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  • JTEKT Success | igear

    Success Stories: JTEKT INDUSTRY: Automotive OE Supplier ​ USE CASE: Process Control and Quality Assurance ​ SOLUTIONS: IGear’s ASSIST Traceability & Process Control Software Quality Check Sheets System Maintenance Call System SQUEAKS Software ​ REGION: North America and Europe ​ RESULTS: 100% zero defects ensured via state-of-the-art real-time manufacturing software that safeguards against all production errors, defects, and noncompliance across all processes executed by human personnel and/or machines. System maintains advanced traceability and product component genealogy as well as machine data results from 450 machines for process control and auditability Innovative mobile machine-to-human communication protocol supports exceptional real-time responsiveness Rapid six-month go-live due to ease-of-integration with no custom coding Roll out continues both to support new plants on a global scale and to support new and expanded use cases, including automation and digitization of Quality Check Sheet process and Maintenance Call System. ​ The JTEKT / IGear partnership has resulted in a state-of-the-art real-time manufacturing solution that safeguards against all production errors, defects, and non-compliance across all processes executed by human personnel and/or machines. ​ IGear technology has enabled this global automotive supplier to improve manufacturing quality by achieving greater adherence to specifications at every stage of the manufacturing process that are resulting in zero defects. ​ Advanced traceability and tighter process control has already resulted in significant savings and reduced liability. DOWNLOAD PROBLEM At its North America Automotive Steering Business Unit, JTEKT Corporation’s fabrication of power steering assemblies is a complex undertaking involving hundreds of machines across dozens of lines in multiple plants – with processes spanning machining and heat treating of parts, to sub and final assembly of components with comprehensive testing each step of the way. It’s imperative for automotive OE suppliers to have robust quality control procedures in place to reduce liability from mis-assembled or defective products that may result in costly recalls or place customer safety at risk. The customer wanted a better, more comprehensive system to support process control and quality assurance by eliminating the possibility of passing bad, wrong, or incomplete parts through the process. They also wanted to better record and maintain process data from hundreds of machines with myriad parameters allowing them to verify that the correct pressures, torques, etc. are applied to each and every assembly for better process control and quality assurance. Additionally, JTEKT also needed to comply with a new customer advanced traceability mandate to ensure sub-assemblies and final products assembled within JTEKT facilities were 100% traceable. This included maintaining traceability for key individually serialized components as well as dozens of other batched serialized components while maintaining a component genealogy of each product produced. Moreover, JTEKT wanted an Intelligent Manufacturing System to orchestrate Human-to-Machine interactions – going beyond the functionality of traditional Manufacturing Execution Systems to address process control when human operators need to intervene to resolve issues on the plant floor. SOLUTION Chosen over two other solutions that were implemented in its manufacturing facilities in Asia and Europe, IGear software – first deployed at the customer’s North American manufacturing site –was proven to be the best-in-class and most comprehensive solution to meet its requirements around manufacturing process control, quality assurance, advanced traceability and human-to-machine communications. As a result, the customer is now standardizing on IGear ASSIST across all of it North American manufacturing operations as its Intelligent Manufacturing System supporting all new lines for automotive assembly production. IGear ASSIST provides a proven method for controlling the quality and performance of production processes. It enables manufacturers to verify standardized operator work instructions are consistently followed by recording a traceable genealogy of all work sequences, component parts, and cycle times, along with the operator actions and machine events involved within each value added work center in the overall manufacturing process spanning some 450 machines in each plant. JTEKT now has a “birth certificate” for every product that’s made, detailing exactly what components are in the build. Additionally – prior to the start of processing – the system ensures the correct part is being run, the correct machine program type is being used, that the part was not previously rejected as bad, and that the part is at the correct operation (no process was skipped). After confirmation of the above points, permission to run is granted and the machine will perform its intended function. Improved visibility of JTEKT industrial machine and process data is supported via powerful web-based data reporting and visualization, which provides a unified reporting framework to simultaneously view and easily discern information from multiple, disparate data sources. JTEKT is also leveraging the IGear SQUEAKS software. Fully integrated with ASSIST, it supports human-to-machine interaction and real-time collaboration among front-line workers and production managers. The technology introduces a new paradigm for real-time connected manufacturers, leveraging the power of mobility, wearables and role-based workflow and analytics to deliver exactly the right mission-critical information to specific personnel in the execution of mission-critical operations ensuring clarity, ownership, accountability, and responsiveness. Fast becoming the human-to-machine communications protocol for the largest manufacturers around the world, SQUEAKS supports better decision-making and closed-loop collaboration, integrating messaging across machines and personnel to surface insights and mobilize prescriptive actions to support dramatically improved production up time and quality assurance. RESULTS The JTEKT / IGear alliance has resulted in a state-of-the-art real-time manufacturing platform that safeguards against production errors, defects, and non-compliance across all processes executed by human personnel and/or machines, dramatically enhancing the customer’s leadership position ofexcellence in manufacturing operations. IGear technology has enabled the company to achieve the pinnacle of quality in manufacturing: absolute assurance to requirements at every stage as products are being manufactured, resulting in zero defects. ​ IGear worked closely with JTEKT’s in-house Production Engineering team on all aspects of integration and implementation.With no custom code required, the first line was up and running in six months and the second, third and fourth lines were live in half the time. ​ JTEKT has dramatically improved visibility of production data, so it can now understand – on a real time basis – is it meeting production targets or falling behind? When problems arise, it now has the insights and support for decision making to speed issue resolution to mitigate costly line stops. Maintenance, quality, management, and other key personnel now collaborate to troubleshoot and resolve issues faster and more efficiently than ever before. Moreover, by instituting the technology framework to tighten product and process traceability and quality control, the company has dramatically reduced its corporate risk and liability profile. As a result of successes to date, new JTEKT use cases to enable via IGear continue to be defined. The previously manual Quality Check Sheet process, which dictated a quality check of every machine every two hours and whenever a product changeover occurred, has now been automated for greater efficiency and improved accountability and auditability. Shortly thereafter, IGear was used to automate the company’s Maintenance Call System by providing visibility of work order status to all levels of personnel via mobile devices, TVs, and wireless light trees on the plant floor. ABOUT IGEAR Over the past 30 years, IGear has been at the forefront of innovation in smart manufacturing solutions. We provide solutions that connect the enterprise, streamline data gathering and analysis, and empower teams through improved communication and collaboration. The world’s leading organizations in the manufacturing industry rely on our solutions to solve their most complex, mission-critical operational and quality challenges by unlocking the power of their data to support better, faster decisions, improved performance and exceptional responsiveness. Learn more at: www.igear.com ABOUT JTEKT CORPORATION With over 40,000 employees and 65 manufacturing facilities globally JTEKT Corporation produces and distributes steering systems, driveline components, bearings, machine tools, electronic control devices, and home accessory equipment JTEKT is committed to its global vision of shaping a better future by proactively researching and developing innovative, next-generation products and technologies for the automotive component, bearing and machine tool industries.

