Case Study: DAIHEN improves transformer quality and reduces manual inspections with FogHorn

DAIHEN automates production of industrial transformers, improves materials quality monitoring and worker collaboration

DAIHEN Corporation, a $1B industrial electronics manufacturer, needed better visibility into factory operations to modernize production of industrial transformers. Heavy regulatory requirements, 200+ manual inspections per transformer, and manual data entry were slowing throughput, reducing quality visibility, and making real-time quality and efficiency monitoring difficult. To address this challenge, DAIHEN turned to FogHorn’s edge computing software.

FogHorn, working with Energia Communications, deployed FogHorn Lightning and VEL real-time analytics with new RFID tracking and sensor infrastructure to automate data collection, cleanse noisy data, and analyze production and environmental conditions in real time. The result was a centralized operational view, faster quality inspections, and less manual logging: within six months DAIHEN had covered 70% of the factory, saved 1,800 hours per year, and expected to reach 100% coverage and 5,000 hours in annual savings.

DAIHEN Corporation

Ichiro Yamano

Executive Officer, Innovation Task Force Team