Lumada Manufacturing Insights: Laying the foundation for Manufacturing 4.0

By Hubert Yoshida posted 09-15-2019 17:44


The vision for Manufacturing 4.0 is a “smart factory” where modular “smart factories” use “smart machines” to monitor physical processes, create a virtual copy of the physical world and make decentralized decisions. “Smart machines” will communicate over the Internet of things and cooperate with each other and with humans in real time. Interconnectivity will allow operators to collect an immense amount of data from all points in the manufacturing process and combine it with supply chain and business data to make the whole organization more efficient and identify areas for improvement and innovation. 

While the vision of Manufacturing 4.0 is still not here today, much of the base technolog is available, and some companies have made significant progress. However, a recent survey of 275 global respondents by LNS Research, showed that only 8% were able to show any real success in terms of business benefit. Some of the major inhibitors are:
  • Lack of connectivity: 69 million machines in factories with 90% not connected.
  • Large legacy: 70% of machines are over 15 years old.
  • Vendor lock-in
  • The shop floor has a large variety of machine types that speak proprietary protocols
  • Data from different departments sit in silos.
  • 88%of survey respondents list Uncertain ROI” as the largest only nontechnical barrier 
  • Most projects fail due to lack of understanding of OT business and too much focus on technologies

Most factory and manufacturing processes are not ready for Manufacturing 4.0 due to the reasons above and not due to the lack of technology. So where do we start? Hitachi Vantara introduced Lumada Manufacturing Insights, an application platform to help manufacturers use data and analytics to improve efficiency, productivity and quality and help them on their journey to Smart Factories and Manufacturing 4.0. Lumada Manufacturing Insightsis a modern software platform that was created to address the problems of legacy infrastructure and disconnected software and processes that slow innovation and impact competitive advantage. With Lumada Manufacturing Insights, customers can lay a foundation for digital innovation that works with the systems and software they already have while providing the agility to incorporate new technologies and processes. This builds on an intelligent manufacturing maturity model and empowers the digital innovation foundation essential to Manufacturing 4.0. Leveraging DataOps, digital twin, AI and ML techniques, 4M (Machine, Man, Material and Methods) and Industrial Analytics to provide machine, production and quality insights that drive transformational business outcomes. 

It encapsulates deep domain expertise and packages data science rigor to catalyze root-cause analysis driving continuous improvement opportunities based on predictive and prescriptive analytics. The solution integrates with existing applications and delivers actionable insights, without the need for expensive and disruptive rip-and-replace. Leveraging Hitachi’s Operational Technology (OT) experience and enterprise-class Information Technology (IT) prowess, manufacturing customers can operationalize digital innovation in a platform agnostic, secure, and with an edge-to-multi-cloud deployment approach. 

This first release of Lumada Manufacturing Insights will deliver the foundation for this maturity model by providing connectivity and eliminate the silos of data with DataOps tools to consolidate different vendor machine types and integrate data from different departments.  Hitachi DataOps will help to create digital twins, which are software models based on data gathered from machine sensors. This allows companies to monitor machines and discover trends and patterns to feed larger digital twin models. They can provide detailed information about large collections of key assets. With digital twins you can do predictive maintenance to improve performance and reduce costs over scheduled maintenance. This allows you to plan rather than react and quantify an ROI. Hitachi’s vast OT experience will help to solve the problem of older machines, by adding sensors where needed to include legacy machines in the creation of digital twins.

Hitachi has created a hierarchical digital twin structure starting from the components of an asset, to the system the asset is part of, and to the process as a whole. While the component, asset, and system digital twins show the operational characteristics, the process digital twin shows the business characteristics. This hierarchy provides unique attributes and monitors them across different types of digital twins and informs us about different aspects of the whole. IT can also provide persona dashboard views of attributes that are relevant to their areas of interest, from the company manager to the maintenance tech. There is full transparency and one source of truth.

Lumada Manufacturing Insights will deliver Industrial Analytics for machine, production and quality insights out of the box. Hitachi’s DataOps advantage will provide the connectivity, integration and curation of data that will ensure that the right data is available at the right time to the right consumers and stewards of that data. This will drive transformational business outcomes while It lays the foundation on which to build smart factories and Manufacturing 4.0.

This is just the beginning. As vendors open up their interfaces and collaborate and co create with customers and partners we will see more progress toward Manufacturing 4.0, based in these foundational Insights.