KaizenHandbook en

The KAIZEN Handbook
~Solutions for Factory Improvement~
www.patlite.com
CONTENTS
Automobile Manufacturing
Scenario 1 Automobile Manufacturing 3 Prevent sand overflowing from the hopper 33
Scenario 2 Food and Pharmaceutical 5 Visualize Amount of Liquid in the Tank! 34
Scenario 3 Logistics 7 Create Uniform Visual Signals Throughout the Worksite 35
Visualize remaining amount 36
Visualize the elapsed time from when the problem occurred 37
Automobile Manufacturing Visualize Work Progress 38
Equipment Operation Management over LAN 39
Building integrated systems for operation management and monitoring 9 Make The Water Level Visible and Reduce Checking Time 40
Easily compile operation status of old equipment! 10 Maintaining Hygiene at Food Processing Site 41
Food and Pharmaceutical

Automating a Handwritten Factory Daily Report 11
Visualize Level of Cutting Oil 12
Visualize the Stages of Equipment Maintenance Create a standardized, color-coded system for equipment status 13
Logistics
Visualize Equipment in Unmanned Areas 14
Visualize / Analyze Stalled Robotics 15 Simple Request System 42

Monitor issues remotely and in real-time 16 Air Conditioner Remote Alerts 43
Visualize Inspection Process Anomalies 17 24-hour Network Camera Monitoring Automatic Camera Restart 44
Prevent Oversights During Inspection 18 Remotely monitor server issues 45
Mistake-free Inspection Process 19 Broadcast disaster information to everyone! 46
Visualize the Casting Process 20
Logistics
Reduce call waiting and call backlogs! 47
LA6 Improves Display of Robot Status and Safety Guidelines 21 UTM External Attack Monitoring Solution 48
Visualize the time required at each work step 22 Improve Notification of Emergency Information For Factory Security, Railway Command,Disaster Prevention and Emergency Services 49
Remote monitoring reduces loss from stoppages 23 Industry or automobile-related manufacturing 50
Takt Time for Manual Assembly Process 24 Notice print output as soon as possible Confirm print output has been received 51
Visualize Takt Time with LA6 on AGV 25 Visualize Print Errors on Network Printers 52
Visualize Takt Time 26 Prevent Picking Errors with Pick-to-Light Implement NE Touch Sensor Beacons to simplify and enhance workflow 53
Regulating the Cell Assembly Line 27
Visualize Lost Time in Cell Production 28
IoT Screw Driver Measures Tightness of Screws 29

Others
Others
Signal From Cells Using an Andon Monitor 30
Smarter, More Efficient Scheduling. Visualize Meeting Room Schedules 54
Reduce Stress and Avoid Work Interruptions Indicate the busyness of current work 55
Food and Pharmaceutical Clear Indication, Simple Installation. Indicate meeting room status 56
Visualize Operation Panel Information 31
Improve Predictive Maintenance Visualize lost productivity from reduction in speed 32 List of Vocabulary 58
1 2
Scenario 1 Automobile Manufacturing
P r es s i n g
P9 Building integrated systems for operation management and monitoring
P10 Easily compile operation status of old equipment!
P11 Automating a Handwritten Factory Daily Report
P12 Visualize Level of Cutting Oil
P13 Visualize the Stages of Equipment Maintenance
We l di n g
P14 Visualize Equipment in Unmanned Areas
P15 Visualize / Analyze Stalled Robotics
Painting
P20 Visualize the Casting Process
P21 LA6 Improves Display of Robot Status and
Safety Guidelines
B ody as s em bly
P22 Visualize the time required at each work step
P23 Remote monitoring reduces loss from stoppages
Te s t s a nd i n s p e c t i o n s P24 Takt Time for Manual Assembly Process
P25 Visualize Takt Time with LA6 on AGV
P16 Monitor issues remotely and in real-time
P26 Visualize Takt Time
P17 Visualize Inspection Process Anomalies
P27 Regulating the Cell Assembly Line
P18 Prevent Oversights During Inspection
P28 Visualize Lost Time in Cell Production
P19 Mistake-free Inspection Process
P29 IoT Screw Driver Measures Tightness of Screws
P30 Signal From Cells Using an Andon Monitor
3 4
Abnormal
Scenario 2 occurrence
Boxing and shipment

P31 Visualize Operation Panel Information
P32 Improve Predictive Maintenance
Raw materials and blending

P33 Prevent sand overflowing from the hopper
P34 Visualize Amount of Liquid in the Tank!
P35 Create Uniform Visual Signals Throughout the Worksite
P36 Visualize remaining amount
Target 8600
Results 5560
Difference -3340
Ra w m
being tr aterials
ansport
ed
BUZZER
Filling and packing

P37 Visualize the elapsed time from
when the problem occurred
P38 Visualize Work Progress
P39 Equipment Operation
Management over LAN
60
seconds
Energy, Energy C
elapsed.
onservation and Environment
P40 Make The Water Level Visible

an Reduce Checking Time
Security
P41 Maintaining Hygiene at Food Processing Site
5 6
Scenario 3 Logistics
Managemen t office
P45 Remotely monitor server issues
P46 Broadcast disaster information to everyone!
P47 Reduce call waiting and call backlogs!
Arrival of stock P48 UTM External Attack Monitoring Solution
P49 Improve Notification of Emergency Information
P42 Simple Request System
P50 Industry or automobile-related manufacturing
11
10 20
30 40
50 12
0 10
20 30 40
50 13
0 10
20 30 40
50 14
0 10
20 30 40
50 15
0 10
20 30 40
50
Picking
P51 Notice print output as soon as possible
Confirm print output has been received
P52 Visualize Print Errors on Network Printers
P53 Prevent Picking Errors with Pick-to-Light
S t or a ge o f s t o c k
P43 Air Conditioner Remote Alerts
Sorting
Shipment
P44 24-hour Network Camera Monitoring
7 8
Building integrated systems for operation
management and monitoring
Report equipment errors via email Wirelessly send operation information
Mail Signal tower + WD

server Email notification feature
Transmitter Receiver
Wireless transmission
LAN
Return
to the
site!
Alarm
Alarm ＮＢＭ−Ｄ８８N
Machine #2 stopped. Auto-compile
Check immediately. operation logs
To operators
away from
equipment…
Before
・With older equipment, it is difficult to build an integrated operation management and monitoring system.
・It would require remodeling the equipment so that it is compatible with the monitoring system, which is both costly and
time-consuming.
After
Email alarms Operation Management
With the WD installed in workstations, Automatically calculate and summarize operation logs based on the signal tower's color
supervisors away from the site receive email information (Red, Yellow, Green) using the WD-Z2 on the wireless network. Visualize
alerts when maintenance is required. overburden (Muri), waste (Muda), and inconsistency (Mura) in the manufacturing site.
Practical and economical solution for data acquisition and analysis, as well as identifying
production bottlenecks.
Use contact
outputs for error Just attach to More
information signal tower efficient
Wireless transfer Save log data
Use the information, Use saved data
operation status change the facility at new facilities!
Monitor operation
Email notification feature Monitor production
Send information
from the
transmitter on Save as CSV data
the signal tower!
To site
manager Signal tower Transmitter Wireless
Alarm communication
LAN
Wireless transmission
Utilize data
Let's check Secure Receiver
it out! communication WDR-LE-Z2
Over the Red: Abnormal stop Yellow: Call the operator Green: Normal
To facility network Facility 11 12 13 14 15
staff name 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50
Unit 1
Unit 2
Unit 3
Signal Tower Transmitter Unit 4
WDT-6M-Z2 Unit 5
WDT-6LR-Z2
* Separate application software is required.
9
Easily compile operation status of
Reduce Labor
old equipment!
Stop (problem) → ● button

Change step → ● button
Return to normal ● button
Receiver
Just press the buttons! WDR-Z2
The performance status of each unit can
be recorded - No need for daily reports.

