Automating factory inspections with temi: FieldLog use case study
This document explains the specific setup method and operational flow for automated patrols using temi and FieldLog in conjunction.
Three challenges of nighttime factory patrols
Nighttime and weekend inspections of manufacturing sites present a common challenge for many factories.
01
Difficulty in securing personnel
Securing staff for night shifts and weekend work is becoming increasingly difficult each year. This is especially true for factories in rural areas, where recruiting young people is challenging, and the existing staff is aging."Even with increased night shift allowances, we're not getting any applicants." "We're overly reliant on veteran employees, leading to a highly dependent workforce."Such comments are not uncommon.
Amidst a worsening labor shortage, reducing the number of patrol personnel from two to one at night has resulted in a decline in the quality of inspections in some cases. A one-person system reduces the ability to respond to emergencies and increases the risk of accidents.
02
Variation in inspection quality
The quality of manual inspections varies greatly depending on the skills and experience of the person in charge.Experienced employees can detect subtle abnormal noises or changes in vibration in the equipment, but less experienced staff tend to overlook them.
Inspection routes can vary slightly depending on the person in charge, and there have been cases where abnormalities were not detected because "they weren't looking in places different from usual." Furthermore, maintaining concentration is difficult during late-night hours, and the risk of overlooking things due to fatigue cannot be ignored.
03
The "invisibility" of records and the inefficiency of management
With handwritten inspection sheets, the record of "who inspected what and where" tends to be subject to individual differences. When the person in charge changes, it becomes difficult to read the records, it takes time to find past records, and managers cannot grasp the situation in real time unless they are on-site—this "invisibility of records" leads to inefficiencies on the ground.
Furthermore, from the perspective of ISO certification and quality management, there is a growing demand for the digitalization of inspection records."To make visible who inspected what."Starting from there will be the first step towards creating a future record management system.
What does it mean to reduce the number of people involved in nighttime patrols?
The mechanism of automated robot patrols
Reducing manpower in nighttime patrols means,Replacing nighttime and holiday equipment inspection and patrol tasks, which were previously performed by humans, with autonomous robots.The robot automatically patrols a set route and photographs and records equipment and instruments at scheduled times.
Basic functions of autonomous robots
Temi, an AI-powered autonomous robot, uses LiDAR sensors and cameras to create a map of the factory using SLAM technology, and automatically navigates to its destination while avoiding obstacles. It can travel at a maximum speed of 1 m/s and adjust its speed according to the site conditions. It can also pass through narrow passages (minimum width of 60 cm).
It operates continuously for approximately 8 hours on battery power and automatically returns to the charging station when charging is needed. For factories requiring 24-hour operation, a system of multiple units taking turns charging can be established.
[Regarding the lighting environment] For image capture and instrument checks during automated nighttime patrols, a certain level of illumination is required within the facility. While many manufacturing facilities have safety lights and night lights that ensure a minimum level of illumination at night, please consult us in advance if your lighting environment is limited, such as in areas where lights are automatically switched off by motion sensors.
Integration with a dedicated app (Field Log)
While the robot alone can only "move," by linking it with a dedicated patrol inspection app, the following functions become possible.
What is FieldLog? This is an inspection record management app for manufacturing sites developed by iPresence Co., Ltd. It consists of two versions: a browser version and a version equipped with temi. Through temi's autonomous patrol and built-in camera photography, patrols, photography, and recording are digitized in one go.
Scheduled automatic patrol
The patrol will automatically start at a set schedule, such as 22 PM, 2 AM, and 6 AM every day.
Checkpoint photography and OCR
The system stops in front of each piece of equipment and automatically takes pictures of the instruments and equipment status (recording the date, time, and location of the photo). OCR reading is also possible to acquire meter readings.
Cloud storage and management
The captured data is uploaded to the cloud. The system allows you to check who inspected what and where.
Anomaly detection and alerts
If the set threshold is exceeded, an email notification is sent to the administrator. Images on the cloud can be viewed remotely, and temi can be remotely controlled as needed.
Remote verification and operation
You can check the current location, view real-time video, and remotely instruct on-site personnel to perform additional inspections from your smartphone or PC.
Differences from conventional fixed cameras and IoT sensors
Fixed cameras can only monitor the area where they are installed, making them prone to blind spots, and installation work is required. Similarly, IoT sensors are fixed in place, and the cost increases with the number of sensors.
Mobile robots can cover a wide area with just one unit, and their routes can be flexibly changed.Even if new equipment is added, it can be handled simply by adding checkpoints on the app. In addition to video monitoring, remote communication with on-site staff is also possible.