  • RealTime Manuf Info | igear

    Real-Time Manufacturing Information Capture the Real-Time Information You Need Now With SQUEAKS Communication Platform For Industry 4.0 Receive real-time manufacturing information, delivered to you when and where you need it, with our mission-critical communication platform, SQUEAKS. SQUEAKS is unique in that its primary goal is to maintain solid communication channels. If you’re tired of alerts not being acted upon, or communication slipping through the cracks, SQUEAKS can help you manage notifications and give you the peace of mind that everything is covered. If you need to review data to keep track of production progress, product quality and employee safety concerns in your facility, SQUEAKS is the right answer. Contact us today at INFO@IGEAR.COM to learn more about how we can help you implement SQUEAKS to get your business on track with better communication. Visit our page SQUEAKS to view videos of SQUEAKS in action and envision how it could work for you while allowing you to focus on what's important to you – your success and profitability. Request A Demo SQDC Boards Software Manufacturing “Call For ...” Mobile Andon Organize & Share Videos Mobile App for Stack Lights Worker Productivity Software IoT Software Communication Platform Real-time Manufacturing Information Manufacturing Productivity Production Efficiency Manufacturing Execution Systems Production Displays Manufacturing Software App Floor Management Development Systems (FMDS) Transforming Visual Management Boards Visual Management Microsoft Power BI + Squeaks Manufacturing Communication