Ethernet
(LAN)
Unit 1 stopped
(equipment failure)
Production information
File(F) Edit(E) View(V) Favorites(A) Tools(T) Help(H)
Production Information Management System Update
Transmitter Operation information CuttingProcessing Production Process Processing Painting Process PackagingProcess Packing Process
Actual information
Production Process
WDT-Z2 Process management
Unit 1 stopped Unit 2 stopped Unit 3 stopped
Equipment monitoring
Alarm histroty Equipment Stopped Equipment Stopped Equipment Stopped
Energy consumption
Equipment failure Quality check Check work procedure
Performance: Performance: Performance:
Equipment No. 9 10 11 12 1 2 3 4 5
Unit 1
Unit 2
Unit 3
Log out
Normal Setup Alarm

Red switch
Logistics
Too old to support Total the Trigger Time and Accumulated Time of each
IoT... ON Signal Tower with ▼
switch box HSST
Find things to improve and increase
productivity!
Before
Creating handwritten daily production reports can be
cumbersome, time-consuming, and inaccurate. Signal Tower with
Furthermore, our machinery is old and does not switch box
support modern protocols and devices to send this HSST-3M2
data over the network. Receiver Transmitter
WDR-Z2 WDT-Z2
Others
After
The WD System allows users to wirelessly acquire
machine data remotely and in real-time, completely
eliminating handwritten reports. The collected data is
accurate and can be used to determine issue severity
Data analysis software is required separately
for more effective predictive maintenance. The WD
and HSST can also be added to any machine,
regardless of brand or age without having to invest
in major machine refurbishment.
10
Automating a Handwritten Factory
Daily Report
Network your machinery regardless of brand or age
Receiver
Automatic Records
Transmitter A Transmitter
Manually
recorded data
Automatically
recorded data
No missing entries
Before After
Operation reports are often handwritten and taken at The WD System automatically records equipment
the end of the business day. Overnight, machines can operation information 24/7 allowing users to identify
stall which will not be reflected in the reports and trends and pin point machine downtime for more
then takes significant time to identify the lot of efficient predictive maintenance.
defective products, resulting in revenue loss.
Wireless Data Communication System, WD-Z2 ■ Chronological order of equipment operations in a Gantt chart
From notification signal tower to Red: Abnormal stop Yellow: Call the operator Green: Normal operation White: Main power supply ON
recording signal tower. 11 12 13 14 15
Facility
name 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50
Unit 1
Unit 2
Signal tower Transmitter Wireless
communication
Unit 3
Unit 4
Unit 5
The screen is an example.

Data analysis software is required separately.
11
Visualize Level of
Cutting Oil
Before After
Checking the amount of oil in the Visualize the oil level with LA6
underground tank is a burden... Signal Tower!
Oil Level Meter

Full
Cutting oil
Low
ISSUE IMPROVEMENT
Checking the oil level requires physically opening ● Meter display of the level of the cutting oil
and checking the underground tank, wihch takes ● As the oil level is visible from a distance by the
effort and time. number of segments, you can manage multiple
Logistics
units at once
Improvement Using LA6 Signal Tower

SOLUTION ● Use the LA6 Smart Mode (Pulse Trigger Type).
① Detect the oil level with a water-level sensor and show the oil level with segments on the LA6
② You can see the status of multiple units
③ By visualizing the remaining oil levels per unit, you can prioritize maintenance
Extension
● Link with a temperature sensor to make abnormal

Others
temperature conditions more visible.
Display Pattern Example
Example
Signal Tower
LA6
12
Visualize the Stages of Equipment Maintenance
Create a standardized, color-coded system for equipment status
Normal Operation Equipment Malfunction Status Confirmation

Tap touch button to
confirm status and
start maintenance
Buzzer
PLC PLC
Work in Progress Touching the NE Sends

Information to PLC
Blue light indicates maintenance in progress PLC changes the NE light color
Normal Operation / Equipment Malfunction- Maintenance in

Maintenance Completed Maintenance Required Progress
Before
Even when there are signal towers to alert operators NE-M1ATB-M
when equipment is down or needs maintenance, Signal Beacons
there are no indicators that tell operators whether
the issue is being addressed. As a result, equipment
issues are sometimes left unresolved.
Options
After
With the NE Signal Beacons, stages of equipment
maintenance is color-coded. Equipment status can
be recognized instantly by everyone at the work site,
helping to mitigate bottlenecks. Upper Bracket Wall Mount Bracket Pole Pole (threaded)
NE-001D NE-002D POLE22-N POLE22-T
13
Visualize Equipment in Unmanned
Areas
Identify the
equipment by
segments on the
LA6-POE. Problem with
machine 1!
Wiring
Machine 1 Machine 2 Machine 3

Signal Tower
Interface Converter
LAN LA6-POE Series
NBM-D88N
By dividing the channels into the NBM, you

can identify which machine has a problem.
Example: CH1 - Machine 1, CH2 - Machine
2 and so on
Before After
Logistics
When workers leave the production site, they are not The NBM is able to convert I/O signals from robots to
notified when equipment issues occur. network commands, triggering the appropriate light
segment on the LA6-POE!
Interface Converter Signal Tower

When light When light
is on is off
NBM-D88N LA6-POE
HTTP LAN LA6-5DSNWB-POE (Stationary)
Commands
Supported LA6-5DTNWB-POE (Direct Mount)
Relay
Wiring is easy with PoE

Freely set up the Luminous Color
https://www.patlite.com/product/detail0000000651.html
Flexibly control the network status monitoring

Others
Easy
SNMP Send PING SOCKET
HTTP RoHS
Web
v1, v2c
email
function
RSH 24
Commu- Command Ethernet
Setup nication
Digital Digital * Optional function expansion

input output 24V software (sold separately)
USB RoHS
8 8 Output PRSH for Windows
Support Stationary Type with
Clear Switch
Direct
Mount
Accessory: AC Adaptor
* Use for exporting logs and settings (cannot control with USB connection)
● 8 digital input contacts and 8 digital output contacts

● Supports various commands
● Ping for alive monitoring
● All terminal blocks use screw-less design
● Set up conditions for detecting digital input
● Get log output in USB memory NH-WST2 SZK-003W SZW-060W
Wallmount Bracket Wallmount Bracket Stationary Bracket
14
Visualize /
Analyze Stalled Robotics
Example system
Robot Operation Andon
Robot #
1 2 3 4 5
WDR 02:42:52 01:28:49 00:00:12 03:10:28 02:52:08
Elapsed
Receiver
6 7 8 9 10 Time
03:16:20 00:40:39 02:08:20 01:15:20 02:10:50
11 12 13 14 15
01:29:52 02:42:52 02:42:52 02:42:52 02:42:52
16 17 18 19 20
01:15:28 00:02:46 00:39:27 00:42:52 00:42:52
LAN
Gantt Chart System
Facility 11 12 13 14 15
name 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50 0 10 20 30 40 50
Unit 1
Unit 2
Unit 3
Email notifications sent for robotics stalls and stops Unit 4
Use a tablet to check the same andon as the facility. Unit 5
Robot 3 is still stalled.

I have to go right
away!
Also, operation analysis of robotics using accumulated data
Before Industry / Equipment Overview

In automated robotic processes, robots will stall Industry ● Manufacturing
without anyone noticing for an extended period.
The goal is to eliminate manual checks to determine Process ● Robotic Cell Production
which robots have stalled in the process.
After Device configuration

Wireless Data Acquisition System WDR Receiver x 1 unit
By using the existing PATLITE signal towers on the Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 20 units
control panels with the WD system, it is easy to make Administration software x 1
a cost-effective wireless data acquisition system to 20 Robots
improve your robotics operation management.
15
Monitor issues remotely and
Factory in real-time
System Overview
Manufacturing site To operators away from equipment
Alarm Alarm

Contact Return to
To site manager the site!
Interface
Converter
Send Email
Alarm
LAN
Office
Alarm!
LAN Internet Machine #2 stopped.

Check immediately.
To facility staff
Network Monitoring Interface Let's check it

Signal Tower Converter out!
Contact Contact Alarm
Logistics
LED Flashing MP3 Voice
Signal Light Annunciator Horn
Before Device configuration

Equipment with Non-Voltage Contact Output
Workers away from the site may not notice when an
issue arises with their equipment, which delays PATLITE
NBM-D88N NH Series LFH EHV
corrective action, resulting in revenue loss.
Usage
Others
Interfaces discrete input/output signals between

indication and control devices over Ethernet. Add a
After variety of PATLITE signaling devices to a network
for real-time remote monitoring and/or data
The NBM is able to take signals from standard I/O and acquisition.
network devices and send emails to remote staff,
alerting them of issues at the office and
manufacturing site in real-time.
Interface Converter NBM-D88N
16
Visualize Inspection
Process Anomalies
Missed the anomaly threshold value in the inspection process?

