Methods to reduce manpower in nighttime factory patrols: The reality of automated robotic patrols.
This article provides a detailed explanation of the challenges of nighttime patrols, mechanisms for reducing manpower, and cost-effectiveness.
If you are considering implementation, please first check it out with a live demo.
This article covers everything from setup to costs. If you want to get started, please try the demo.
① Challenges of factory inspections and how FieldLog can solve them
Many manufacturing sites face the following challenges when conducting nighttime and holiday inspections:
Three challenges faced on the ground
- Labor shortage and reliance on individual expertise:When skilled staff retire, inspection expertise is lost.
- Inadequate and non-standardized records:Paper inspection sheets are prone to errors such as forgetting to fill them out or being misread.
- Increasing nighttime labor costs:In some cases, a two-person night shift can cost over 16.8 million yen per year.
What FieldLog × temi will change
temi autonomously navigates a set route, automatically taking photos and recording data at each checkpoint. Not only does this eliminate the need for inspection personnel, but the data accumulated in the cloud can be viewed and analyzed at any time via a web management screen, simultaneously achieving "visualization" and "standardization" of inspections.
- Fully automate nighttime patrols:Temi operates autonomously even in the middle of the night.
- Complete digitization of records:Automatically saves captured images, timestamps, and detected anomalies.
- Administrators can remotely check via the dashboard:Understanding the situation without having to visit the site.
② The process for implementing FieldLog (overall picture)
The process from initial inquiry to system launch typically takes 4-6 weeks. You can first check the actual equipment with a free demo, and then, if necessary, proceed with a Proof of Concept (PoC) before deciding on full implementation.
| Phase | Message | Period |
|---|---|---|
| ① Inquiry and Interview | Identifying on-site issues and confirming needs | 1-2 days |
| ② Free demo | Live demo or online demo | 1 days |
| ③ PoC (optional) | Rental trial implementation | 1 weeks to 1 month |
| ④ Full-scale implementation and configuration | On-site inspection ~ Training ~ Test operation | 2-3 weeks |
| ⑤ Start of operation | Automatic patrol started, regular support commenced. | Continued |
③ A Proof of Concept (PoC) is optional. If you are satisfied with the free demo, you can proceed directly to full implementation (implementation can be completed in approximately 2-3 weeks without a PoC).
③ Setup Phase: What to do before implementation
Once you've decided to implement the system, we'll proceed with the initial setup using the following steps. FieldLog's dedicated staff will support you throughout the process. The entire process will take approximately 1-2 days.
STEP 1: Prepare the temi device (Wi-Fi and network settings)
First, connect the temi unit to the network. Connect temi to the factory's Wi-Fi network and establish communication with the cloud.
- Wi-Fi settings for the temi unit (connecting to the factory network)
- Communication check and firmware update
- Installing the FieldLog app on the temi device
A Wi-Fi environment is required within the factory. If there are areas where the signal does not reach, please consult with the person in charge in advance. SIM card support is also available.
STEP 2: Factory mapping (map creation using temi)
We will actually drive the temi inside the factory and use its LiDAR sensor to automatically create a map of the factory.
- The temi is manually operated to travel through the patrol area.
- The LiDAR sensor automatically recognizes walls, obstacles, and pathways to generate a map.
- Import the generated map into the FieldLog management screen.
Vehicles can travel on paths with a minimum width of 60 cm and an incline of 5 degrees or less.
STEP 3: Checkpoint Registration
Register patrol points on the map. Set detailed instructions for each point, such as "stop and take a photo at this location."
- Stop time: Set to 10-30 seconds (adjust according to instrument readings)
- Shooting direction: Angle adjustment is possible, including forward, upward, and downward.
- Alert conditions: Email notification to administrator when an anomaly is detected.
STEP 4: Route setting
Connect the checkpoints and create a patrol route.
- Drag and drop checkpoints onto the floor map to place and set their order.
- Multiple routes can be registered and switched between depending on the time of day and day of the week.
- Layout changes and the addition of new facilities can be handled simply by editing the route within the app.
