“Factory Explorer”: A point cloud viewer integrated with equipment documentation system

We developed a system that balances quick searches with ease of use, helping to reduce the burden on maintenance staff.

When equipment breaks down, production stops, causing delays in the subsequent processes, and ultimately making our customers wait for their cars. To complete repairs as quickly as possible, digitalization was one of the solutions we considered.

The biggest issue in digitization was the “search speed.” Simply digitizing the documents alone wouldn’t solve the problem fundamentally. It was necessary not only to eliminate the "wasted time" spent walking to the archives to retrieve materials but also to quickly locate the needed information from the vast amount of paper documents. In addition to the “search speed,” we needed the system to be intuitive and easy to use, even for staff who were not familiar with digital tools. That’s how the development began.

I experienced this myself, the first job for a new employee assigned to equipment maintenance was "to fetch documents from the storage as instructed by senior colleagues." During that time, those seniors would move on to other investigations or repairs. I felt that missing out on observing the work process up close was a significant loss of a learning opportunity.

Work efficiency has improved dramatically. We were able to reduce MTTR(Mean Time to Repair) by 10 to 15 minutes.

For the major issue of the search speed, we took inspiration from the hashtag searches on social media and came up with the idea of tagging drawings and specifications with hashtags to quickly access the necessary information. However, when we actually implemented this, the search scope was too broad, and it took much longer than expected to retrieve the relevant items. When we consulted with developers from Toyota Systems about shortening the search time, they actually came to the factory to observe the usage scenarios. It was very encouraging to have them see the maintenance site, where every second counts to restore equipment as quickly as possible, and then improve the search logic to better suit the needs of the field.

Not only has the search time for information been significantly reduced, but it has also become the standard practice to use the camera function on tablets to keep records and videos of the work. This has helped us accumulate and share valuable know-how related to maintenance works. We believe this has also increased opportunities for new staff to learn by watching their more experienced colleagues at work.

After introducing the "Factory Explorer," we were able to reduce MTTR(Mean Time to Repair) by 10 to 15 minutes. When we needed to migrate the server to support the new production line, we completed the transition smoothly thanks to the clear instructions and the new server URL provided on the trial environment page, and there was no confusion in the production site.

We have achieved greater efficiency in equipment maintenance operations and strengthened our safety measures. We also look forward to further advancements and developments in the future.

With the introduction of the “Factory Explorer,” which links documents and maps and also includes a point cloud viewer, we are now able to unify data management required for equipment maintenance in one place. Being able to check equipment status, arrange replacement parts, and enter maintenance records directly from a tablet has significantly improved our efficiency

In equipment maintenance, we often have to work in high places or tight spaces, so implementing safety measures beforehand is absolutely essential. By utilizing point cloud data to gain a clear understanding of the surrounding area before starting work, we have been able to carry out maintenance more safely and smoothly.

When we introduced the system, Toyota Systems didn’t just listen to our initial requirements, they also took feedback from the people working on the ground and made continuous kaizen. As a result, even our veteran staff who weren’t very familiar with digital tools have been giving us a lot of positive feedback, saying it’s easy to use and has made their work much easier.

I am sure that these digital technologies will continue to evolve even further in the future. I’m counting on Toyota System to keep improving the accuracy of the point cloud data and expanding the system’s capabilities, so they can provide us with an even more comfortable and efficient environment.