NH-FV Series make threshold values for anomaly visible!
Error occurred during

Threshold problem. inspection process!
Please check.
LAN
When a threshold value is exceeded, the

screen program issues a command and
activates the signal tower.
MP3 Playback Network Monitoring Signal Tower
NH-FV Series
Before Visual and audible notification

Workers tend to miss alerts on their monitors due to
their busy workload or being away from their MP3 Playback Network Monitoring Signal Tower
terminal. NH-FV Serie
After 88 dB Sound resonates

Play
Sound Voice message
notification
The NH-FV is able to accept commands from the With its compact housing, the unique horn With audio notification, you can communicate
terminal and provides visual and audible alerts to structure achieves sound pressure of 88 dB
or more (at 1 meter).
information with messages that tell you, "What
and how that's a problem," and combine with
ensure the operator is aware of the threshold input conditions.
anomalies. ■ Actively get the equipment status

In addition to PING monitoring, the NH Signal Towers are equipped with an SNMP
monitoring function. It actively obtains MIB information from supported SNMP
network devices and is able to notify personnel with visual, audible and/or email
notifications when changes occur.
17
Prevent Oversights
During Inspection
Are you rushing visual inspections?

Inspection line

Start Count at 0.6 second intervals Done
Inspection period = 3 seconds
For consistent inspections, use the signal tower as a timer.

When inspections start, output a signal to LA6. The signal tower is activated,
and the worker will inspect the product until all segments are blue.
Logistics
Goal: Deliver defect-free products
Inspections are carried out on the production line before distribution.
PROBLEM To quickly reach their daily targets, workers may rush inspections.
Pros/Cons
● ●
Rushed inspections result in oversights and lead to the distribution of ●

●
●
●
defective products.
Improve
Use "Time-Trigger" to manage the inspection time

You can use the signal tower as a timer You can customize the display pattern with
SOLUTION by using "Time Trigger" in the Smart the editing software.
Mode setting of the editing software.
Others
Inspect one product per display cycle.

Once all the segments are blue, the
worker can end the inspection. Then
proceed to the next product.
0.6 0.6 0.6 0.6 0.6

sec sec sec sec sec
18
Mistake-free Inspection
Process
Example system
Red FAIL
USB-controlled signal tower
Green PASS LR6-USB
Works with USB bus power

*USB Cable sold separately
Simple connection to the

FAIL PC with a single USB
cable. Achieve reduced
wiring.
USB connection

During the inspection process, Pass and Fail
Industry ● Manufacturing
notifications on the screen are sometimes
overlooked, resulting in error. Process ● Inspection Process

USB-controlled signal tower LR6-USB x 1 unit
By adding the LR6-USB, the visual and audible alerts
indicate Pass or Fail, adding another notification
layer to further prevent oversight and errors.
19
Visualize the Casting
Process
Before After
Cast manufacturing equipment Signal Tower LA6 Solution
Signal Tower indicates completion. As time elapses, the tower displays different
patterns according to its progress. When casting is
complete, the tower will flash blue.

Logistics
Reduce the workload for staff on site
● Must continually go back to machine to check its status.
PROBLEM
● Unwanted downtime if machine is unattended when work is complete.
New feature!
Using the LA6 Signal Tower, make the elapsed time visible until complete
● With the application software EDITOR For Benefits
Others
SOLUTION Signal Tower, customize the display Visualize elapsed time until casting is complete. Signal Tower
pattern and time of each work process. Understand the situation even from a distance. LA6
Easy to see the process of equipment even
from a distance. Increase EFFICIENCY !
All lights
Download the editing software here: Example flashing
www.patlite.com/la6/app.html
Extension
● Use tower to display information from the operation panel.
● Integrate with sensors to display tank fluid levels.
20 min 30 min 40 min 50 min Complete
20
LA6 Improves Display of Robot Status and
Safety Guidelines
Before After
In the robot motion display, the signal light or pilot Visibility is greatly improved by programming all
light was the only indication that the power was on. five light segments of the LA6 a single color.
Understanding the status of the device can be done
from a distance without having to approach the
control monitor.
Remote monitoring of robot operation status and safety improvements
● With fewer workers on site, the need for clearer visual information as well as
■ Display all lights
safety lighting increases.
New feature! Improvements Using LA6 Signal Tower

Rich expressions, high visibility
21 color display using multi-color LED. Display various status
conditions in a variety of colors. [Orange: Servo power ON, White:
Teaching, Green: Automatic run] By emitting the same color on all
five light segments, visibility is increased.
Count up from when problem occurred to show the elapsed time
Using the LA6 timer function, count up every 5 minutes from when
the problem occurred. → You can use this to reinforce the level of
priority.
Count down to show the process completion time
5 min 15 min 25 min
Previously, a green light from a signal tower only expressed that it elapsed elapsed elapsed
was in operation.
Now you can visually identify the remaining time until completion, thus Signal Tower
improve productivity. LA6
21
Visualize the time required
at each work step
Do increases in work-in-process inventory create bottlenecks?

Use LA6-POE to make elapsed time visible and to notify managers.
Example
Factory Flash all lights
& emit audio
5 minutes elapsed

1 min 2 min 3 min 4 min 5 min 5+ min
Mirroring at the office s

I need to addrese
that part of th
process.
WIP Inventory
Contact LAN
output
● Detect with a sensor, and show

the elapsed time since completion
Sensor of previous process.
● Use mirroring function to display
Logistics
the status in the office
Signal Tower
When light When light
Visualize signal tower information from various locations LA6-POE is on is off
LA6-5DSNWB-POE (Stationary)
Problem at LA6-5DTNWB-POE (Direct Mount)
the factory!
Command Easy wiring with PoE
communication
Freely set up the Luminous Color
https://www.patlite.com/product/
detail0000000651.html
Maximum 8 locations
Office
Stationary Type with Direct

Others
Clear Switch Mount
Manufacturing
site A
Manufacturing
site B
You can use the mirroring function to send the equipment

operation status to multiple locations.
NH-WST2 SZK-003W SZW-060W

Wallmount Bracket Wallmount Bracket Stationary Bracket
22
Remote monitoring reduces loss
from stoppages
Callout Notification System
Operative Operative Operative
Network
Ethernet Ethernet Ethernet
Line A Line B Line C Production

manager
Line C Red Light is on.

Immediate action
required.
NBM-D88N NBM-D88N NBM-D88N
Alarm
Contact input Contact input Contact input
Nor m al Stopped Em e rge nc y
Alarm
Problem with Line C.

Gre e n Yellow Red
Check immediately.
Retrofit existing equipment easily. Remotely monitor contact information over the network.
Network Monitoring Signal

Tower - NH Series
Signal Tower ⇔ LAN
● Compatible with a wide

range of protocols such as
LAN ⇔ Relay
Interface Converter NBM-D88N SMTP, SNMP, RSH
● Notify receipt of TRAP and
● Get contact inputs → Control network monitoring
commands from NBM with
signal tower over Ethernet
visual and audible alerts
● With email notification feature, you can report to
supervisors in charge, even at night
23
Takt Time for Manual
Assembly Process
10 second 30+ second

delay delay
Work
Takt time 100 seconds complete Time up Overdue
100 sec 50 sec 0 sec
Switch
ON

Flashing
Delayed
Hang from Switch
ceiling ON
● Release lock to send to next work process.

