, AI, and IoT technology is effective in maximizing profits with limited manpower and without imposing a burden on the workforce.

Comparison of Traditional Management (TBM) and IoT Management (CBM)

One approach to solving the issues with TBM is Condition Based Maintenance (CBM). This is a method of diagnosing the condition of equipment and determining the appropriate timing for maintenance. Advances in IoT devices such as sensors and cameras, as well as computing, have made it possible to achieve CBM without the burden on humans.

Macnica has developed a prototype "remaining amount sensor" to realize CBM for inventory and remaining amount management in restaurants, etc. This is a solution that supports the optimization of store operations, consisting of a sensor that measures the amount of remaining liquid and a device that displays an alarm when the amount falls below a certain threshold.

We have compiled a comparison of traditional and new methods, which is important when considering the introduction of AI and IoT.

About ARCH Toranomon Hills

ARCH Toranomon Hills is the world's first incubation center designed specifically for organizations whose mission is to reform large companies' businesses and create new businesses. We focus on the possibilities and challenges that are unique to large companies with abundant resources and networks, and support business creation from both the hard and soft aspects.

What is ARCH CAFE & BAR?

ARCH CAFE & BAR is an open-air all-day cafe and dining establishment.

Our sophisticated and comfortable space offers a wide range of uses, from our proud daily lunch specials that satisfy the appetites of our members, to breakfast, coffee and sweets to take a break from work, and even a glass of authentic craft beer after work.

You can also rent out this space for private parties and events.

The cafe had the following problems:

The cafe faced the following challenges in managing the self-service coffee servers (approximately 3L capacity) used by customers:

• Poor visibility: The remaining amount cannot be seen from the kitchen counter, making it difficult to visually check.
• Opportunity loss: In many cases, customers only notice that the container is empty when they point it out.
• Work load: Stocks needed to be replenished about six times a day, but the timing was difficult to predict, which placed a psychological burden on staff.

After introducing Macnica 's remaining battery level sensor solution

To address this issue, we implemented an IoT solution with the following features:

1. Non-contact/contact sensor: Measures the remaining liquid level physically or optically.
2. Threshold judgment logic: The trigger is activated the moment the remaining amount falls below a certain value (e.g., 2 cups remaining).
3. Notification device: An LED installed in a location that is easily visible to staff lights up to notify them when it is time to replenish.

Actual Case Studies & Customer Testimonials

We spoke with Takashima, who works at ARCH CAFE & BAR.

Q1: What problems did you have before?

"At this café, members of ARCH facilities can pour their own coffee using a coffee server. The coffee server's tank holds approximately 3 liters, but this needs to be replaced and refilled approximately six times a day. However, the display for the remaining coffee is located in a place that cannot be seen from the kitchen counter where the staff are, so it was not possible to replace the tank before it ran out. Each time a customer noticed that the tank was empty, they would have to let us know, and we would then have to replace the tank, which was a repeated routine. When the tank was empty, we were unable to serve coffee to customers right away, which sometimes caused inconvenience."

Q2: What did you think about introducing Macnica 's remaining charge sensor?

"When the tank is low on coffee, a refill notification LED that can be seen from the kitchen counter lights up. Since installing the level sensor, we've been able to always refill the tank before it runs out of coffee. We also find it convenient that we can control when the refill notification LED lights up by adjusting the mounting height of the sensor. The biggest benefit is that we can now serve coffee to customers without having to keep them waiting."

Q3: Was there anything that you didn't expect?

ARCH Toranomon Hills has many members who are looking for new business ideas from the "negatives" of their daily lives, so we have had many opportunities to be approached by members who have started working on the project, such as, "I didn't realize you were having trouble with this," or simply, "What is this? Is it useful?" This was an unexpected benefit. Someone who was interested in the remaining amount sensor that was installed approached us, and this led to more regular conversations than ever before."

*Replacing the tank of a coffee server

*Image of remaining amount sensor alone

Manufacturing consulting service

Macnica is not just a trading company; we specialize in developing solutions that solve on-site issues by combining cutting-edge sensor technology with AI and IoT.

Even if you find that "off-the-shelf products don't fit" or "there are site-specific constraints," we will provide support from prototype development to mass production considerations. If you are considering automating inventory management with remaining quantity sensors or introducing IoT, please feel free to contact us.