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Kaizen SystemGemba Reporter

Features	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

Features

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

Models

Model	Product Name	Unit Price
GB-1000	Smart Counter	Please send an inquiry
GB-2100	Base Station	Please send an inquiry

Specifications

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

(3) Machine Status: RUNNING/DOWN/COMPLETED/OFFLINE

Machine Status

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

Down

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

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Specifications

Smart Counter

Model	GB-1000
Input Mode	Contact / Non-contact (opencollector) Input
Input	Contact / 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 Speed	Count Input: 20Hz (Pulse Width: 25ms Duty 1:1) State Input: 1Hz (Pulse Width: 500ms Duty 1:1)
Input Terminals	Count Input x 2; State Input x 7
Count Range	0 – 1,000,0000,000 (both CNT A and CNT B)
Output Mode	Non-contact output Open-collector: DC35V / 40mA max.
Output Terminals	Running, Productive, Unproductive, Prewarn
Indicator	Wireless: LED (RGB) Output Status: 4 LED(Amber) – Running, Productive,
Wireless Communication	Unproductive, Prewarn
Wireless Range	IEEE 802.11 b/g/n (2.4GHz)
Operating Channel	Up to 25m Line-of-Sight (LOS)
Antenna	1 – 13 (adapts Base Station configuration)
Certification of	PCB Antenna (built-in to the module)
Wireless Module	FCC, IC, Japan Radio Law, NCC, SRRC
Memory	Data Retention: Approx. 20 years; 100,000 erase/write cycle (typ.)
Operating Humidity	35 – 85% RH (Non-condensing)
Operating Temperature	0 – +50°C (Non-freezing)
Storage Temperature	-10 – +60°C (Non-freezing)
Power	12VDC (-15% / +10%), 3W max.
Dimension	90(L) x 53(W) x 57(H) mm
Weight	Approx. 150g
Compliance	RoHS

Base Station

Model	GB-2100
CPU	Celeron® N3160 Quad Core 1.60 GHz
SSD	32GB mSATA 3.0
RAM	4GB DDR3
OS	Linux
LAN	RJ45 LAN port
Wireless Communication	IEEE 802.11 b/g/n (2.4GHz)
Wireless Range	Up to 25m Line-of-Sight (LOS)
Certification of Wireless Module	FCC, IC, Japan Radio Law, NCC, SRRC
Operating Humidity	35 – 80% RH (Non-condensing)
Operating Temperature	10 – 35°C
Power	12VDC 3A
Dimension	136(L) x 126(W) x 43(H) mm
Weight	Approx. 750g
Accessories	AC Power Adapter x 1, Antenna x 2
Compliance	RoHS