Cart Lock ● A new cart arrives, start work.
Release Button At the same time, LA6 is reset and starts a new
countdown.
Cart Lock Cart Lock
Logistics
Work flow
Before ● 21 different colors

Assembly line at a major car manufacturer ● Flashing mode
As assembly work is done by hand, work speed may ● Easy set up from a PC
fluctuate. At times, a worker may not be able to keep ● Easy to change Takt time by
up with the main assembly line and other workers changing input signal
may not be fully aware of the situation or the
Others
assembly pacing.
Signal Tower
LA6
After
Install a signal tower showing the work progress.
By making delays clearer, awareness at the work
site is improved, and supply delays are reduced.
The cart travels on rails, and requires a button to
send it to the next process. As the button is
pressed, the signal tower is automatically reset.
24
Visualize Takt Time with
LA6 on AGV
LA6 visualizes Takt time A production line utilizing AGV (automated guided vehicles).
Mount the LA6, and display the work time for each assembly process.
Assembly line for outdoor equipment

Exceeded
Takt time
Make workers aware of the Takt time, to keep pace with assembly speed.
Awareness Keep pace Reduce lost time
Reduce lost time caused by AGV stops.
SOLUTION Smart Mode - Time Trigger Type

● Register 15 types of takt time patterns
● Pulse input at the start of production starts the takt count
● Pulse input at the end of production resets the count

Example: Production takt time = 10 seconds
→
After input at start of production, the display changes to show the passing of time When takt time exceeds a certain threshold,
lights flash and audible alarm sounds
g
Flashin
lights
Audible
Elapsed Time 1 sec 2 sec 3 sec 4 sec 5 sec 6 sec 7 sec 8 sec 9 sec 10 sec
Registered display patterns change as time elapses
25
Visualize Takt Time
Set The Pace with Signal Tower
Main Line
Manage progress of the sub line
Sub Line

Adjust work pace with
takt time colors
With the signal tower's takt time
Warning
function, the color changes
indicate the elapsed work time. Red light!
Alert
Yellow light!
Supply parts from the sub line just
Start work
in time for assembly on the main
Yellow light is on! Green light!
Better hurry!
line, reducing time loss
Signal Tower
Picking and assembling parts on the sub line to the main line
Logistics
Improve quality and productivity by pacing the work.
● Currently, our main line and sub line are running separately, although the
PROBLEM
main line is dependent on the sub line for parts. When the sub line is not
keeping up with the main line, it can cause errors and/or delays in the
production while also affecting subsequent processes.
SOLUTION: New LA6 Signal Tower

● Set up a takt time display with colors indicating elapsed time so that both Impr
Improve
Others
SOLUTION
the sub line and main line are aware of the work progress of each line.
Increase EFFICIENCY !
Using visual presentations, information that was hidden is now visible.
Signal Tower LA6
● Install a program on the signal tower to set the display patterns and colors.
● Set or change the Takt time even without a control program device
(personal computer required)
● IP65 protection rating with integrated globe
● Display as much information as a production analysis board.
26
Regulating the Cell
Assembly Line
Collect Working Time and Visualize the Bottlenecks

Hands free by using Automatic collection with
foot switch proximity sensor
WDT-LR-Z2 1st unit Start - Complete 1st unit Start - Complete
2nd unit Start - Complete 2nd unit Start - Complete
WDR
Receiver
Replace the HSST pushbutton with a foot switch or sensor

to reduce or eliminate the worker's load.
Before After
Seconds Seconds
50 50
45 Bottleneck Takt time 35 seconds 45
40 40
35 35 Reduce takt time to
30
25 seconds
30
25 25
20 20
15 15
10 10
5 5
0 0
Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10
Example chart of csv log file collected by WD

Additional equipment
By collecting the work time for all the processes, you can
Wireless Data Communication System WDR Receiver x 1 unit
visualize the bottleneck and clarify where balancing is Wireless Data Communication System WDT Transmitter x 1 unit
required.
With WD-LR transmitters, you can have 1 receiver and
up to 30 transmitters in a single cell.
Visualize Workflow in Chronological Order

Actual
Step 1
Step 2
Step 3
Step 4
Step 5 1 2 3 4 5 6 7 ← Total production
Ideal
Step 1
Step 2
Step 3
Step 4
Step 5 1 2 3 4 5 6 7 8 ← Total production
Lost time adds up and

By visualizing the work time of all processes, you can increase overall reduces productivity
efficiency by evenly distributing workload. by 12.5%
27
Visualize Lost Time in Cell
Production
Example system
Issue: Cannot see accumulation

of lost time
Getting

parts
Work outside the Garbage

work area disposal
PATLITE Sanda Factory Example
Mechanisms for Visualizing Lost Time
LAN
Transmitter Mounted
WDT receiver
WDR-L
PC
Logistics
Sensor
By using an integrated system of the Non-working
WDT and sensor, you will be able to time ratio
visualize lost time accumulated from 15.6%
workers leaving their work area. The ↓
collected information can be analyzed 8.3%
to make necessary improvements and 7.3% reduction!
increase productivity.
Before Industry / Process Overview

The main focus at the factory is the assembly of
many types of small quantity parts in cell stalls.
Industry ● Manufacturing
Managers are unable to see time loss resulting from Process ● Cell Assembly Line
workers leaving their work area to pick parts or
perform other duties.
Others
After
By installing a sensor at the workbench of the cell
stall to collect the simple data of when the worker is
in the stall (working) and when the worker is away
(not working), we were able to make improvements
in just 1 month without adding a burden for
collecting this data.
28
IoT Screw Driver Measures
Tightness of Screws
System example
WDT-LR-Z2
Transmitter
LAN
WDR Receiver
Possible to use 1
receiver with up to
20 transmitters
Save to PC in CSV format.
Electric screwdriver
● Example CSV data Electric screwdriver label Start Increase Torque Reverse Not used
Easily process data in Excel.
0: OFF, 1: ON
● WD can collect the start, increase torque, and reverse signals only.
Caution
(WD cannot use the stop signal from an electric screwdriver.)
● An electric screwdriver signal cannot turn on an LED lamp of the LR series.
Before After
I want to keep a record of the work performed for Connect the signal output of each electric screwdriver
tightening screws and prevent output of defective to the WD to quickly and easily build a system that is
products. Additionally, improvements cannot inexpensive.
happen without understanding the current situation 1. Automatically record the screw tightening value
with the variations in assembly work. (with the increase torque signal)
2. At each cell, automatically record the number of
operations and the order for multiple screwdrivers
(Electric screwdrivers are identified by registering
Industry / Equipment Overview their names with the WD transmitter's MAC
address)
Industry ● Manufacturing 3. Automatically record loosen screw operations
(with the reverse and start signals)
Process ● Cell stall 4. Compile all the electric screwdriver operations at
the facility (with the WD unit's csv log file)
Device configuration
Wireless Data Acquisition System WDR Receiver x 1 unit
Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 5 units
LR Series Body Unit x 5
5 Electric screwdrivers
29
Signal From Cells Using
an Andon Monitor
Example system
Andon Monitor
Missing parts
Cell
1 2 3 4 5
00:00 00:00 00:15 00:00 00:00 Check quality of work
Elapsed
Time 6 7 8 9 10 Jig issue
00:00 00:00 00:00 00:07 00:00

11 12 13 14 15
00:53 00:00 00:00 00:00 00:00
16 17 18 19 20
00:00 01:27 00:00 00:00 00:00 Missing parts
in cell 3.
Check on a tablet!
Logistics
Signal Tower with
switch box HSST
All button operations are recorded – such as ON: Attention, OFF: resume work – so they can
be the basis for improvement data such as frequency of occurrence and response time.

Currently, there is not a way to call for parts from a cell Industry ● Manufacturing
stall. It is also difficult to determine order of priority,
resulting in lost time due to waiting for managers to Process ● Cell stall
address an issue.
Others
After Wireless Data Acquisition System WDR Receiver x 1 unit
Signal Tower with switch box HSST-3M2 x 20 units
The manually-controlled HSST allows assembly Wireless Data Acquisition System WDT-LR-Z2 Transmitter x 20 units
workers to send requests to the Andon monitor so Administration software x 1
managers can determine priority and reduce lost time. For 20 Cell Stalls
30
Visualize Operation Panel
Reduce Labor Information
Regular, manual operation panel checks are inefficient
With the LA6 Signal Tower, visualize panel information from a distance
Out of
Line 1
material!
Equipment can be checked for
abnormalities at a glance from
a distance, without needing to
Line 1 Line 2 Line 3 approach the machine.
Increases efficiency!
Abnormal
Line 2
stop
Line 3
Exceeded
cycle time
Mulitple staff needed to manage various equipment.

