SOLUTION PROFILE

AI-Enabled Industrial Analytics To Optimize Machine, Production and Quality Outcomes

Lumada Manufacturing Insights From Hitachi

Manufacturers face challenges such as defective products, on-time delivery slippage, excessive

scrap and rework, unacceptable equipment downtime, and supply chain disruption. As the number

of assets and production facilities increase, it becomes more difficult to diagnose and react to

these challenges in a timely and scalable manner. Such difficulties can have cascading effects on

production schedules and translate to higher production costs, lost profits, missed order fulfilment and

reputational damage. Information silos and manual data collection add complexity to making near-

real-time operational decisions.

Consider a manufacturing enterprise that needs to operate at maximum production capacity to meet

aggressive quarterly targets. It is imperative that its machines operate reliably and that parts and

materials are available at every production step, to ensure that products being made meet quality

standards. Lumada Manufacturing Insights from Hitachi leverages AI and machine learning (ML)

techniques to provide answers to these challenges, by connecting data from man, machines, method

and materials for situational awareness.

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Maximizing Profits Is Difficult Without Knowing Where Value Is LostTypically, the manufacturing plant floor is a heterogeneous environment, home to interconnected machines from different vendors, people with varying skill sets and complex supply chains. Manufacturers must prevent operational challenges, and ensure effective and efficient resolution when they occur. Irrespective of the stage of your intelligent manufacturing journey, you can address these challenges by unlocking insights derived from operational data. By combining Hitachi’s unparalleled 110+ years of manufacturing domain expertise with machine learning and artificial intelligence, you can accelerate your journey towards Manufacturing 4.0.

Derive Data-Driven Outcomes for Your Operations With AI-Powered Solutions, Provided by Lumada Manufacturing Insights

By offering end-to-end solutions that encompass sensors, connectivity, data integration, event-driven alerts, forecasts and dashboard visualization, enabled by sophisticated analytics models, manufacturing organizations are able to realize transformative outcomes. Lumada Manufacturing Insights builds on the intelligent manufacturing maturity model and empowers the digital innovation foundation essential to Manufacturing 4.0. It leverages AI and ML techniques, as well as 4M industrial analytics to provide machine, production and quality insights.

Lumada Manufacturing Insights provides answers for improving on-time delivery (planning and scheduling optimization), minimizing defective product, scrap, and rework (maximizing first-pass yield) and reducing unplanned equipment downtime (predictive and prescriptive maintenance), as well as quickly and effectively reacting to external factors such as supply chain disruptions upstream and downstream of the factory floor.

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Machine Productivity OptimizationGranular visualization of overall equipment effectiveness (OEE) in near real time allows production managers to quickly identify machine-related issues and take corrective action. Track asset availability, performance and quality for various pieces of equipment, regardless of type, vendor, model or year.

Promptly respond to issues that impact plant productivity: Stoppages (unplanned), idling and slow cycles, and rejects (startup and production).

Maximize Performance at the Plant Floor by Applying Industrial Analytics

Operational Threshold Monitoring and AlertingOperational threshold monitoring and alerting provides notification of parameter threshold-crossing events, lead- and cycle-time exceptions, degrading-quality events, anomaly detection and predictions. Timely detection of actionable events allows rapid reaction in order to take corrective action.

Rapidly respond to performance, quality and availability-impacting events.

Maximize First-Pass YieldLumada Manufacturing Insights integrates with existing quality systems to track and alert on degrading quality trends, identify dominant quality issues via pareto analysis, identify root causes based on operational parameters or raw material batches, and forecast impending quality issues.

Enable quality kaizen to minimize scrap, rework, and returns, and maximize first-pass yield.

Anomaly DetectionBy continuously monitoring production lines, Lumada Manufacturing Insights uses machine data and machine learning models to automatically detect and notify plant floor personnel of anomalies that may lead to machine health issues or quality problems down the line.

Proactively detect unseen equipment degradation even if individual operating parameters are within threshold.

●● Enable real-time situational awareness of shop-floor operations and equipment.