See the 5 steps to automating factory inspections →
This guide explains the specific setup methods and operational flow for temi×FieldLog, from route configuration to automated patrols and cloud recording.
Benefits of automated robot patrols:
Cost-effectiveness, quality stability, and record keeping.
Benefit 1: Significant reduction in labor costs and return on investment
Let's consider a factory that had two people assigned to nighttime patrols, and estimate the actual implementation costs.
Traditional labor costs (annual)
- Labor costs per night shift worker: approximately 400,000 yen per month
(Includes base salary, night shift allowance, and social insurance contributions) - Two staff members: Approximately 800,000 yen per month x 12 months
- = Approximately 960 million yen per year
FieldLog implementation costs (3-year lump sum payment, tax included)
- temi V3 SuccessPlan (3-year support and operational guarantee): Approximately 240 million yen
- Field Log License (3-year usage rights / equivalent to 3 yen per month): Approximately 120 million yen
- Total: Approximately 360 yen
*Includes initial setup and implementation support fees.
[Notes regarding pricing] The current Field Log license is ¥30,000 per month (excluding tax). We plan to revise the price to ¥50,000 per month when we expand the functionality (timing TBD). The price at the time of contract will be applied for 3 years. From the 4th year onward, the Field Log license fee will be the price applicable at the time of renewal.
💰 Estimated cost reduction (assuming 2 night patrol personnel and monthly personnel costs of 80 yen)
- Payback period:Implementation cost of approximately 360 million yen ÷ monthly personnel costs of 80 yen = Collection in approximately 4.5 months
- Labor costs over 3 years:80 yen per month x 36 months = approximately 2,880 yen
- Implementation costs over 3 years:Approximately 360 million yen (3-year lump sum payment, tax included)
- Cumulative difference over 3 years:A cost difference of approximately 2,520 million yen.
* Estimated effectiveness may vary depending on the facility's lighting environment and the design of the patrol route.
Benefit 2: Standardization and stabilization of inspection quality
The variability in inspections performed by humans will be eliminated.Inspections are always conducted along the same route, at the same checkpoints, and at the same time.Will be
Reducing the risk of oversight
We ensured that every checkpoint was passed through and that no photos were missed.
We ensured that every checkpoint was passed through and that no photos were missed.
Does not depend on the skill level of the person in charge
Same quality whether you're a newcomer or a veteran.
Same quality whether you're a newcomer or a veteran.
No effects on fatigue or decreased concentration.
The same performance whether it's 2 AM or 6 AM.
The same performance whether it's 2 AM or 6 AM.
Visualization of inspection routes
Management can verify the actual inspection routes on the system.
Management can verify the actual inspection routes on the system.
Fixed-point photography allows for a time-series comparison of equipment conditions, which can be used for predictive maintenance. Changes such as "the area of rust has expanded compared to last month" or "instrument readings are gradually increasing" can be identified from the accumulated image data.
Benefit 3: Digitalization and centralized management of inspection records
All inspection records are stored in the system, allowing for centralized digital management of "who inspected what and where":
- Record the date, time, and location of the photo.
- Filming location (name of checkpoint on the patrol route)
- Images taken (status of equipment and instruments)
- Patrol log (start/end time, travel route, battery level, etc.)
- Inspection records can be exported in CSV or ZIP format.
[Digitizing records will change the workplace] By implementing FieldLog, inspection records that were previously buried on paper can now be instantly viewed on the system, showing "who inspected what and where." This eliminates the need to search through past records, and managers can grasp the situation on-site in real time from anywhere. This is a practical first step in steadily advancing the digitalization of the quality control system.
This eliminates the need to print, distribute, collect, and store paper checklists, contributing to a paperless office environment.
Installation results
Currently, it is being implemented in multiple companies, primarily in the manufacturing sector.
Case Studies
🏭 Metal surface treatment manufacturer (with fewer than 100 employees)
📋 Background of the Introduction
The starting point was the need to remotely manage inspection work within the factory and to handle it at night. Existing water temperature gauges sound an alarm when the temperature exceeds a set value, but the challenge was to create a system that would not miss the "predictive zone" before that point. We began to consider whether the water temperature check, which was previously done visually by people, could be replaced by email notifications linked to a robot.
🔍 Challenges before implementation
- We want to reduce the manpower required for nighttime and holiday inspections, but we cannot overlook the condition of the equipment.
- The water temperature gauge has an alarm, but it failed to detect the "warning signs" before the alarm sounded.
- We want to catch signs of abnormalities early and prevent problems before they occur.
- We want to establish a system that allows us to check the situation on-site and give instructions remotely.
✅ How to use it
- Automatic, scheduled patrols capture water temperature at a fixed point:Using temi×FieldLog, the system automatically patrols a set route and takes a regular photo of the water temperature gauge. The images are automatically saved to the cloud.
