No one could predict the extent of the COVID-19 crisis. In this global pandemic characterized by extreme uncertainty, governments, businesses, and common people alike have been flung into situations they weren’t prepared for. From paralyzed industries and shuttered businesses to job losses, COVID-19 has effectively ushered in chaos and continues to affect the pace of evolution in the enterprise landscape. Novel coronavirus’ disruption in the manufacturing sector alone has led to severe notable operational, social, and financial consequences. Ergo, manufacturers are being forced to rethink risk management and contingency plans, workforce safety protocols, manufacturing operations, and new ways of working opportunities—all at the same time.
Safe and Productive Manufacturing Environment
Against this challenging backdrop, there is one company that is helping manufacturers minimize the impact of the COVID-19 storm—Tutelar Technologies. To assist companies in monitoring and approving employees’ health clearance for work, Tutelar has created an online cloud application that manufacturers can use at no cost. Most governments today require employers to treat COVID-19 under the Employee Health and Safety regulations. This puts specific liabilities on employers to follow public health guidelines and document the actions taken to provide a safe work environment. The online electronic screening tool, Ujigami SAFE (secure access for employees), provides rapid data entry for company “screeners” to certify eligible/ ineligible employees to work based on the company’s screening protocol.
Based on their proven Ujigami framework, Tutelar is offering manufacturers free access to the Ujigami SAFE cloud-based application. Companies can sign up at safe.watchover.us to start using this online tool to manage COVID-19 electronic health screening requirements. “The application uses the same controls and platform that make our Ujigami PDMS system the best mistake-proofing and quality system in the industry,” mentions Edward Dickson, president of Tutelar Technologies. The platform is easily customizable, and so every facility can integrate its own set of criteria and business rules for evaluation. Ujigami SAFE automatically records all screening results including the last check date and time. These screening results are immediately available to all authorized users to identify eligible and ineligible individuals. For employees deemed ineligible, the system can also apply additional company criteria; for example, they are not eligible for re-evaluation or plant access for 14 days. Employers can access the Ujigami SAFE historical records to monitor employee health status for traceability and compliance.
A supplier of plant-floor manufacturing software, Tutelar offers next-generation manufacturing software—Ujigami—which makes it easier to control, monitor, manage, and improve every aspect of production and warehousing facilities, while significantly reducing the reliance on direct human interactions. The groundbreaking plant floor software comprises a product directed manufacturing system (PDMS), a world-class manufacturing suite (WCM), a warehouse management system (WMS), and now, an online Safe Access for Employees (SAFE) tool.
The Ujigami software gets its name from the ancient Shintō religion of Japan, where every local community had a tutelary guardian deity, known as Ujigami. These local deities played a vital role by watching over the village and its people to protect them from harm.
“What makes Ujigami unique are its speed, capabilities, ease-of-use, and universality. Customers who use the Ujigami software tools can achieve the highest levels of traceability, quality, and production performance,” says Dickson. This industry juggernaut is at the forefront of delivering zero-defect solutions to the manufacturing space and empowering its clients with software systems that improve productivity and drive immediate results to their bottom line—quickly reducing costs associated with inefficient production, poor quality, and missed deliveries. Users can view results and make changes to their manufacturing process from anywhere in the world, simply by accessing Ujigami on any device with a web browser.
Customers who use the Ujigami software tools can achieve the highest levels of traceability, quality, and production performance
Zero Defects through Artificial Intelligence, Industry 4.0, and IIoT
With Ujigami’s artificial intelligence (AI) capabilities, Tutelar offers next-generation manufacturing capabilities by incorporating the knowledge of the workforce and the features of both new and existing equipment to deliver zero-defect products. The purpose-built shop floor software offers product directed manufacturing capabilities that focuses on knowing and controlling individual part requirements. This approach is combined with advanced mistake-proofing, dock-to-dock management, flexible manufacturing environment, and the fastest device level interfaces. A notable aspect of the Ujigami software suite is that it can be quickly configured to achieve the desired results with rapid and sustainable ROI. Each of the integrated software products comes with built-in industry 4.0 capabilities, automated alerts, and integrated IIoT, which ensure rapid deployment and guaranteed results.