Some staff may need to travel long distances just to
check the status of an equipment.
Signal Tower
After LA6
With the equipment status visible from a distance,
the LA6 signal tower minimizes the need to
Usage
continually check the operation panel. Audible
notification can also be added for additional
LA6 Smart Mode lets you set up your own light
indication.
patterns with 21 different colors to choose from.
Create a display pattern for each operating state.
31
Improve Predictive Maintenance
Visualize lost productivity from reduction in speed
System example
LA6 Series
Processing equipment with cycle
time of 60 seconds
Exceeds cycle time by 5 seconds
Productivity down approximately 8%
Exceeds cycle time by 10 seconds
Productivity down approximately 16%

By visualizing the extra time that has elapsed,
you will not miss any required maintenance.
12 sec 24 sec 36 sec 48 sec 60 sec 61 sec 62 sec 63 sec 64 sec 65 sec 66 sec
Logistics
Operate at standard cycle time Visualize extra time
Visualize the timing of maintenance: Cycle time for processing equipment is 60 seconds.
A yellow light is lit for every second over the standard cycle time. When the standard cycle
time is exceeded by 6 seconds or more, all the lights on the signal tower change to red.

When running automatic processing equipment, ● Machinery, Metal Products, Electrical Equipment,
cycle time becomes increasingly longer. It then Industry Transportation Equipment, Manufacturing, and others
becomes more difficult to predict maintenance, ● Forge, polishing machine, other automatic
resulting in delays and thus reducing productivity. Equipment processing machine
Others
Scale ● Number of target equipment

The LA6 allows you to visualize the processing time Signal Tower LA6 Series x 1 unit
and when it exceeds the standard cycle time, it per equipment
enables operators to plan required maintenance
more effectively.
Signal Tower
LA6
32
Prevent sand overflowing from the
hopper
Make the amount of sand in the hopper visible!
High Amount of Sand Low
Level Sensor
LA6 displays the remaining
amount of sand in the hopper.
Make visible the level of sand in the hopper
PROBLEM ● When the level of sand in the hopper is not monitored, it could cause overflowing.
With new Signal Tower functions, create an intuitive display

● When used with a sensor, the signal tower can indicate different statuses based on
SOLUTION user-specified display pattens using colors, number of segments, and flashing lights.
● You can customize the display pattern with configuration software. Impr
Improve
ove
Download the application from here (free): www.patlite.com/la6/app.html
1 2 3 4
MODE MODE MODE MODE
Signal Tower
LA6
33
Visualize Amount of Liquid
in the Tank!
Visualize tank status with minimal configuration
No PLC
Floatless Switch Overflow is

imminent...

Relay output
Wastewater
Electrode holder
DANGER
CAUTION
Electrode SAFE
Logistics
Light color and number of segments
change in correspondence with status.
Wastewater tank *Electrodes, electrode holder, and floatless switches are not supplied.
Product Configuration
1. With minimal equipment configuration, the LA6 clearly displays the

fluid levels. No need to utilize complicated PLC controls.
Others
2. Tower-type display for clear visibility even from a distance.

3. The signal tower can be set up for both water supply and drainage.
Easy set up from a computer.
Signal Tower
LA6
34
Create Uniform Visual Signals
Throughout the Worksite
Before After
Factory A Factory B Factory A Factory B

Critical Critical Critical Critical
error error error error
Consistent
Factory B support staff
Factory A displays are Set the display

different! pattern after
Is it safe to approach? purchase.
Make consistent status displays on all Signal Towers in the worksite
PROBLEM ● Light color codes for errors are not consistent between factory locations.
SOLUTION: Signal Tower LA6 with new functions

● With the application software EDITOR For Signal Tower, set up various displays for errors.
SOLUTION
● Even after installation, you can change signal colors using the application.
Signal Tower
Download the application from here: www.patlite.com/la6/app.html LA6
1 2 3 4 Increase EFFICIENCY !
MODE MODE MODE MODE
35
Visualize remaining amount
Before After
Casting Site Visualize Using LA6 Signal Tower
Tank with Liquid Aluminum Detect the level of liquid aluminum in the tank with
sensors. Use LA6 to display the level.

Alarm Alarm Alarm
Bottlenecks occur when liquid aluminum is completely
depleted.
ISSUE Benefits
● I want to reduce downtime caused by the depletion of ● By making the remaining amount of liquid visible from
liquid aluminum. a distance with the LA6 signal tower, we were able to
● Furthermore, checking ever y machine manually is reduce non-operating time and increase work efficiency.
Logistics
time-consuming.
Improvements Using LA6 Signal Tower

● Use the LA6 Smart Mode.
SOLUTION Receive pulse signal from sensors, remaining fluid level is displayed by segments on signal tower
● Pulse Trigger Type: Register display patterns for different operating status
Change the display based on pulse outputs from sensors

In the level meter display, show the remaining amount of material.
Others
Extension
● Link with a temperature sensor to make

1 2 3 4 5 6 abnormal temperature conditions more
visible.
Gradually change display pattern Signal Tower

Notifications via audible alarm LA6
36
Visualize the elapsed time from
when the problem occurred
Before After
Alarm ● The LA6 Signal Tower emits different light patterns
and audible alarms. Additionally, one segment lights
Only 1 red light
up every 10 minutes, until the alarm is restored.
● If 1 hour elapses, all the lights flash in sky blue.
Benefits
● Visualize the elapsed time from when the problem
occurred
● Maintenance on equipment that takes a long time to
restore can improve production efficiency
All lights
Example flashing
10 min 20 min 30 min 40 min 50 min 1 hour
Make maintenance time visible

● Long equipment maintenance time lowers operation rate
PROBLEM
● Difficult to manually record the time elapsed after alarm goes off
SOLUTION: LA6 Signal Tower

● After an alarm goes off, signal tower increases one tier every 10 minutes until the
SOLUTION problem is resolved.
● Easy installation; no programming required to activate timer display. Impr
Improve
● Use editing software to change display time, display, color (21) and pattern (15).
● Download free from our home page → https://www.patlite.com/la6/app.html
1 2 3 4
MODE MODE MODE MODE
37
Visualize Work Progress
Before After
Current status is unknown...

LA6 to visualize each process
● Color code processes
Industrial Washing Machine ● Flashing light/audible when there is an error

Error
Process 1 2 3 4
ISSUE IMPROVEMENT
To check the progress of the current process, the Each process is assigned a color, and the segments
operator must get close to the equipment indicates the progress, with flashing lights and
With a small number of people, productivity is audible when an error occurs, makes it possible to
Logistics
affected by delays in checking check even from a distance to enable a fast response
SOLUTION ● Solved with LA6 Smart Mode (Time Trigger Type).

① Assign a color for each process. Know the working process right away
② When work is started, the progress is made visible by the number of segments
③ When an error occurs, alert with flashing light + audible

Others
Flashing lights
Example
audible
Elapsed
Time
10 min 30 min 50 min 10 min 30 min 50 min 10 min 30 min 50 min 10 min 30 min Error
Process Signal Tower

Wash Rinse Spin Dry
LA6
38
Equipment Operation Management
over LAN
System example
PoE HUB
Power over Ethernet
File(F) Edit(E) View(V) Favorites(A) Tools(T) Help(H)
Production Information Management System Update
Operation information CuttingProcessing Production Process Processing Painting Process PackagingProcess Packing Process
Actual information Production Process

Process management
Equipment No. 9 10 11 12 1 2 3 4 5
Equipment monitoring
Alarm histroty
Energy consumption Unit 1
Unit 2
Unit 3
Log out
Signal Tower Signal Tower Signal Tower Signal Tower

LA6-POE LA6-POE LA6-POE LA6-POE

Typically, older equipment is not networkable and
we are not able to easily collect performance data Industry ● Electronic equipment manufacturing
for analysis. Equipment ● Electronic components, modules,
inspection equipment

LA6-5DTNWB-POE
By switching signal towers to LA6-POE, you are
able to collect operation data over the LAN
infrastructure. Because the LA6 supports POE, it
does not require a power supply.
39
Make The Water Level Visible and Reduce
Checking Time
Before After
Visualize water level with the LA6
Chemicals Signal Tower.
Water level is visible!
Simple set up of display patterns (color, elapsed
Where is the time) for input signals

water Use Case
overflow? Drain tank reaches irregular level → all segments of tower
light up and audible alarm sounds.
Additionally, the timer display shows the elapsed time from
when the alarm was triggered.
Benefits
① It is clear which drain tank is overflowing.
② By visualizing elapsed time you can prioritize your
response to urgent issues.
Turn on all Lights +

Drain tank ① Drain tank ② Drain tank ③
segments + flashing depend
Logistics
audible on elapsed time
Make levels of wastewater treatment visible

① Using a single-segment warning light to alert when liquid volumes reach
PROBLEM a certain level as well as indicate which tank is overflowing.
② Hard to determine urgency, as elapsed time from overflow is unclear.
① With the LA6, it is clear which tank is overflowing.

