The term "sensing" is being heard more frequently these days, but many people may wonder: “What is actually being measured, and how is it being utilized?”
If you would like to know the basics of what sensing is, please check our previous Market News issue, “Introduction to the Sensing Data Utilization Workshop.”
At Aska Company, we implement "sensing technology" by placing various sensors on factory equipment and production lines to gather real-time data on temperature, power consumption, pressure, flow rate, vibration, and more.
Furthermore, we go beyond simply collecting and visualizing this data. By leveraging IoT and data analysis technology to analyze trends and anomalies, we translate these insights into shop-floor improvements—such as promoting energy savings, detecting early signs of equipment failure, and stabilizing product quality. By combining these approaches, we achieve data-driven manufacturing that no longer relies solely on intuition and experience.
In this issue, we will introduce our latest energy-saving case study achieved through chiller (cooling system) sensing, alongside an event report on our recent "Sensing Seminar."
We hope you enjoy reading to the end!
Visualizing Data and Analyzing with AI! Reducing Chiller Power Consumption by up to 16.7%
In plastic molding, cooling systems called "chillers"—which cool hot resin to solidify products—are indispensable.
At our factories, chillers are cooled using water supplied from outdoor cooling towers.
Recently, by sensing and monitoring the "cooling water temperature" data across two of our plants, we discovered a significant difference in their graph waveforms.
Monitoring water temperature revealed a discrepancy between settings and actual water temperatures across different cooling towers.
“Which plant’s data (and configuration) is more energy-efficient?”
To answer this question, we leveraged AI using our accumulated data to explore optimization strategies.
Using AI to analyze graph data and suggest the most promising solutions.
By optimizing the chiller settings based on AI-generated advice, we successfully stabilized the cooling water temperature and operated the cooling towers much more efficiently.
As a result, we achieved up to a 16.7% reduction in chiller power consumption compared to before the settings were changed!
Monitoring confirms that the cooling water temperature stabilized after adjusting the settings.
This case demonstrates how introducing sensing to factory equipment to visualize "hidden issues" directly leads to tangible cost savings and improved energy efficiency.
Clear Doubts by Seeing Real-World Examples! Holding the "Sensing Seminar"
At Aska Company, we offer seminars and workshops to share the know-how we have developed inside our own manufacturing plants.
Here is a brief look into our recent seminar event:
- Factory Tour & Case Studies
Following a brief company introduction, participants viewed actual machines in operation and live data displays to see firsthand how sensing functions on the shop floor. - Lecture & Classroom Session
We explained the fundamentals of data utilization and walked through the practical steps for implementation. - Technical Consultation & Roundtable Discussion
We held an open exchange of ideas, addressing questions about introducing sensing systems submitted in advance by attendees, as well as discussing their specific operational challenges.
Participant Testimonials
We are delighted to share some of the feedback we received from our attendees:
- Hearing directly from those who built the system and actively use it on the shop floor helped bridge the gap between our vague assumptions and reality.
It gave us a much clearer direction for where we need to head next.
The factory tour was also incredibly informative. - I was able to get specific advice tailored to the exact case studies our company is trying to implement.
- They answered all our questions without holding anything back, giving us truly valuable insights and know-how.
- I was impressed by their company culture, which we don't have at ours—such as each department building its own problem-solving apps.
Customized Solutions Tailored to Your Business
Aska Company’s Sensing Workshops can be fully customized to meet your specific needs.
In addition to hosting sessions at our facilities, we can also visit your actual manufacturing site to conduct the workshop.
If your company is thinking, “We want to promote energy savings and data visualization in our own factory,” or “We don’t know where to start,” please feel free to contact us.
Stay tuned for the next issue!