●● Maximize revenue by enhanced line productivity and throughput, as well as reduced cycle-time bottlenecks.

●● Optimize quality and yield via historical trending, pareto analysis and forecasting.

●● Proactively react to changing conditions on the shop floor, before issues occur or spread.

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Edge Data Collection and ProcessingConnect and filter with common industrial protocols such as OPC-UA, MQTT and MTConnect, as well as proprietary controller protocols and APIs. This enables the basic data extraction from machines and other industrial equipment, and the ingestion into Lumada Manufacturing Insights for analytics, visualization and notification.

Collect and analyze data on the edge, even in environments with intermittent connectivity.

Production Scheduling Optimization, Powered by AIApply machine learning models to data from enterprise resource planning (ERP), manufacturing execution system (MES), and machine or operator data: Quickly adapt to changing operating conditions at the plant floor, minimize changeover time, and avoid impacting customer order fulfillment.

Optimize production scheduling to fulfill customer orders, despite changing conditions at the factory floor.

of captured production data generated goes unused. World Economic Forum white paper, “Technology and Innovation for the Future of Production: Accelerating Value Creation,” 2017.

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Humans and machines working together to deliver the vision of ‘digital drilling’ is driven by our ambition to achieve transformative outcomes; drilling our best wells every time and consistently achieving Target Zero for accidents. With Hitachi Vantara, we are realizing time-to-value with industrial analytics and the powerful Lumada platform to process more than 20,000 data streams per second per rig; providing actionable information to the right people at the right time, helping make optimal decisions. This drives our operational excellence and consequently our competitive advantage. We’re leveraging insights from video and Lidar, integrating it with Lumada Manufacturing Insights to deliver business outcomes.

Shuja GorayaCTOPrecision Drilling Corporation

Hitachi Helps Manufacturing Industries Become Digitized, Smarter, More Productive and EfficientLumada Manufacturing Insights from Hitachi embodies decades of in-depth domain expertise, with 100+ years of operational technology (OT) excellence with 50+ years of IT innovations. Leveraging decades of best-in-class data science tailored to industrial challenges, Hitachi’s portfolio of software and services is second to none in delivering outcomes to organizations around the globe. From sensors, connectivity, data collection and processing, to analysis, dashboarding and alerting, Lumada Manufacturing Insights offers end-to-end solutions to manufacturers in various stages of their digital transformation. Hitachi is ready to

partner with customers in this journey.

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HITACHI and Lumada are trademarks or registered trademarks of Hitachi, Ltd. All other trademarks, service marks, and company names are properties of their respective owners.

SP-290-A BTD September 2019

Hitachi Vantara

Corporate Headquarters 2535 Augustine Drive Santa Clara, CA 95054 USA hitachivantara.com | community.hitachivantara.com

Contact InformationUSA: 1-800-446-0744Global: 1-858-547-4526hitachivantara.com/contact

Next Steps

Take Manufacturing to the Next Level with Industrial Analytics: Explore the Whitepaper from ARC Advisory Group.

Achieve better outcomes with data-driven IoT applications: Drive IoT solutions faster with Hitachi’s expertise to unify the physical and digital worlds.

Discover the Smart Road Map to Manufacturing 4.0: Visit the Infographic here.

Evaluate where you are on your digital journey: Take the Digital Readiness Survey and find out where to start.

Accelerate your digital transformation: Achieve cost efficiency, reduce time to market, increase customer loyalty and grow revenue through data analytics.

Learn more about how Lumada Manufacturing Insights improves your asset utilization, boosts quality, enhances productivity and increases on-time delivery.

We Are Hitachi Vantara Get Your DataOps Advantage, connecting data consumers with data creators. Accelerate your collaboration and digital innovation with one great solution partner.

The IoT revolution has arrived, and forward-thinking manufacturers have realized the potential of unlocking the value hidden in their data to propel the next round of innovation, operational transformation and competitive edge. Lumada Manufacturing Insights can assist you in every step of the way of your digital transformation.