  • CAREERS | IGear

    CAREERS Wanted -- passionate and driven individuals to help us create all phases of product roadmaps, technical designs & customer solutions.

  • REAL-TIME INFO | igear

    REAL-TIME INFORMATION SQUEAKS facilitates the automatic flow of real-time information – making for faster and better decisions. SQUEAKS provides out-of-the-box, reliable connectivity to all the data in your plant, leveraging open standard protocols and native interfaces. SQUEAKS eliminates manual data collection and data entry – allowing employees to focus on improving operations and doing more innovative work. REAL-TIME INFORMATION Out-of-the-box Connectivity SQUEAKS eliminates islands of information and data silos. SQUEAKS is automation and information-vendor independent, integrating with all your data sources, including rich, multi-media content that provide greater context and insight. Realtime Information Play Video Facebook Twitter Pinterest Tumblr Copy Link Link Copied ASSIST Plug-ins and 3rd Party App Integration SQUEAKS open architecture simplifies the integration with your existing applications and other 3rd party apps, such as ERP, Maintenance, and MES. The information you see is updated in real-time. As an example, the IGear MES application, ASSIST ™, delivers real-time content in the areas of Safety, Quality, Production and Labor Assignments – while at the same time allowing you to enter information directly into the application to provide greater context. ASSIST Plugins Play Video Facebook Twitter Pinterest Tumblr Copy Link Link Copied Across Your Devices SQUEAKS operates on all your communication devices (desktop, tablet, mobile, smart watch, touchscreen TVs, etc.) – including Android, iOS, and Windows devices. With SQUEAKS , you can work virtually anywhere. Synchronize Files The SQUEAKS File Synchronization technology ensures employees are working with the correct and most recent file – essentially eliminating the problem of employees working with outdated information. SQUEAKS allows you to work directly with the tools and applications that you use today – making the most of your existing investments. File Synchronization Play Video Facebook Twitter Pinterest Tumblr Copy Link Link Copied + MEET SQUEAKS VISIBILITY + ACTION + REAL-TIME INFO +

  • WHO WE ARE | igear

    WHO WE ARE IGear Vision To create software tools that empower the most productive workers and teams in manufacturing. IGear Mission Statement To enhance our customers’ ability to achieve their goals through the appropriate application of information technology. Our success is achieved only through the success of our customers. IGear Values We have the customer as the focal point of all our activities. ​ We consistently provide high quality, responsive services and products to our customers – meaning that we mutually define their expectations, measure ourselves against them and strive to exceed them. ​ We provide value-add services and products so the revenue we earn is considered reasonable by our customers, based on the benefits they receive. ​ We exceed our customer’s expectations by looking beyond the scope of our engagements and applying our individual and collective experience to improve their business. ​ We attract and retain professionals of the highest competence, integrity and intensity who must seek to improve themselves and those around them, who must communicate honestly and openly, and who must consider the broad interest of the customers, co-workers and the Company in all of their actions. ​ We instill a proactive behavior in a team environment, recognizing that success comes to those who act rather than react and to those who see the total as greater than the sum of its parts. ​ We provide our people with an enriching work environment and support them in their personal and professional development. ​ We have an obligation to continuously practice safety. ​ We value our vendors and business partners as integral team members in providing customer solutions. ​ We actively support the communities in which we do business. ​ We have an obligation to consistently improve our financial performance, which is essential to our Company. ​ Finally, each employee has the responsibility to protect and promote these values. You'll Find Us Here. IGear, LLC 8016 Vine Crest Ave. Louisville, KY 40222 Info@igear.com

