KOBELCO

Amazed that such comprehensive support would continue indefinitely - at no extra cost.
Thanks to RK, I was able to achieve my goal of "citizen development!”
We were able to save 400 hours of work annually by automating with RK.

KOBELCO introduced KEYENCE's RPA (Robotic Process Automation) tool, RK, with the aim of "citizen development" by on-site staff. In less than a year since its introduction, they have created more than 30 scenarios (automation programs), leading to an annual reduction of 400 working hours. We spoke in detail with Mr. Fujita from the Planning and Management Department who is involved in promoting RK internally, and Ms. Kubo from the QA Team of the Testing and Inspection Group who is involved in the development of RK, about the background of the introduction and the appeal of the tool.

KOBELCO

KOBELCO is a steel manufacturer established in 1911. The company develops various businesses centered on its three main pillars: the materials division, machinery division, and power division. A major feature of the company is its comprehensive strength and high competitiveness, with each business organically linked. As evidence of this, it has developed and manufactured many products with high market shares, such as about 50% of the world's wire rods for automobile valve springs and about 40% of the world's assembled and integrated crankshafts for ships.

  • Founded: June 1911
  • Capital: $1.6 billion
  • Revenue: $15.8 billion
  • Number of employees: 39,488

About 40 employees are benefitting from RK

First, please tell us about how you are implementing RK.

RK is being used within KOBELCO's Welding Business Division. There are about 40 users within the company, sharing three creator licenses and one runner license. Users are ranked based on usage frequency into "heavy users," "moderate users," and "light users." Licenses are allocated accordingly to prevent usage conflicts.

Currently, more than 30 scenarios (automated workflows developed in RK) are in operation. There are also approximately 120 scenarios currently in development.

Specifically, in my (Ms. Kubo's) role in the Testing and Inspection Group, we have automated tasks such as "issuing inspection slips" and "retrieving information from the quality management system." Previously, inspection slips were manually created, but now they are automatically issued. Additionally, the quality management system retrieves regulatory updates accurately, which is very convenient.

The primary goal of introducing RK was to achieve "citizen development" by on-site staff

Please tell us about the background for introducing RK.

Our company, being a conglomerate, has different policies and budget sizes for each business division. Due to these internal dynamics, our Welding Business Division has maintained a stance of not allocating much budget to system development, and preferred to handle everything ourselves.

In this context, another company's RPA was initially implemented before RK. However, it was difficult to operate, with limited support channels, hindering what we call "citizen development" by internal employees. As a result, RPA hardly gained traction within our Welding Business Division.

RK came into play when our ICT Planning Group Leader learned about it at an exhibition in April 2023 and shared this information with me (Mr. Fujita), noting its potential for enabling citizen development. After comparing RK with our existing RPA solution, we decided to adopt RK for the following reasons:

  • Strong user support
  • Intuitive workflow and user interface
  • No need for centralized management
  • No strict version control requirements
  • Error logging capabilities
  • Flexible license allocation
  • Cost-effective licensing and minimal implementation and operational costs

We particularly placed high hopes in the robust user support offered by RK. It seemed to us that RK could help us achieve our crucial goal of citizen development effectively.

The appeal of RK from the perspective of scenario developers

Is “citizen development” practical with RK?

Yes, even though I'm not particularly knowledgeable about computers, I (Ms. Kubo) have been able to develop scenarios smoothly without any issues. It is easier and more useful than using macros in Excel.

The interface is intuitive, so it was very easy to take an idea for automation and create a scenario from it.

From the position of having completed several scenarios with RK, please tell me about the appeal of RK as a tool.

The appeal of RK, as I (Ms. Kubo) see it, lies in two points:

Accurate and Easy Repetitive Tasks

In factory operations, there are critical tasks that if done incorrectly can have significant consequences. RK allows for easy automation of these repetitive processes and ensures accuracy, making it an ideal tool for handling such tasks.

Easy Maintenance

It's easy to understand what processes are being executed when reviewing a scenario, making scenarios very easy to modify if needed. Just recently, when we needed to irregularly input dates for issuing invoices per product, we were able to implement this functionality promptly.

Surprised by the swift ongoing support provided at no cost

How would you rate the support you’ve received while using the product?

I rate the support system higher than expected and greatly appreciate it. The responsiveness to inquiries is particularly impressive, with almost real-time responses received within a few hours. This has been rare in my experience with other companies where responses often take until the next day.

Being able to contact support directly without going through company channels is also invaluable. Previously, when I had a very general inquiry about what I wanted to achieve, they immediately set up a remote meeting. During the session, they provided guidance through screen sharing, offered suggestions for refining the scenarios I created, and showed an incredibly detailed level of support. I believe only KEYENCE provides such comprehensive assistance.

What surprised me even more was when I asked how long this level of support would continue, they assured me it would be ongoing.

Achieving a reduction of 400 hours annually through automation

It has been about one year since RK was introduced. Please share the positive effects on your processes observed during this period.

We have achieved a reduction of 400 hours annually in tasks. However, this is just the current effect. New scenarios are beginning to operate, and we have many scenarios currently in development, so I expect the impact to increase further.

Another significant benefit is the identification of business processes through "process mapping." For example, automating a workflow for generating a report, stamping it, and converting it to PDF led to questioning whether the task was necessary at all. This led to eliminating unnecessary tasks and has been very useful for understanding and organizing internal workflows.

Moreover, beyond visible effects, there are substantial intangible benefits. Engaging in repetitive tasks that anyone can do but are critical and error-prone is inherently stressful. Manual processes inevitably led to mistakes and sometimes required starting over from scratch. Being liberated from such tasks has greatly relieved stress and allowed us to focus on more complex tasks that require deeper thought and innovation.

Overall, RK has not only delivered tangible efficiency gains but also enhanced our organizational clarity and employee satisfaction.

Tips for promoting and mastering RK within the company

Please share tips for promoting and mastering RK within the company.

The key to spreading RK internally is to quantitatively analyze logs. It's highly recommended to track who within the company is using RK and how extensively, based on license usage. This information allows for immediate, flexible adjustments such as reallocating licenses based on usage frequency. Furthermore, dissecting RK usage data enables tracking automation trends across different locations. Essentially, it involves collecting data and interpreting its significance. This approach not only facilitates internal promotion but also proves beneficial for reporting to management.

As for mastering RK, a useful tip is to build it incrementally, part by part. Instead of creating everything in one go, breaking down tasks into smaller parts makes it easier to troubleshoot errors and run scenarios excluding problematic parts, thus simplifying the process.

KEYENCE's RK is a comprehensive solution that creates "citizen developers" for us

Please tell me about the future of RK at your company.

Looking forward, from the perspective of automation, our company's factories still have significant room for growth. Therefore, we believe it's essential to delve deeper into the operations of various departments and expand the applications of RK in the future. Achieving this requires increasing the number of "citizen developers" who can use RK.

Already, the ICT Planning Team has identified potential new users for RK and plans to continue seeking and increasing the number of candidates for "citizen developers" in the future.

However, with only 10 members in the ICT Planning Team, providing detailed growth support is challenging. Therefore, we place high expectations on KEYENCE's support system.

KEYENCE's support truly resembles a comprehensive service that creates "citizen developers" for us. Their responsiveness has been beyond our expectations, providing us with great reassurance. We hope to continue receiving such robust support for a long time, as it is crucial for achieving our dreams.

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