STEP 5: Various FieldLog settings
You can configure various settings necessary for operation from the FieldLog management screen.
- Registration and editing of notification email list (notification recipients in case of anomaly detection)
- Various editing options for meters and checkpoints (shooting conditions and judgment criteria)
- Various numerical settings (alert threshold, number of shots, etc.)
- Setting the cloud storage period
STEP 6: Schedule registration (temi side)
You register the automatic patrol schedule from the temi device's app.
- Setting the start and end times for patrols (e.g., 22:00 daily, 2:00 the next day, 6:00 the next day)
- Setting patrol schedules by day of the week and date
- Automatic return setting to charging station after patrol completion.
After setting the schedule, a test patrol will be conducted, and if there are no problems, the system will be moved to full operation.
④ Operational Phase: Dashboard and Record Management
Real-time confirmation via web dashboard
You can check the patrol status, anomaly detection, and temi operating status anytime from your smartphone or PC.
- Real-time display of today's patrol count and completion rate.
- When an anomaly is detected, an alert will be displayed on the dashboard and an email notification will be sent.
- Check temi's battery level, current location, and travel route.
- The temi can be manually controlled remotely, and instructions can also be given to on-site staff.
Digital management and CSV export of inspection records
All patrol records are automatically saved to the cloud and can be downloaded as a CSV file.
- Patrol date and time / Checkpoint name
- Number of photos taken / Anomaly flag
- Battery level and patrol route ID
This eliminates the hassle of printing and storing paper checklists, and makes it easier to search and analyze past data.
⑤ Operational Phase: Daily use after implementation
Once FieldLog's automated factory patrol system is fully operational, the daily workflow will change as follows:
Daily operation: Automatic patrol, photography, and notification.
- temi automatically starts up at a specified time at night and autonomously drives along a set route.
- Automatic shooting and anomaly detection at each checkpoint
- If an anomaly is detected, an email and app notification will be sent to the administrator (immediately).
- After completing its patrol, it automatically returns to the charging station.
Weekly review: Performance check and anomaly detection review
- We review the patrol rate, number of abnormal cases, and captured images on a weekly basis.
- Anomaly detection accuracy tuning (adjust settings if there are false positives or missed detections)
Monthly activities: Monthly KPI review and CSV download
- Download patrol record data as a CSV file.
- KPI review: Number of patrols, number of anomaly detections, equipment utilization rate, etc.
⑥ Regarding costs: Comparison of deployment methods (per unit)
There are three different ways to implement FieldLog×temi, depending on your purpose and circumstances. All prices are per unit.
| Item | PoC Rental (1 month, 1 unit) | Phased implementation (3-year lump sum payment, 1 unit) | Full-scale implementation (3-year lump sum payment, 1 unit or more) |
|---|---|---|---|
| temi V3 | 300,000 yen/month (excluding tax) | Including | Including |
| FieldLog License | 30,000 yen/month (excluding tax) | Including | Including |
| Subtotal (excluding tax) | ¥330,000 | ¥3,280,000 | 3,280,000 Yen ~ |
| Consumption tax (10%) | ¥33,000 | ¥328,000 | 328,000 Yen ~ |
| Total (tax included) | ¥363,000 | ¥3,608,000 | 3,608,000 Yen ~ |
| Annual fee (tax included) from the 4th year onward. | ¥946,000 | 946,000 Yen ~ |
*FieldLog licenses are subject to price revisions when new features are added. The price at the time of contract will apply for three years.
*All prices are shown including tax (10%) unless otherwise specified.
*All prices are shown including tax (10%) unless otherwise specified.
PoC Rental Process
- We will verify its effectiveness in a real-world setting through a short-term rental of 1-2 months.
- temi V3 rental: 300,000 yen/month (excluding tax) + FieldLog license: 30,000 yen/month (excluding tax)
- Total for one month: 363,000 yen (tax included)
⑦ ROI Calculation: Expected Effects of Implementation
[Assumptions for the calculation]
- Two night shift staff members are assigned (10 PM to 6 AM the following day, with each patrol lasting approximately 1.5 hours).
