Macnica provides Togo Plant with its manufacturing site DX service "DSF Cyclone," achieving quantitative results within one year of implementation. From "intuition" to "evidence-based improvement," the service improves productivity throughout the factory by identifying abnormalities daily and sharing KPIs.

Macnica (Head office: Yokohama, Kanagawa Prefecture; Representative Director and President: Kazumasa Hara; hereinafter referred to Macnica) has provided its manufacturing site DX service, DSF Cyclone, to Togo Manufacturing Co., Ltd. (Head office and factory: Togo-cho, Aichi-gun, Aichi Prefecture; Representative Director and President: Shigeo Aiba; hereinafter referred to as Togo Manufacturing). One year has passed since the implementation, and the company has made great progress in becoming a smart factory, with quantifiable benefits now apparent, so the company is announcing the results today.

■Background
Founded in 1881, Togo Manufacturing is a long-established manufacturer with a global presence, primarily focused on small automotive springs, and handles a variety of products, including hose clamps. When it came to digitalization at manufacturing sites, traditional handwritten records and homemade systems meant that data utilization was limited to a small percentage, and improvement activities relied on on-site experience and intuition, preventing factory-wide optimization. To address this issue, a year ago the company introduced DSF Cyclone, which visualizes indicators that can be used for management decisions, such as overall equipment effectiveness (OEE), and enables on-premise operation and cross-departmental data sharing. During the implementation, the company worked with Macnica to repeatedly improve the dashboard configuration and display content based on on-site feedback, ensuring the system was firmly established at the site.

■Effects of implementation
One year has passed since the introduction of DSF Cyclone, and the following effects have been seen:

1. Company-wide business optimization using common KPIs
Previously, only partial indicators such as equipment utilization rates were available, and there was a lack of comparison between products and processes, and a common understanding with management. However, after introducing DSF Cyclone, indicators that can be used for management decisions, such as overall equipment effectiveness (OEE), were shared across departments, making it possible to compare productivity across products and processes, and accelerating decision-making between the workplace and management. This has enabled improvement activities with a bird's-eye view of the entire factory, achieving "company-wide business optimization" that improves the performance of the entire organization. Furthermore, the establishment of common KPIs has shifted improvements from being based on intuition to proposing evidence, and the number of improvement proposals has increased.

2. Rapid launch and flexible operation
Previously, home-made systems required a large maintenance burden and took a long time to set up, which tended to slow down improvement activities. DSF Cyclone allows for flexible operation through an on-premise configuration immediately after installation, enabling immediate results with the speed of package implementation. Data sharing has now taken hold across departments, creating an environment in which anomalies can be detected in real time and evidence-based improvement activities can be carried out swiftly.

3. Reducing waste and promoting awareness of resource utilization
Until now, waste loss was only perceived intuitively, but immediately after the introduction, real-time anomaly detection made the occurrence of waste loss visible. By making the "wastefulness" clear and quantifiable, awareness of the need to use resources effectively has spread on-site, and waste loss reduction is also making visible progress.

4. Shift from intuition to evidence-based improvement
Previously, improvement activities relied on on-site experience and intuition, which meant that signs of abnormalities and outages could not be detected in real time, often resulting in delayed responses. However, after the introduction of DSF Cyclone, data visualization improved, and abnormality detection and information sharing became faster. Furthermore, discussions based on numerical values became more active on-site, and abnormalities and outage trends could now be identified on a daily basis, significantly shortening the time lag until improvement. Furthermore, a culture of on-site employees analyzing causes and considering countermeasures on their own has taken root.

■ Future outlook
Togo Manufacturing is currently expanding the system from the hose clamp assembly process to upstream processes, with plans to complete visualization using DSF Cyclone at all four domestic factories by 2027. In the future, the company aims to expand its efforts to areas such as data sharing between factories, optimizing production plans through the use of AI, and reducing inventory, with the aim of creating a smart factory that connects domestic and overseas bases.
Macnica will use the power of digital transformation to support Togo Manufacturing in realizing its vision of "next-generation manufacturing that is friendly to people and easy to work in."

*: Manufacturing site DX service "DSF Cyclone"
DSF Cyclone is a manufacturing performance system that connects the manufacturing site and production management with performance data to optimize factory production efficiency and productivity. It enables data-driven decision-making for factory operations. Data collection, normalization, and utilization are all in one package, with functionality that makes it easy to deploy throughout the factory. DSF Cyclone was developed by Macnica and has been implemented in a wide variety of manufacturing processes. At manufacturing sites where it has been implemented, efficient manufacturing is achieved based on daily performance data.
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