In a factory, there is an important relationship between the people working there, the machines, and the products that are produced. All of them must work in harmony for the factory to grow and be successful.
At DENSO, we are on a mission to produce high-value products in the hopes they will help contribute to a better world.
With a vision for the future, we are always looking for new tools to help us accomplish our goals.
Since the emergence of the Internet of Things (IoT),
DENSO has been at the forefront, implementing these technologies within our factories to aid in the development of our people, machines, and products.
At DENSO, we believe that the connectivity and information gathered from Factory IoT systems helps to stimulate the creativity of people. Access to more information will allow our people to come up with creative solutions to problems
while creating innovative and higher value products.
Factory IoT will be the key to encouraging mutual growth with both our people and machines. Feedback from our machines to our people will be reciprocated back through innovative KAIZEN solutions, leading to a repeatable improvement cycle.
Factory IoT will enable us to communicate knowledge over vast distances and share a perception that anyone can create things with teams and partners throughout the world.
With DENSO Factory IoT, we hope to deliver a more enriched spirit to all people involved with MONOZUKURI, and to bring more happiness to the hearts and minds of the people of the world.
*MONOZUKURI: The Japanese term meaning "to create things". MONOZUKURI consists of the idea of possessing the spirit to produce excellent products with
the ability to improve production systems and processes.
*KAIZEN: The Japanese term for "continuous improvement". KAIZEN is the practice of continuous improvement by everyone, everywhere.
*UTOPIA: Useful Total Organized Plant
Integrated systems for Action Unification of Things and Information
At DENSO, we continuously work to create what we envision as an “ideal factory” through the fusion of automation and information technology. With this ideal factory, we strive to create products through the strength of our four principles focusing on Quality, Delivery, Cost, and Human. After the creation and success of our Ikeda factory in 1985, this image of the “ideal factory” was expanded across all of DENSO. In addition to the automation of our production lines, we unified the flow of "things (products)" through our factories with the flow of "information (forms, KANBAN etc.)" in order to maximize the production efficiency of our lines and achieve an optimized factory. DENSO has been at the forefront of FA (Factory Automation) by continuously introducing advanced technologies to the factory floor including AGVs (Automated Guided Vehicles), order information reading and automated sorting by KANBAN system, real-time data collection and status updates on our RFID-tagged products.
*KANBAN: The Japanese term for "signal". KANBAN is a Just-In-Time method of inventory control that helps to visualize work and workflow.
eFA (2001-) *eFA: efficient Fast Action Expanding the Quality Control System to the Entire Company
With defect issues occurring all over the world, we developed DENSO Original Process Quality Control System to improve the quality of our products to meet DENSO's stringent quality standards. We began automating the collection of equipment production data and generating control charts (X-r charts, etc.) to obtain an overall account of data that previously could only be captured by hand. With this data, we applied advanced analytical functions to monitor the quality of our products and find difficult to see patterns such as the correlation history between the characteristics of a product and the part lot. These practices have been rapidly expanded across all of our DENSO plants around the world and have resulted in extensive quality and process improvements.
Development System and Locations
- Silicon Valley, North America
- IMS (Cincinatti University)
- Munich, Europe
Around the world, DENSO is working to develop and integrate an overall Factory IoT (Internet of Things) concept. To take advantage of our worldwide perspective, we have established locations in Japan, Silicon Valley, and Germany while helping to train data scientists through joint research with the University of Cincinnati. We are validating core technologies including sensors, big data, artificial intelligence, networks, and HMIs (Human Machine Interfaces) to further develop our plan to roll out our Factory IoT strategy.
- DIAM, DMTN, DMMI, DMAT, and DNMX in North America
- DMHU, DNEU, DMCZ, DNBA, DNTS, and DMIT in Europe
After the development phase, our Factory IoT concept will run on our production lines to test and analyze our strategy’s effectiveness and to monitor for possible issues. We have selected locations throughout North America and Europe to serve as our model factories for this purpose. DENSO offices and factories around the world are working together to develop, test, and analyze our IoT concepts and to realize our Factory IoT goals.
- Worldwide Locations
Implementation of Mass Production
DENSO has 130 factories in 60 countries worldwide. By 2020 we will have all of our factories digitally connected together as though we were all under one roof. With these connectivity capabilities we will share resources for data sharing, monitoring and analyzing, allowing us to strive to double our global productivity.