- Labor costs per night shift worker: Approximately 400,000 yen per month (including base salary, night shift allowance, and social insurance contributions)
- Assigning 2 people: Approximately 80 yen per month x 12 months = Approximately 960 yen per year
[Calculation Results]
- 3-year lump-sum installation fee: 3,608,000 yen (tax included)
- Monthly savings: Approximately 800,000 yen (personnel costs for two night shift workers)
- Payback period: Approximately 4.5 months
- Total personnel costs over 3 years: Approximately 2,880 million yen (under previous system)
- Total implementation costs over 3 years: Approximately 360 million yen (FieldLog x temi)
- Cumulative cost difference over 3 years: Approximately 2,520 million yen
[Expected effects after implementation (estimated after 3 months)]
- Nighttime patrol costs: reduced by approximately 80%
- Automated patrol record keeping rate: 100% (photography, cloud storage, and searching are all automated)
- Search time for past records: several minutes → approximately 5 seconds
- Overtime hours for staff in charge: Reduced by an average of 40 hours per month.
- Many users report seeing results within one month of implementation.
*Estimated effectiveness may vary depending on the facility's lighting environment, patrol route design, and staffing configuration.
*The figures are model cases based on the performance of companies that have implemented the system.
*The figures are model cases based on the performance of companies that have implemented the system.
Try it out with a PoC rental →
First, try a short-term rental of 1-2 months to see how it performs in a real-world setting.
Summary: Start with a Proof of Concept (PoC) rental.
You can start with a Proof of Concept (PoC) rental (1-2 months) to verify the actual effects before deciding on full-scale implementation of FieldLog×temi.
- Cost reduction:Significant reduction in labor costs for nighttime patrols, with investment recovery expected in approximately 4.5 months.
- Quality improvement:Standardization of inspections, zero oversights, and digitalization of records.
- Improved safety:Reduced risks associated with nighttime staffing and rapid remote anomaly detection.
- Data utilization:Use CSV export to search, analyze, and predictively maintain historical data.
Please contact us first for a demo/PoC rental.
Frequently Asked Questions (FAQ)
We will answer frequently asked questions from customers considering implementing FieldLog×temi.
What are the costs involved when switching from a proof-of-concept (PoC) rental to a full-scale implementation?
You can test the effectiveness in a real-world setting with a PoC (Proof of Concept) rental (1-2 months) before deciding on full-scale implementation.
Can it accommodate existing layouts?
Yes, we can accommodate that. temi automatically creates a map of the factory during installation. It can operate on routes with a minimum aisle width of 60cm and an incline of 5 degrees or less. Adding new equipment or changing the layout can also be done simply by editing the route within the app.
How can inspection records be managed?
All inspection records are automatically saved to the cloud. You can check them in real time from the web dashboard, and export data such as inspection date and time, captured images, and anomaly flags in CSV format.
Will it work in dark environments at night?
While temi's autonomous driving itself can operate in dark environments, 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 have concerns about the lighting environment, we recommend checking the site in advance.
What are the costs like from the fourth year onwards?
From the fourth year onward, only annual renewal of the FieldLog license will be required. The current price is ¥946,000 per year (per device), including tax. Please note that while we plan to revise the price of the FieldLog license when we expand its functionality, the price at the time of contract will apply for the first three years.
If we're implementing this at multiple locations, can we manage it centrally?
Yes, you can centrally manage multiple locations and multiple teams from the FieldLog web management screen. You can compare the patrol status of each location on the dashboard, and manage KPIs for the entire group.
For inquiries and consultations regarding implementation →
Please feel free to contact us with any questions or concerns. Our expert consultants will provide you with thorough support.
📚 Related Articles
For managers in factories and manufacturing facilities
For factory managers and DX promotion personnel
Automating factory inspections with temi: FieldLog use case study
This article explains the mechanism of integration between FieldLog and temi, and provides an example of its implementation at a metal surface treatment manufacturer.
