Bridging the Labor Gap in Japan: Digital Transformation with Nippon RAD and Advantech’s Solutions

Many manufacturers in Japan still rely on manual, paper-based data collection, requiring operators to walk the shop floor, record data, and later input it into Excel spreadsheets—a time-consuming process prone to errors. Moreover, PLC, HMI, MES, and ERP systems often lack seamless integration, and many companies may not have the budget for full-scale digital upgrades.

To address these challenges, a leading IoT and enterprise solutions team in Japan developed an end-to-end service, leveraging Advantech’s IoTSuite and their expertise in system integration to accelerate digital transformation in the manufacturing sector.

Automated Data Acquisition: The Cornerstone of Digital Transformation

Facing labor shortages and rising operational demands, improving productivity and efficiency has become essential for manufacturers in Japan. A major metal processing company in the region sought to digitize its production environment—moving from paper-based reporting to real-time, automated data capture that directly feeds into dashboards and ERP systems. Their goals: save time, gain transparency, and enable real-time operational insight.

To meet this need, a comprehensive solution was introduced using Advantech’s IoTSuite, ECU-1051, and ADAM-6051, combined with a digital form platform. The system enabled automated data acquisition, real-time monitoring, and seamless integration across production machines and enterprise systems.

Machines with PLCs used ECU-1051 IoT gateways running WebAccess/SCADA for automatic data collection. For non-PLC machines, ADAM-6051 I/O modules captured operational times. Both types of devices interfaced with digital forms, which also allowed operators to manually input additional data such as production output, defect counts, or abnormal events.

To ensure a smooth transition from manual systems, the company’s existing paper-based forms were digitized and mapped into the system—linking work orders, tracking outputs, and logging issues. The collected data was transmitted to a centralized platform for full operational visibility through intuitive dashboards and comprehensive reporting.

Digital Evolution: Driving Efficiency and Expanding Innovation

With the new system in place, the manufacturer was able to monitor uptime, downtime, output, and errors in real time. This enabled immediate corrective actions, improved machine visibility, and enhanced quality control. The automation also removed over 1,000 hours of manual work previously spent on paperwork and data entry.

Following the success of this initiative, the company plans to scale the solution to its other sites across Japan and continue digitizing other paper-based workflows.

Looking ahead, the development team aims to position this initiative as a benchmark for digital transformation in Japan’s manufacturing sector, where labor shortages and efficiency challenges are increasingly common. With a scalable model and proven implementation, similar solutions can be rolled out much faster to other factories across the country.

Case Benefits

1. Eliminate working hours on paperwork and manual data entry.
2. Automated data acquisition and aggregation and digitalized report forms.
3. Identify production issues in real time.

Advantech WISE-IoT Solution

The WISE-IoT Suite boosts operational efficiency and scalability, offering real-time insights tailored to diverse industries. Designed for adaptability, it empowers productivity and accelerates digital transformation, helping businesses thrive in today’s fast-evolving industrial landscape.