1. Case Overview
- Client Industry
- Manufacturing (sanitaryware/housing equipment maker)
- Location
- Georgia, USA
- Service Implemented
- IT infrastructure construction (factory networking, wiring, and security)
2. Background
As TOTO USA launched its new factory, it needed a large-scale, future-ready network foundation covering production areas, office areas, and security systems such as video surveillance. Since the plant spans multiple floors, each combining offices, Wi-Fi, and security cameras, the design had to deliver stable connectivity, a single integrated network, and optimized construction and operating costs, all at the same time.
Client Feedback
Mr. Baba, Sr. Director of Sanitaryware Production, TOTO USA, Inc.
Demand for premium one-piece toilet units (compact designs combining tank and bowl into a single unit) has been growing in the U.S. market, with further growth expected. Rather than continuing to supply these from Asia or Mexico as before, TOTO needed a stable local production and supply base. Given the size and weight of the products, shipping costs were also a significant burden, making stronger local production a key strategic priority from a "local production for local consumption" standpoint.
3. Implemented Solution
The project covered the design and construction of the site-wide network and cabling infrastructure for the entire new plant. Key elements included:
・A floor-distributed network design
・Distribution hubs (HubBox) on each floor, consolidated via fiber optic lines back to the server room
・A hybrid fiber-optic and LAN-cable network architecture
・Centralized network management using Cisco Meraki
4. Challenges Before Implementation
Because network and infrastructure work proceeded in parallel with the plant's construction, close coordination with the building work was essential. Wiring and network installation in particular were closely tied to the general contractor's construction schedule, making it critical to clearly define responsibilities and avoid risk from scheduling misalignment.
Client Feedback
The decision to build a new plant stemmed from capacity limitations at the existing facility. That plant relied heavily on long-used, aging equipment and lacked the capability needed to manufacture premium one-piece products, particularly due to constraints on molding machine size and specifications that prevented production of larger, more design-intensive items.
Equipment and processes also fell short of the quality and productivity levels required for high-value products, making an overall review of the production system necessary.
5. Implementation Approach
Three priorities guided the rollout: cost optimization, just-enough redundancy, and construction efficiency, together delivering a practical, workable configuration.
①Cost-conscious cabling design
Reviewing wiring methods and equipment placement produced a lean, efficient setup with minimal waste.
②Redundancy focused only where truly needed
Critical areas were built for reliable, worry-free operation, while the overall system stayed simple and unburdened, balancing cost against usability.
③Cable routing designed for constructability
Wiring methods were planned around the building's construction schedule, with roles clearly divided in coordination with the construction company, shortening the timeline while maintaining consistent quality.
Client Feedback
The move to the new plant proceeded in phases, without halting production. Some equipment from the existing plant continued in use while operations gradually shifted to the new facility, maintaining stable output throughout. Because process constraints made it impractical to relocate everything at once, molding and glazing now take place at the new plant while firing remains at the existing one, linking the two facilities into a coordinated production system.
On quality control, the company tightened management of process conditions such as temperature and humidity, and introduced QR-code tracking for manufacturing data on every product, enabling faster root-cause identification when issues arise and data-driven quality improvements. Remote monitoring and control of equipment status was also built in, allowing technical support from Japan and supporting both global coordination and stable operations.
6. Results
Client Feedback
The new plant has made it possible to manufacture premium one-piece products that were previously difficult to produce, establishing a stable supply of high-value-added products. The introduction of robotics has automated part of the process, easing workloads while letting staff focus more on quality.
A system that accumulates and tracks manufacturing data for every product now supports data-driven analysis and improvement, creating an environment geared toward better quality and yield. None of this would have been possible without a stable network foundation and a system environment supporting remote data access and equipment monitoring, which also enables global collaboration including technical support from Japan. This has become a vital foundation for stable operations and ongoing quality improvement at the new plant, and we're grateful for SYSCOM's support.
7. Project Team
Project Manager: Yong Choa
Engineer: Yuki Hisata
Account Executive: Hikaru Kayamori
8. Impressions of SYSCOM
Client Feedback
SYSCOM was on-site from the earliest stages of construction, before the walls were even up, and handled everything through to network setup and installation, which was a huge help. The site presented various constraints, limited space, schedule delays, and SYSCOM's flexibility in adapting to the situation stood out.
Support in both Japanese and English also made communication with headquarters in Japan and local equipment vendors much smoother, bridging conversations effectively even for people without an IT background. SYSCOM has also continued supporting post-launch troubleshooting and follow-up, making them a partner we feel confident handing operations to.
9. Summary
SYSCOM is a comprehensive IT solutions provider delivering optimal digital solutions to address our clients’ business challenges. Our services span the entire IT lifecycle—from solution planning and consulting through implementation and ongoing operations. Supported by experts across multiple domains, we approach each challenge from multiple perspectives to deliver effective outcomes.
As in this case, we provide full support for large-scale IT infrastructure projects, coordinating carefully across many stakeholders to see projects through reliably.
Beyond infrastructure, we also support ERP and CRM implementation, data collection, analysis and forecasting, and new application development, offering broad proposals and support for clients' specific needs. If you have a business challenge you'd like to address, please feel free to contact us.