SOLUTION ② By visualizing the elapsed time, your can prioritize urgent issues.
Signal Tower
LA6
Others

Wastewater ②
30 minutes elapsed
audible
Wastewater ① Wastewater ② Wastewater ③ Highlight with Light all the colors in

Overflow Overflow Overflow flashing + audible accordance with the
location
40
Maintaining Hygiene at Food
Processing Site
Before After
The opening and closing of doors allow for intrusion
of contaminants such as dust and insects. LA6 Signal Tower Solution
Because contamination could be fatal in a food LA6 displays the amount of time doors are left open.
processing center, we want to ensure that we are not Flashing when the doors are opening, and for the
letting exterior contaminants inside. amount of time they remain open, there is a change in
However, the door may accidentally be left open the colors and number of segments.
when carrying items in or when multiple people pass Benefits
through.
By making people more conscious of opening and
closing the door, we can avoid contamination threats
that occur from leaving the door open.
30
seconds
elapsed
Make visible the amount of time the door is open

● Workers need to be more cautions about the amount of time the door is left open.
PROBLEM ● Without any criteria, it is hard to make a set of rules and have them followed.
● Fatal risks if bacteria or other substances enters work area.

● Use the LA6 to visualize the amount of time the door is left open.
SOLUTION ● Easy time-keeping so workers can concentrate on their daily tasks.
Signal Tower
● The LA6 notifies workers right away when there are hazards such as the door not LA6
fully closed or if something is caught in the door.
Extension
● Link with a temperature sensor to make abnormal
temperature conditions more visible.
5 sec 5 sec 5 sec 5 sec Close
41
Simple Request System
Example system
Request
Warehouse A Warehouse B
Network Monitoring Signal Contact

Tower - NH-FV Series

Please supply parts
(light is green)
I will bring the parts Light is on! Get ready

(light is red) as delivery from
Warehouse A will
Network Monitoring
Contact arrive in about 5
LAN Signal Tower - minutes!
NH-FV Series
LAN
After confirming receipt, push the

Internal LAN clear switch on the signal tower and
OK turn off the green light.
Confirm
output
Also turns off at the other end
Notifications for a warehouse delivery
Logistics
Warehouse B requests supply of parts from Warehouse A.
Warehouse A notifies Warehouse B when the parts will be supplied.
Push the clear switch on the NH signal tower to notify delivery is complete.
Before Industry Overview

With a lack of personnel, parts are not supplied in a Industry ● Manufacturing
timely manner, which results in decreased
productivity.
Others

NH-FV Series x 2 units
The NH-FV gives visual indication of when and what
supplies are being requested. Wait time for parts is
reduced, and productivity increases.
Network Monitoring Signal Tower

NH-FV Series
42
Air Conditioner Remote
Alerts
Example system
Temperature / humidity
sensor with alarm
output function
Temperature /
humidity error!
Contact
Network Monitoring Signal

Electronic component warehouse temperature Tower - NH-FV Series
and humidity management Notify by sending email
Temperature Range 60-85℉ (15.6-29.4℃)

Alerts when temperature
or humidity is beyond Flashing Red
Email sent to notify
Humidity Range 30 - 75% the manager.
normal levels

To maintain the quality of parts, temperature and Industry ● Semiconductor and electronic
humidity control is essential. However, periodic work components
site checks are time-consuming.

NH-FV Series x 1 unit
The NH-FV Network Monitoring Signal Tower alerts
site managers via visual, audible and email alerts
when there are irregularities in temperature or
humidity.
NH-FV Series
43
24-hour Network Camera Monitoring
Automatic Camera Restart
Freeze
365 day operation

Ping monitoring of LAN
network camera
PoE HUB
LAN
PoE
ON/OFF
Camera restarted monitoring ports on Command
PoE HUB
Send Command
Logistics
NH-FV Series
Remote Power Supply Controller
Before
MP3 Playback Network Monitoring
The camera freezes and stops recording, but there are Signal Tower
no operators at the site to realize and address the
issue. Additionally, it is inefficient to send an operator NH-FV Series
to the site every time the camera needs to be reset.
Others
After 88 dB Sound resonates Play Voice message

Sound notification
When the network camera freezes, the remote power
With its compact housing, the unique horn With audible alerts, you can play
controller used to monitor the port automatically structure achieves sound pressure of 88 dB or messages that tell you "what and how
restarts the camera. The PATLITE NH-FV series uses more (at 1 meter). that's a problem"
ping monitoring and in the event the camera cannot ■ Actively get the equipment status
recover automatically, the NH-FV alerts via visual,
In addition to PING monitoring, the NH Signal Towers are equipped
audible, and email notifications. With this sort of with an SNMP monitoring function. It actively obtains MIB information
configuration you can use network cameras with from supported SNMP network devices and is able to notify personnel
confidence. with visual, audible and/or email alerts when changes occur.
44
Remotely monitor server issues
Notified via email

transmission.
Email
Server room Office
Server
NAS
Server error!
UPS and others Server error
SNMP
LAN
PING
PING for alive monitoring!

SERVER・NAS・UPS・PATLITE NH-FV Series
There are servers and network systems in place, but
no operators that can constantly monitor the
operation status of the equipment. Therefore, there is
a delay in noticing and addressing equipment issues.
Usage
The Network Monitoring Signal Tower uses the ping

monitoring function or SNMP for servers, NAS, and
UPS to notify the status of network equipment via
After visual, audible and/or email alerts.
When a server issue occurs, you can immediately
notify the operator with visual, audible and/or email
alerts. Even without an operator responsible for
constantly monitoring the systems, this notification
method ensures a quick response for any problems.
NH-FV Series
45
Broadcast disaster information to
Emergency Situation everyone!
Notify receipt of disaster information Notified via email

transmission.
Disaster Email
information
issued!
Local government

Earthquake
Terminal for
receiving information Received disaster
Internet
information!
Tsunami
Administrator PC
er
Received disast
information!
Audio Deck / Amplifier
Hurricane External speakers
You can link broadcast equipment with

the audio line output.
Logistics
Eruption

Terminal for receiving information, Administrator PC,
Need to respond immediately to disaster alerts such
PATLITE - NH-FV Series, Amplifier / Speakers
as early earthquake warnings, however this
information cannot be transmitted right away from
administration computers.
Usage
By linking the disaster information delivery system with either
Others
socket communication or SNMP, status can be indicated via

visual, audible and email notification.
After
When a natural disaster alert is received, the NH-FV
notifies administrators immediately with visual and
audible alerts to ensure prompt response to
emergency situations.

NH-FV Series
46
Reduce call waiting and call
Call center backlogs!
Display the status of the call center
Call center A Headquarters
rt
We need suppocall
due to increasin
volume!
g
Help with call
support.
Transmit
command
Normal operation Call waiting Dropped calls

Green light on Amber light on + audible alarm Flashing Red + audible alarm
Call center system PATLITE

There are periods where callers experience unusually
NH-FV Series
long call wait times due to call volume spikes,
unusually long calls or insufficient operator
resources at the call centers.
Usage
By linking the call center system with either socket
communication or SNMP, status can be indicated
After via visual, audible and email notification.
By indicating operator's call status with the NH-FV,

administrators are able to monitor the situation
remotely and in real-time, allowing them to route calls
to another call center, mitigating long wait times for
multiple call center locations.
NH-FV Series
47
UTM External Attack Monitoring
Office Solution
Alert for unauthorized operation or an external attack
Unauthorized external access

or virus attack Security software detects unauthorized
operation in the company
Unauthorized Unauthorized Virus

access copy
SPAM
Unauthorized
Server detects access detected!
unauthorized
operation!
TRAP transmission!
Security
Server
Unauthorized operation alert!

