Manufacturing of drive components for forklifts
from Japanese
The client is a Japanese FDI manufacturer operating in the field of high-precision mechanical components for forklifts and material-handling equipment, located in Thang Long Industrial Park (Dong Anh, Hanoi). The company is part of the manufacturing ecosystem of a Japanese industrial group under the Sumitomo network and is integrated into the global value chain of NACCO / Hyster-Yale, one of the world’s leading forklift manufacturers. Within this supply chain, the client serves as a Tier 1–2 supplier, producing critical components for drivetrain and control systems. The company’s product portfolio includes gears, drivetrain assemblies, control units, and precision-machined components that directly support torque transmission, motion control, load stability, and overall operational reliability of forklifts. With manufacturing processes aligned to Japanese standards—covering machining, heat treatment, and automated quality inspection—the client exports products to high-demand markets such as the US, Europe, and Southeast Asia. The factory operates under a continuous production model, supported by heat-treatment lines and automated inspection equipment. The production process strictly follows Japanese quality-management standards, ensuring full traceability and maintaining product stability. As a key link in the international supply chain, the client plays a strategic role in providing drivetrain and control components for global forklift manufacturers—demonstrating the scale, complexity, and high standards of its manufacturing operations.
Establishing a real-time monitoring system to accurately capture machine run/stop status.
Eliminating manual paper/Excel recording to reduce delays and human errors.
Automating error detection and classification for more reliable downtime insights.
Ensuring consistent, standardized operational data for faster reporting.
Improving alert responsiveness to prevent missed incidents and reduce unplanned downtime.
Providing a clear data foundation for performance analysis and decision-making.
Before implementing NxFactory, the client encountered several operational bottlenecks:
No accurate visibility into machine running and downtime status.
Manual error logging led to slow, inconsistent and incomplete data.
Downtime reasons were unclear, making root-cause analysis difficult.
Paper and Excel records caused reporting delays and fragmented information.
Late awareness of abnormalities prolonged machine stoppages and affected output.
To address these issues, NxFactory deployed a real-time machine monitoring system that digitized the entire operation, replaced manual data logging and enabled accurate performance tracking across all production lines.
Real-Time Machine Monitoring : NxMES continuously tracks run time, stop time and error states for all machines, allowing supervisors to detect abnormalities instantly and respond faster.
Automated Error Logging & Categorization : Every downtime event is automatically recorded and assigned a clear error category, eliminating manual logging and reducing inconsistencies.
Digitized Production Data Flow : Operational data is captured directly from machines instead of paper or Excel, ensuring accuracy and enabling timely reporting.
Performance & Downtime Visibility : The system provides clear insights into cycle time, downtime distribution and line efficiency, supporting root-cause analysis and performance improvement.
Instant Alerts for Abnormal Events : Supervisors receive immediate notifications when a machine stops or exceeds thresholds, reducing reaction time and limiting unplanned stoppages.
Standardized Reports : Daily and shift-based reports for each machine are automatically generated, ensuring consistent, reliable data for decision-making.
31
Machines centrally monitored
90%
Manual logging eliminated
21%
Downtime reduction after 6 months
Centralized and Transparent Data Management : A unified monitoring system delivered accurate, real-time visibility into machine status and downtime causes. Managers gained reliable dashboards for performance tracking and rapid decision-making, eliminating fragmented paper/Excel reporting.
Maximize Efficiency : Automated data capture removed 90% of manual logging. Machine availability improved, and overall downtime decreased by 21% within 6 months, stabilizing cycle times and enhancing productivity across shifts.
Enhanced Connectivity : A total of 31 machines were fully connected and synchronized, enabling consistent data flow, standardized reporting and smoother coordination between operators and supervisors.
Real-Time Alerts & Predictive Response : NxMES instant alerts helped supervisors detect abnormalities earlier, shortening reaction time and reducing unplanned stoppages. Continuous visibility enabled quick root-cause identification and strengthened operational stability.