  • CONNECT | igear

    CONNECT Data Service Platform Connectivity & Data Movement ​ CONNECT is a comprehensive connectivity and data movement platform. It enables global manufacturers and industrial equipment OEMs to quickly and reliably build, implement, and support Connected Manufacturing business applications by integrating real-time information among a diverse set of technologies, including plant floor machines, tools, robots, programmable logic controllers (PLCs), sensors, scanners, and a myriad of other manufacturing device technologies along with the software systems used for manufacturing execution (MES) and enterprise resource planning (ERP). ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ Unmatched “Brownfield” and “Greenfield” Connectivity Because industrial automation has been around for so long, there are literally millions of legacy “brownfield” devices, software systems, and technologies operating on control networks with disparate communication protocols in plants all over the world. Having the luxury to only support modern “greenfield” devices, software systems, and technologies is not the reality for global manufacturers. CONNECT includes: Data Link Included with CONNECT is an extensive set of linkages to a wide range of both native and open standard protocols. Visit the Support Center for a complete list of CONNECT Data Links. https://support.igearonline.com/#/connect Industrial Strength, Reliability & Resilence ​ In industrial settings, system reliability and resilience are absolutely non-negotiable. When a networked home thermostat stops working for a while, it is simply inconvenient. If an interlocked manufacturing process fails, production stops as expensive equipment and costly labor resources sit idle. CONNECT provides : ​ Data Integrity CONNECT’s advanced data queuing algorithms guarantee information is valid at the instant in time a triggering event occurs. Its architecture buffers data in queues to ensure references receive the correct snapshot value as defined by the time validity of the trigger event. Detailed L ogs & Statistics The information you need to troubleshoot connection or faulty-device issues is readily accessible through CONNECT’s event logs and command statistics. CONNECT tracks all successes and failures and automatically calculates statistics for execution times and device-throughput capabilities. Fault Tolerances The reality is, systems go down. Whether you encounter a network issue, a server failure, or any other potential disruption, CONNECT automatically saves failed commands and resubmits them on user- defined intervals to ensure that system failures do not result in critical data loss. A gile manufacturing demands flexible, up-to-the-second processes to accommodate highly customized products with build-to-order production schedules, as well as to swiftly respond to ever-changing business conditions. CONNECT offers: Configuration Assistant CONNECT is equipped with step-by-step dialog screens that guide you through even the most complex connections in a fraction of the time it takes to write custom code or configure monolithic software tools. All connections are easily managed through an intuitive point-and-click user interface . Advanced Triggering Even the most complicated data-exchange rules are simplified with CONNECT's flexible triggering system. Both time- and event-based triggers are supported. Custom triggering allows Boolean combinations of time and event triggers, as well as other custom criteria. Flexible Deployment CONNECT is ideally suited for centralized or distributed On-Premise server and Embedded deployment models. Simple to Configure. Quick to Adapt.

  • Get Demo | igear

    Get Your Demo Book a 45-minute demo with one of our staff to learn the different capabilities our software suite has to offer. Request a Demo Please provide your information below and we'll get back to you to set up a date and time that works for you. State Submit Thanks for submitting we'll get back to you shortly!