SNMP
Detected by UTM!
TRAP
Transmission!
Logistics
UTM
External attack! SNMP
Unified Threat Management (UTM) has been UTM・Security Server PATLITE

implemented to prevent unauthorized access, filter NH-FV Series
emails, and counter Web threats, but we are unaware
of any immediate threats.
Usage
By linking the UTM or security server with either
Others
socket communication or SNMP, status can be

indicated via visual, audible and
After email notification.
Detect an external attack with UTM, and use the
NH-FV series to notify administrators immediately.
By noticing as early as possible, you can take
measures to improve the safety of servers that
handle personal information.
NH-FV Series
48
Improve Notification of Emergency Information
For Factory Security, Railway Command,
Disaster Prevention and Emergency Services
System example
PC and software Just use PATLITE signal towers to make

not required!* equipment problems visible!
* Personal computer required for set up.
Camera is down
Fix immediately
PING monitoring
SNMP monitoring
LAN
MIB monitoring
TRAP monitoring
HUB
Send RSH
TRAP monitoring
command
Office
● Monitoring network equipment for signs of life

Before
(PING monitoring of 24 nodes)
It is critical that IT staff is able to monitor the ● Get status of all the network equipment
increasing number of devices on the network and be (You can register 20 MIB for SNMP compatible
notified immediately when and where an issue is
equipment)
occurring.
● Receive and distinguish TRAP (64) messages
After
In additional to visual alert functions, the NH-FV can
also play user-specified voice message alerts to MP3 Network Monitoring Signal Tower
specify where the issue is coming from instead of
coding multiple locations with lights or sounds.
NH-FV Series
49
Industry or automobile-related
manufacturing
System example
Site Office
Machine 1
operation is
almost done.

LAN
Signal Tower
LA6-5DTNWB-POE
Operating is
almost Signal Tower
complete. LA6-5DTNWB-POE
Control Panel
Logistics
Mirror status of LA6-POE master over LAN connection
Remote notification of core equipment operation cycle time
Before ① Synchronize Signal Tower LA6

LA6 master control via PLC I/O contacts
Make visible the operation cycle and changeover time.
Build a centralized monitoring display center and make ② Connect LA6 slaves via LAN lines
that site responsible for multiple remote facilities. Synchronize display with mirroring
Others
After
The LA6 conveniently integrates into your facilities' Signal Tower
existing LAN infrastructure. Operators are able to LA6-5DTNWB-POE x 2 units
mirror status from the LA6-POE master over the
network to the LA6-POE slave in the office.
Leveraging the existing LAN connection minimizes
time and wiring costs.
50
Notice print output as soon as possible
Confirm print output has been received
Improve Efficiency Starting with Printing
Off ice Work site
Send print job to

1
the printer
Network
Ethernet
Print Print
confirmed started
Network Supported Signal Tower
NH-FV Series
Network Supported Signal Tower
NH-FV Series
Push button when

2
print confirmed
By using the NH-FV Series print monitoring and audible

Before notification features, you can remotely notify printing
I do not notice when my colleague sends me a print instructions.
job to my printer from his remote office.
My colleague has no way to tell if and when I have
received his printed documents.
After
The NH-FV uses visual and audible notification to
alert me when a print job is being sent.
NH-FV Series
I can then confirm receipt of the printed documents
by simply pushing a button, which triggers visual and
audible notification to the NH-FV Signal Tower at the
sender's work site.
51
Visualize Print Errors
on Network Printers
Example system
Distribution depot
Send print Printer status alerts with

command visual and audible alerts.
Start printing and Problem with the printer...

the signal light is
LAN triggered
Problem with the printer.
Out of paper...
Printer
server Out of paper.
NH-FV
Series
Immediately Receive print command...

emits visual
and audible Printing.
alerts
LAN
Logistics
*For NH-FV setup, either check with the printer manufacturer or contact us.

At sites where work is initiated by instructions Industry ● Manufacturing
output by a printer, sometimes no one notices when
the printer is out of paper, there is a paper jam, or
other printer issues that could delay work.
Others
After
NH-FV Series x 1 unit
● Constantly monitor the printer status.
ex: light indication when printing.
● Visual and audible notifications when there is a
printing error.
NH-FV Series
52
Prevent Picking Errors with Pick-to-Light
Implement NE Touch Sensor Beacons to simplify and
enhance workflow
PLC
A barcode that contains parts and shipping The PLC processes the scanned information and
instructions is scanned with a barcode reader. illuminates the NE signal beacons corresponding to
the bins the operator needs to select parts from.
As parts are picked from bins, operators simply touch the

sensor located on the top of the NE to turn off the light,
allowing operators to accurately keep track of the parts and
reduce picking errors.
Before NE-M1ATB-M
Signal Beacons
When there is no system in place to ensure the
accuracy of picking processes, human error can
cause mistakes during picking. Additional time and Options
resources are spent re-picking, reducing work
efficiency. Upper Bracket
NE-001D
Wall Mount Bracket

After NE-002D
Implementing a pick-to-light system with NE signal Mounting Bracket

beacons simplifies the part picking process and T85130016-F1 Mounting example
prevents human error. Furthermore, the NE features a

compact size for installation in tight spaces.
Mounting Screw
T81800030-F1
53
Smarter, More Efficient Scheduling.
Visualize Meeting Room Schedules
They're still in
the meeting
In a meeting Reserved Available Over time
Meeting management system

contact output NBM-D88N Interface Converter
(red light command)

HTTP command
Ethernet
The meeting room status can be confirmed

from outside the room Contact input
(touch button)
Touch the button on the NE
Start meeting Signal Beacon to indicate
How long have I the start of meeting.
been presenting?
This meeting was
only supposed to be
1 hour long... 1 hour
After a set time, the
later NBM-D88N Interface
Converter activates the NE
Buzzer Signal Beacon buzzer.
Logistics
The NE outside of the
meeting room changes to
red via contact output from
the NBM.
Before
Interface Converter
Without a visual meeting room system, meetings NBM-D88N
tended to run longer than allotted for, causing
schedule delays and reducing productivity.
Signal Beacon (with buzzer)
NE-M1ATB-M
Others
After Signal Beacon

NE-M1ANN-M
By implementing a visual meeting room indicator
system, meetings became more efficient and
reduced delays in the meeting room schedule which
improved productivity. Wall Mount Bracket
NE-002D
54
Reduce Stress and Avoid Work Interruptions
Indicate the busyness of current work
Unavailable Available; unoccupied
Busy; The hand is free

Do Not Disturb It can correspond Touch to switch color
Options Mounting Examples
N type T type
Nut
included
Upper Bracket Wall Mount Bracket Pole Pole (threaded)

NE-001D NE-002D POLE22-N POLE22-T
Before
In a time-sensitive work environment such as call
centers and broadcasting stations, it can be difficult
to respond to a coworker's request when working on
another task. Interruptions in employee's busy work
flow causes delays, errors, and further stress.
After
The NE Signal Beacons is installed on the employee's
desk, allowing them to toggle indication between red
for "busy" and green for "available" with a single NE-M1ATB-M
touch button. This avoids time-sensitive work from Signal Beacons
being interrupted, and coworkers can clearly see
when it is an appropriate time to have a discussion.
55
Clear Indication, Simple Installation.
Indicate meeting room status
In use Available

Logistics
In use Available Touch to switch color
Mounting example
Before
In a large facility with multiple meeting rooms, it is NE-M1ATB-M
unclear which rooms are in use and which ones are Signal Beacons
vacant. It was an inefficient process to have to check
each room to confirm its vacancy, and important
meetings were often disrupted by this.
Others
Upper Pole
Bracket (threaded)
NE-001D POLE22-T
100mm
After
The NE Signal Beacons are implemented in a
color-coded system with red signaling "in use" and Mounting Mounting
green signaling "available," enabling quick and clear Bracket Screw
indications, even from a distance. Furthermore, it can T85130016-F1 T81800030-F1
be connected using a single M12 cable, making
installation quick and easy.
56
Vocabulary
Vocabulary Explanation
Stands for "Internet of Things", an industr y term describing the interrelationship of devices
IoT
connected to the internet, which collect and share data.
Stands for "Machine-to-Machine" and refers to technology that enables the exchange of data
M2M
between networked machines, without requiring human assistance.
Stands for Eliminate, Combine, Rearrange, and Simplify.

