Ujigami is making significant strides in the Manufacturing Execution System (MES) space by offering a comprehensive and efficient solution that prioritizes real-time coordination and control, complete traceability and robust reporting. With over 25 years of experience, the company has successfully developed and widely deployed a dynamic active control approach to manufacturing.

In its early days, MES was seen as a tool to coordinate, control, and report on the manufacturing processes. However, according to Edward Dickson, CEO of Ujigami, the industry’s view of MES has devolved to simple data collection and monitoring.

“But we have retained our focus on coordination and active real-time control, ensuring that the Ujigami software is not just collecting data, but actively managing and improving the processes as they occur,” explains Dickson.

Ujigami’s unique approach is built on its ability to handle real-time data processing and rules based decision making with minimal latency. Unlike most other MES solutions that respond to data inputs in seconds, Ujigami’s system works in milliseconds, making it capable of controlling processes at a speed that drives tangible productivity gains. This real-time capability allows Ujigami to take on functionality typically programmed in PLCs. Ujigami’s MES solution can be configured (no programming required) to replace the logic embedded within PLCs, simplifying machine control and eliminating unnecessary complexities while improving machine speed, efficiency and uptime.

Ujigami’s active controls are easily configured by a technical employee with no knowledge of programming. Ujigami builds on the familiar tools of process flow diagrams, control plans and work instructions.

“If someone can create a work instruction, they can configure Ujigami. But instead of being a static document that few people reference, Ujigami takes active control of the manufacture of every part to ensure it is produced to specification” states Dickson. “Ujigami is like having your best supervisor continuously working directly with every machine and operator to ensure all tasks and processes are completed to specification. And if a problem arises, Ujigami automatically invokes containment and corrective actions.”

In addition, Ujigami’s contextual graphical work instructions are displayed to operators and setup personnel at the correct time that the information is required. Because Ujigami can be easily connected to every device and operation, and has intimate control of the manufacturing process, Ujigami is able to provide detailed traceability and extensive reporting.

In addition to its real-time control and coordination features, Ujigami offers a robust suite of browser-based reporting tools. These include customizable scoreboards and dashboards, which display critical metrics like parts per hour and cycle time, giving employees immediate feedback on their performance. This helps drive Continuous Improvement by allowing users to see how they’re doing in real time. Furthermore, Ujigami’s reporting capabilities extend beyond basic metrics to include comprehensive OEE (Overall Equipment Effectiveness) calculations and real-time metrics such as Mean Time between Failure and Mean Time To Repair. These insights help organizations identify performance opportunities and areas of excellence, allowing them to celebrate successes and focus on solving critical problems. And Ujigami’s direct connection to ERP systems enables those systems to perform more effectively as well.

In a market where speed, accuracy, and real-time insights are critical, Ujigami stands out as a game-changer in the MES space. Its system provides the tools needed to control and coordinate production and a deep reservoir of data that can be leveraged for continuous performance improvements. With its commitment to real-time control and insightful reporting, Ujigami is helping manufacturers stay ahead of the curve in an increasingly competitive industry.