We were responsible for “3D KATADASU” system development, which allows us to record and manage mold defects directly on 3D models.

To solve the issues of defect management using paper, we introduced the “3D KATADASU” system that allows defects to be recorded directly on 3D models.

We used to manage defect information for die-cast molds by writing on paper and then transfered them to 2D Excel files. This process was time-consuming and the information was not updated in real time. In addition, certain areas were difficult to capture accurately in 2D, so we added more descriptions like "the rear side of this surface". Even though experienced staff could interpret these notes to some extent, younger or less experienced staff could not understand it well.

When implementing DX, we focused not only on accurately recording information but also on making the system easy to understand, simple, and intuitive to operate. Since many staff are unfamiliar with digital tools, it was important that the system be user-friendly and intuitive for everyone.
We collaborated with Toyota Systems, gathering feedback from on-site and continuosly refining the specifications with a strong focus on usability.

In addition to improving the speed of the work, the burden of the tabulation work was also eased. It is also contributing to the smoother passing on of skills.

After introducing “3D KATADASU,” we became able to link and register maintenance information to part on 3D model, which greatly improved work efficiency. Being able to check the 3D model from anywhere using smartphones or other devices allowed us to complete tasks on the spot. Many staff commented that "We can now check the mold shapes via the web from anywhere, which has increased work efficiency."

There were also major progress in information management and sharing. By digitizing repair records that were previously managed manually, we greatly reduced the time required for data aggregation. Furthermore, since the necessary information can now be viewed in real time, maintenance before failures can be performed more accurately. As a result, this has led to improved productivity and time savings, enhancing the overall efficiency of the site.
Moreoever, we believe that closer information sharing between design team and on-site staff has contributed to improved quality.

With traditional 2D management, experienced staff could understand the information, but it was often difficult for younger or less experienced staff to grasp, making skill transfer a major issue. However, these problems were resolved with the introduction of “3D KATADASU.” The benefits have exceeded our expectations in many ways, and we plan to continue using it while further evolving and improving the system moving forward.

This has become a very meaningful case that holds great potential for future developments. We have great expectations for the future.

We believe that if this technology is widely adopted at other plants in the future, it will lead to improved productivity across many more sites. Furthermore, with the 3D KATADASU technology, we expect its applications can extend beyond mold maintenance to equipment management and other areas as well.

Achieving this would not be possible without the support of Toyota Systems. This time as well, they consistently approached things from the perspective of on-site and collaborated with us to create solutions that are user-friendly for many people.
Going forward, we want to make the system even more user-friendly for a wider range of staff by enhancing language options and accessibility functiond. Another goal is to utilize it as a parameter for CAE analysis to further improve the simulation accuracy.

We very much hope that Toyota Systems will continue to be a key supporter of the entire manufacturing industry as a member of the Toyota Group.