Tutelar’s turnkey solution, the Ujigami PDMS, is first-of-its-kind software that is specifically designed to assist operators and machines to produce a wide variety of parts back-to-back, without downtime for change-overs. It interfaces with and controls all machines, devices, and sensors to self-verify every machine, device, and operator is executing to the manufacturing control plan. The software has a built-in “machine translator” that instantly communicates using each machine’s native protocol while optimizing the manufacturing process to generate a zero-defect manufacturing environment along with uninterrupted uptime for optimized performance. Ujigami’s operator, machine, inspection, test, and repair stations with interactive graphical work instructions ensure operators’ learning curves are near vertical. Operator certification, quality alerts, scheduling, part and container labeling, inbound and outbound sequencing, inventory management, and OEE/KPI reporting provide integrated functionality.
In contrast to traditional shop floor systems that limit themselves to simple data collection and reporting functions, Ujigami’s active real-time controls ensure accurate process execution and prevent machines and operators from making incorrect decisions during production.
“Software like Ujigami PDMS goes well beyond traditional MES to create an intelligent manufacturing environment that helps manufacturers increase quality, reduce costs, and decrease time to market”
Highest Throughput at Lowest Cost
To further elucidate the benefits of Ujigami, Dickson informs, “Although digitization has permeated every industry, the manufacturing sector still manages most of their operations manually, which results in various complexities and difficulties in production and inventory management—coupled with a corresponding high need for direct human interactions.” For instance, manufacturing schedules and production reporting are manufacturing practices that often rely on paperwork. In today’s COVID-affected world, this poses a considerable threat, since the virus could be transmitted via these document and people interactions. But with Tutelar’s Ujiboard WCM system, manufacturers can avoid these problems. The browser-based software eliminates the chore of communicating and coordinating information on the shop floor, making it easy for operators to view their schedules and record real-time production results and feedback. There is no physical interaction; rather, everything is electronically managed. In short, manufacturers can achieve immediate connection with the plant floor using the Ujiboard WCM; it drives plant-floor collaboration and ensures the manufacturing plant always operates at peak performance.
On the other hand, the Ujigami WMS system simplifies the movement of materials through the manufacturing plant and accelerates kitting, restocking, sequencing, and distribution operations. By managing all activities within the warehouse that involve shipping, receiving, put-away, labeling, storage, and packing, the Ujigami WMS drives fast and accurate inventory transactions. The software can also be used to inspect and mark/track defects, and display quality alerts and packing instructions. The extended functionality in the Ujigami WMS ensures the fastest material delivery times, and the software’s high-speed intelligence reduces inventory size and warehouse footprint requirements. Another differentiating factor of Ujigami WMS is that it can be customized to integrate with any system using any kind of interface scheme, which means that higher-level MRP systems become more effective.
Unleashing Smart Manufacturing Along the Way
The team at Tutelar has multiple success stories to its name and is optimistic about the road ahead. “We consistently enable our customers to create new intelligent production environments by providing knowledge-based, time-critical, active management of manufacturing and warehouse operations, delivered by a creative, dedicated, cross-functional team of professionals,” states Dickson. The firm’s primary purpose is to help its clients improve the competitiveness of their production floor, and to that end, Tutelar will combine and leverage its abilities to help their clients quickly solve problems and increase returns. By providing products and services that link a facility’s manufacturing processes to the industry’s requirements, the firm will continue to help manufacturers accelerate their plant quality, productivity, and responsiveness. “With Ujigami ‘on-the-job,’ you can focus on moving your business forward, truly enjoying the peace of mind this unique software brings to your business,” concludes Dickson.