- Early warning alert email delivery:Email notifications are set up when the system enters the "warning zone" just before an alarm sounds, enabling a system that prevents problems before they occur.
- Nighttime/remote site inspection:Upon receiving an anomaly notification, the person in charge can remotely check the camera footage from temi. If necessary, they can also remotely instruct on-site staff using the video chat function.
In this way, rather than replacing the existing alarm system,Add a mechanism to "notice before the alarm sounds."Complementary implementations are also possible. For details on implementation examples, please contact us and our representative will provide further information.
Frequently Asked Questions (FAQ)
What exactly does it mean to reduce the number of personnel involved in nighttime patrols?
This involves replacing nighttime equipment inspection and patrol tasks, traditionally performed by humans, with autonomous robots. These robots automatically patrol pre-set routes, photographing and recording equipment and instruments at scheduled times. This not only reduces labor costs but also enables standardization of inspections and digitalization of records. Even in cases where complete automation is difficult, it's possible to reduce the number of personnel from two to one.
What are the advantages of automated patrols using robots?
There are three main advantages.
① Staffing levels during nights and holidays can be reduced:If two people are assigned to the night shift, introducing robots can significantly reduce labor costs.
② Because inspection routes and times are fixed, quality is stable:This system eliminates human error and oversights, ensuring consistent quality inspections every time.
③ Centralized digital management of inspection records:The system allows you to check who inspected what and where, streamlining internal record-keeping and reporting processes.
How much will it cost to implement?
For a 3-year lump-sum contract, the total cost for temi V3 SuccessPlan (3-year support) + Field Log license (3-year usage rights) is approximately 3.6 million yen (including tax). Compared to the personnel costs of two night patrol personnel (approximately 800,000 yen per month), this estimates that the investment can be recovered in approximately 4.5 months. From the 4th year onward, continued use is possible for approximately 900,000 yen per year (including tax, at current prices). Please note that while the price of the Field Log license is scheduled to be revised when features are expanded, the price at the time of contract will apply for the first three years.
Can it accommodate existing equipment and factory layouts?
Yes, we can accommodate that. The robot automatically creates a map of the factory upon installation and sets a patrol route and checkpoints on that map. It can travel on any path with a minimum width of 60cm and an incline of 5 degrees or less. The travel speed can be adjusted to suit the site, with a maximum speed of 1m/s, and the route can be flexibly edited via the app to accommodate layout changes.
Will the facility operate even if it's dark at night?
While temi's autonomous driving itself can operate in dark places, a certain level of illumination is required for instrument capture and image recording using its camera. In most factories, sufficient illumination is provided by safety lights and night lights. If you are concerned about the lighting environment in each area, we recommend checking the site in advance.
Can inspection records be used for audits?
FieldLog functions as a record-keeping platform that allows you to verify "who inspected what and where" within the system. By digitizing and centrally managing inspection records, it contributes to the efficiency of internal reporting and record organization. On the other hand, we are currently working on improving its functionality to meet the requirements for legal evidence (prevention of time tampering, long-term storage, etc.). Please feel free to contact us for specific ways in which it can be used in audits.
Review the implementation process, costs, and operation methods in one place →
This article explains the FieldLog×temi implementation process, initial setup, and detailed costs.
You can also request a demo or consult about a Proof of Concept (PoC) from this page.
Summary: By reducing the number of personnel required for nighttime patrols,
Safety, quality, and cost: a win-win-win situation.
Replacing nighttime factory patrols with automated robotic patrols will yield the following benefits:
💰 Cost reduction
The initial setup cost was approximately 3.6 million yen (including tax) over three years, with the investment recovered in approximately 4.5 months. The cumulative difference over three years was approximately 25.2 million yen.
📊 Quality improvement
With fixed inspection routes and times, there are no oversights. Fixed-point photography also allows us to understand the changes in equipment over time.
🛡️ Improved safety
Reduced risks associated with nighttime staffing; immediate notification and remote verification via alert in case of anomalies.
👥 Work style reform
Reducing the burden of night shifts, alleviating staff shortages, and allowing staff to focus on value-added tasks.
Instead of "reducing inspections due to labor shortages," the approach should be "improving inspection quality by entrusting them to robots."This will become the standard for manufacturing sites going forward.
We recommend starting with a 1-2 month Proof of Concept (PoC) to verify whether it's suitable for your own workplace. It's being increasingly adopted by manufacturing companies, including metal surface treatment manufacturers.
* Estimated effectiveness may vary depending on the facility's lighting environment, patrol route design, and labor cost levels. Please feel free to contact us for details.
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