  • SQUEAKS for Teams | igear

    SQUEAKS + TEAMS SQUEAKS for Microsoft Teams 300 Million people already use Microsoft Teams to communicate and collaborate, chat, share files, conduct meetings, ... ​ • “Centralized”, common, familiar platform • No need to install a new app Extend visibility into plant operations and drive action based on events (machine faults, drops in performance, operator call for, etc.) that demand attention. ​ • “Personalized” experience – tune in to what matters • Proven production principles – modern technology Closing the gap between office workers and frontline workers Escalating Alerts Drive action with targeted messages, workflows, and escalation rules. Shorten Response Times Receive “escalated” alerts in a Teams Chat – autom atically generated from a PLC, HMI, etc. HMI on plant floor Equipment faults from PLCs Know the status of every concerning event - clarify ownership, drive accountability and create a greater sense of urge nc y. Metrics & Data Know what’s important now by extending visibility of critical KPIs. Real-time SQUEAKS dashboard on plant floor Optimize Collaboration Concerning gaps in performance relative to goal are pushed into a Teams Chat to the right people – minimizing distractions ​ SQUEAKS Metrics & Dashboards are visible on production displays at the line and within Microsoft Teams SQUEAKS ​ Consolidate information in one place for better decision making and problem solving SQUEAKS interactive display on plant floor Find Information Faster Ask the SQUEAKS bot to find what you need to save time and know you are working with the latest information. ​ Consolidate SharePoint files, web pages (from HMI screens, etc.), Microsoft 365 files, PDF documents, video streams, etc. - in one place. SQUEAKS Browser App Access the SQUEAKS website inside of Teams. Full user Home Page access wit h integrated security.

  • MES | igear

    MES Solutions IGear Manufacturing Execution Systems (MES) Solutions are built to help you realize the value of your existing investments and accelerate digital transformation with solutions that advance product quality, traceability, and operator efficiency. IGear equips every aspect of your production line with state-of-the-art efficiency and end-to-end excellence. ​ Our MES Solutions perform a range of critical production tasks – from detecting assembly line issues and flagging quality control errors, to providing real-time data reporting and seamless integration with your independent software and hardware systems. ​ IGear MES Solutions deliver better outcomes in the areas of: ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ASSIST ensures no defects are going to leave the building while maintaining 100% traceability to satisfy customer and governmental requirements. ASSIST is a user-configurable solution that error-proofs processes while verifying operator instructions are executed properly. ASSIST integrates with ERP systems for build-to-sequence production demands and work-in-progress inventory updates. ​ SQUEAKS PI delivers real-time insight, with context, on key performance metrics such as OEE, downtime, cycle time, and quality to cite a few. SQDC boards can be quickly created and updated manually or automatically. SQUEAKS PI provides a rich set of interactive plugins for the SQUEAKS platform. Employee Productivity Traceability & Genealogy Product Quality Worker Safety Asset Utilization Production Scheduling On-Time Delivery Reduced Costs ERROR PROOFING & TRACEABILITY PRODUCTION INTELLIGENCE

  • Visual Management | igear

    Visual Management Address Problems Sooner By Consolidating Manufacturing Information SQUEAKS provides total visibility around what is important and relevant to you – consolidating real-time information from all your data sources, in one place – personalized the way you want to see it. SQUEAKS makes it easy to organize information that is updated automatically from a wide range of data sources including Microsoft products like Excel and PowerBI, video files, video streams, web pages, HMI screens, and dashboards, to cite a few. Visual Management from SQUEAKS delivers real-time information on digital FMDS touchscreen Boards as well as on low-cost, high-impact TVs that can be hung at the production line – keeping everyone consistently aware of current performance relative to your target. With SQUEAKS, total visibility is just half the story. After a performance gap or process abnormality has been identified, SQUEAKS then asks the question “Now what?”. SQUEAKS drives action – linking problem-solving activities to the problem. Corrective actions and countermeasures are mapped out, advancing collaboration, while driving accountability until the problem is solved. REQUEST A DEMO SQDC Boards Software Manufacturing “Call For ...” Mobile Andon Organize & Share Videos Mobile App for Stack Lights Worker Productivity Software IoT Software Communication Platform Real-time Manufacturing Information Manufacturing Productivity Production Efficiency Manufacturing Execution Systems Production Displays Manufacturing Software App Floor Management Development Systems (FMDS) Transforming Visual Management Boards Visual Management Microsoft Power BI + Squeaks Manufacturing Communication

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