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Kaizen SystemGemba Reporter

  • Simple configuration to grasp the "now" at factory floor

  • Put a server on site: no subscription, no fixed cost, but only initial cost

  • Device #1 Smart Counter

  • Collects data from a machine: production quantity, machine status, etc.
    Sends the collected data to Base Station

  • Device #2 Base Station

  • Receives machine data from up to 10 Smart Counters
    Saves the received data as an organized collection
    Loaded with in-house developed software
    >> The software implements the organized storing plus data analysis
    >> Serves production information at the shop floor to computers and mobile devices
  • Movie


    ModelProduct NameUnit Price
    GB-1000Smart CounterPlease send an inquiry
    GB-2100Base StationPlease send an inquiry


    Device Configuration

    Deploy Smart Counter and Base Station at factory floor.
    Mount a Smart Counter on a machine on site, collect “production quantity” and “machine status” using input from sensors, and send the garnered data to Base Station.
    The communication between Smart Counter and Base Station is wireless.

    Device Configuration1

    Up to 10 Smart Counters can hook up to one Base Station at the same time.

    Device Configuration2

    Information Flow

    Phase 1) Smart Counter collects machine data by using sensor input etc.
    Phase 2) Collected data with timestamp is sent from Smart Counter to Base Station over the wireless.
    Phase 3) Base Station stores the data from Smart Counter in an organized way.
    Phase 4) User can access the database at Base Station via Google Chrome, from their computer/mobile device.

    Information Flow

    Production Information on Computer/Mobile Device

    Real-time Information per Machine
    (1) Produced Quantity & Progress

    Produced Quantity & Progress

    (2) Total Time and Continued Downtime

    Total Time and Continued Downtime


    Machine Status

    When the status turns to “Down”, user can record the “downtime cause” that was pre-registered in Gemba Reporter system.


    Information that can be checked per machine, after recording
    (1) Production/Downtime History

    Production/Downtime History

    (2) Rejects Quantity History

    Rejects Quantity History

    (3) Analysis of Production Efficiency

    Analysis of Production Efficiency

    Get in Touch with Us

    If you have any questions and/or requests concerning Gemba Reporter, get in touch with us by clicking here.


    Smart Counter

    Input ModeContact / Non-contact (opencollector) Input
    InputContact / Non-contact Input:
    Open Collector L: <1V (Sink Current approx.1.5mA)
    NPN Voltage Input:
    H: <30V, L: <1V (Sink Current approx. 1.5mA)
    Input SpeedCount Input: 20Hz (Pulse Width: 25ms Duty 1:1)
    State Input: 1Hz (Pulse Width: 500ms Duty 1:1)
    Input TerminalsCount Input x 2; State Input x 7
    Count Range0 – 1,000,0000,000 (both CNT A and CNT B)
    Output ModeNon-contact output Open-collector: DC35V / 40mA max.
    Output TerminalsRunning, Productive, Unproductive, Prewarn
    IndicatorWireless: LED (RGB)
    Output Status: 4 LED(Amber) – Running, Productive,
    Wireless Communication Unproductive, Prewarn
    Wireless RangeIEEE 802.11 b/g/n (2.4GHz)
    Operating ChannelUp to 25m Line-of-Sight (LOS)
    Antenna1 – 13 (adapts Base Station configuration)
    Certification of PCB Antenna (built-in to the module)
    Wireless ModuleFCC, IC, Japan Radio Law, NCC, SRRC
    MemoryData Retention: Approx. 20 years; 100,000 erase/write cycle (typ.)
    Operating Humidity35 – 85% RH (Non-condensing)
    Operating Temperature0 – +50°C (Non-freezing)
    Storage Temperature-10 – +60°C (Non-freezing)
    Power12VDC (-15% / +10%), 3W max.
    Dimension90(L) x 53(W) x 57(H) mm
    WeightApprox. 150g


    Base Station

    CPUCeleron® N3160 Quad Core 1.60 GHz
    SSD32GB mSATA 3.0
    LANRJ45 LAN port
    Wireless CommunicationIEEE 802.11 b/g/n (2.4GHz)
    Wireless RangeUp to 25m Line-of-Sight (LOS)
    Certification of Wireless ModuleFCC, IC, Japan Radio Law, NCC, SRRC
    Operating Humidity35 – 80% RH (Non-condensing)
    Operating Temperature10 – 35°C 
    Power12VDC 3A
    Dimension136(L) x 126(W) x 43(H) mm
    WeightApprox. 750g 
    AccessoriesAC Power Adapter x 1, Antenna x 2

    Feel free to contact us

    Please contact us
    for further information.