They are a set of processes that aim to carry out a procedure in a disciplined and effective way.
Eliminate: Identify processes that can be eliminated.
ECRS
Combine: if work cannot be eliminated, try to combine them.
Rearrange: Rearrange resources to optimize work efficiency.
Simplify: Simplify processes and make continued efforts for long-term improvement.
Stands for "Power of Ethernet" and describes a system where both data and power are supplied to
PoE
a machine using a single Ethernet cable.
Stands for Total Productive Maintenance, which refers to a stategy for equipment maintenance in
TPM
efforts to optimize production efficiency.
The 7 Wastes
Seven wastes (or Muda) that hinder production productivity.
of Lean
Overproduction, Excess inventory, Excess motion, Defects, Over-processing, Waiting, and Transporting.
Manufacturing
Refers to the digitalization and automation of logistic processes, as well as the interaction of
Logistics 4.0 people, machines, and products within the digitally-networked system.
Examples include: AGVs, Drones, parts picking robots.
Refers to the management of a company and its suppliers, from the raw components and services
Supply Chain
all the way to delivery to the consumer.
Refers to inefficiencies that occur in a production system.

Bottleneck
The term is derived from the apprearance of a bottle: wide at the base, but narrow towards the top.
A status-display system in a production area that alerts managers of machine or process errors
Andon in real-time, so that the issue can be addressed right away.
It originated from Toyota's production system.
57
Vocabulary Explanation
The rate at which one unit of a product must be produced in order to meet the customer's demand.
Takt time is the quantity of products requested by a customer, in relation to the total time it takes to produce
Takt Time
those items.
Takt time = Total Time Available for Production / Average Daily Customer Demand
Refers to the average time required to complete production of one unit.

Cycle Time (C/T) "When cycle time > takt time, it creates a shortage
When cycle time < takt time, it creates a surplus"
Refers to the ability to trace all pocesses of the production of an item, from the procurement of
Traceability
raw materials, production, consumption, all the way until disposal.
Refers to the worldwide spread of a new disease.

Pandemic Pandemic countermeasures are actions taken by the country or an organization to eliminate the
pandemic disease.
Refers to the percentage of time that is actually used to perform productive work, in relation to the total
Utilization Rate available time.
It can be used to measure operational efficiency, as well as how well capital investment is being managed.
Refers to the percentage of total time that an equipment is properly functioning when it is
Operational required for production.
Availability Of course, an operational availability rate of 100% is ideal. However, events such as maintenance,
cleaning, and resolving machine errors can reduce the operational availability rate.
Refers to the percentage of total time that an equipment is properly functioning when it is
Predictive required for production.
Maintenance Of course, an operational availability rate of 100% is ideal. However, events such as maintenance,
cleaning, and resolving machine errors can reduce the operational availability rate.
Refers to techniques using machine-monitoring devices that track the machine's status while in operation, to
Small Lot detect and address signs of error before they result in failure.
Production Unlike conventional methods of equipment maintenance that address equipment issues after they occur,
predictive maintenance aims to realize signs of potential issues, and resolve them before they occur.
Production Refers to a production technique where the rate of production remains constant, regardless of
Leveling the fluctuation in demand over time.
L a b o r red u c ti o n c a n b e ac hi e v e d by i mprov i ng ope ra ti ona l proc e dure s a nd i mpl e ment ing

Labor and
equipment that can replace human labor.
Manpower
Manpower reduction can be achieved by optimizing work efficiency and reducing any unnecessary
Reduction
or redundant work.
58
Please use your products with ease from the time of purchase to after-support
through PATLITE's global network.
EUROPEAN HQ
(GERMANY) CHINA
KOREA
TATSUNO
GLOBAL HQ (JAPAN)
SANDA
TAIWAN
U.S.A.
MEXICO
ITALY
FRANCE
SPAIN
THAILAND
Head Office
SINGAPORE
Factory
INDONESIA
Sales Office
Representative Office
20130 S. Western Ave. Torrance, CA 90501, U.S.A. A2603, Daesung D-POLIS, 606, Seobusaet-gil, Geumcheon-gu,
TEL. +1-310-328-3222 FAX. +1-310-328-2676 Seoul, 08504, Korea
E-mail: sales@patlite.com TEL. +82-2-523-6636 FAX. +82-2-861-9919
E-mail: sales@patlite.co.kr
No.2 Leng Kee Road, #05-01 Thye Hong Centre, 2F-1, No.215, Sec. 2, Chengde Rd., Datong Dist., Taipei City 10364,
Singapore 159086 Taiwan (R.O.C.)
TEL. +65-6226-1111 FAX. +65-6324-1411 TEL. +886-2-2552-9611 FAX. +886-2-2552-9811
E-mail: sales@patlite.com.sg E-mail: info@patlite.tw
Room 1102-1103, No. 55, Lane 777, Olympia Thai Tower, 15th Floor 444 Ratchadapisek
Guangzhong Road (West), Jing an District, Shanghai, Road Samsennok, Huay Kwang Bangkok 10310, Thailand
China 200072 TEL. +66-2-541-5431 FAX. +66-2-541-5429
TEL. +86-21-6630-8969 FAX. +86-21-6630-8938 E-mail: sales_150716@patlite.co.th
E-mail: sales@patlite.cn
Am Soeldnermoos 8, D-85399 Hallbergmoos, Germany 4-1-3, Kyutaromachi, Chuo-ku, Osaka 541-0056 Japan
TEL. +49-811-9981-9770-0 FAX. +49-811-9981-9770-90 International Sales Division
E-mail: info@patlite.eu TEL. +81-6-7711-8953 FAX. +81-6-7711-8961
E-mail: overseas@patlite.co.jp

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The KAIZEN Handbook

~Solutions for Factory Improvement~

Visualize remaining amount 36

Visualize the elapsed time from when the problem occurred 37

Automobile Manufacturing Visualize Work Progress 38

Equipment Operation Management over LAN 39

Food and Pharmaceutical

Visualize Level of Cutting Oil 12

Visualize / Analyze Stalled Robotics 15 Simple Request System 42

Visualize Lost Time in Cell Production 28

IoT Screw Driver Measures Tightness of Screws 29

Smarter, More Efficient Scheduling. Visualize Meeting Room Schedules 54

Visualize Operation Panel Information 31

Boxing and shipment

Raw materials and blending

Filling and packing

onservation and Environment

P40 Make The Water Level Visible

Report equipment errors via email Wirelessly send operation information

Mail Signal tower + WD

To facility network Facility 11 12 13 14 15

Signal Tower Transmitter Unit 4

Stop (problem) → ● button

Food and Pharmaceutical

Production Information Management System Update

Alarm histroty Equipment Stopped Equipment Stopped Equipment Stopped

Equipment failure Quality check Check work procedure

Performance: Performance: Performance:

Normal Setup Alarm

The screen is an example.

Oil Level Meter

Food and Pharmaceutical

Improvement Using LA6 Signal Tower

● Link with a temperature sensor to make abnormal

temperature conditions more visible.

Display Pattern Example

Normal Operation Equipment Malfunction Status Confirmation

Work in Progress Touching the NE Sends

Normal Operation / Equipment Malfunction- Maintenance in

Food and Pharmaceutical

By dividing the channels into the NBM, you

Interface Converter Signal Tower

Wiring is easy with PoE

Flexibly control the network status monitoring

Digital Digital * Optional function expansion

● 8 digital input contacts and 8 digital output contacts

Robot Operation Andon

* Separate application software is required.

Gantt Chart System

Email notifications sent for robotics stalls and stops Unit 4

Use a tablet to check the same andon as the facility. Unit 5

Robot 3 is still stalled.

Before Industry / Equipment Overview

After Device configuration

Manufacturing site To operators away from equipment

Food and Pharmaceutical

LAN Internet Machine #2 stopped.

Network Monitoring Interface Let's check it

Before Device configuration

Interfaces discrete input/output signals between

Interface Converter NBM-D88N

Missed the anomaly threshold value in the inspection process?