世界経済フォーラム(WEF)より先進工場Lighthouseに認定された
日立大みか事業所のこれまでの取組みと今後
Past Efforts and Future of Hitachi Omika Works,
recognized as an Advanced Factory "Lighthouse" by World Economy Forum

Naohiko Irie
Senior Strategist,
Control Systems Platform Division (Omika Works)Service and Platform Business Unit
Hitachi Ltd.
© Hitachi, Ltd. 2021. All rights reserved.

1. About Omika Works
2. Past Efforts of Production Reformation
3. Challenges in Future© Hitachi, Ltd. 2021. All rights reserved.

1

Overview of Omika Works

Omika Works was established
to become a world-leading factory for total systemIbaraki
prefectureTokyo

Established1969

PlaceOmika-cho, Hitachi-shi, Ibaraki

Site area

200,000 m2 (about four times the area of Tokyo Dome)

Workers

Approximately 4,000(Including employees of Hitachi, Ltd. and affiliated companies)

Businesssummary

Manufacturing and maintenance of information control systems
for social infrastructure, etc.

© Hitachi, Ltd. 2020. All rights reserved.
© Hitachi, Ltd. 2021. All rights reserved.

2

Social and Industrial infrastructure systems by Omika Works

EnergyMobility

Industry

Generation, Transmission &Distribution control

Train operations control

Production line control

Steel
Provide products, systems, andsolutions to support all aspectsof power grid systems, frompower generation totransmission, transformation,and distribution as well as
information systems for electric
power companies to support
stable operation.

Provide operation systems to
manage high-density train
operations in a secure, safe, andreliable manner.

Provide production systems to
support high-quality, highlyreliable operations of steel mills

Water
Providing a control system thatrealizes a secure and safe watersupply© Hitachi, Ltd. 2021. All rights reserved.
© Hitachi, Ltd. 2021. All rights reserved.

3

Example of an information control system configuration
Information control systems provide stable and optimal operations on machines andfacilities in the social infrastructure
Power distribution
systems

Power generation
systems

Railwaysystems

Iron and steel
systems

Industrial
systems

Water environment
systems

Information control system
Information system server
Information system
Information system network

Monitoring terminal
Control system

Control panel

Control server

Control system network
Control panel

Control panel

Control panel

Implements components andsystem technologies
Plant (machines and facilities)© Hitachi, Ltd. 2021. All rights reserved.

4

Omika Works: Recognized as a “Lighthouse” factory
Lighthouse (Lighthouse signifies a guiding light for business organizations)⚫ In 2018, the World Economic Forum (WEF) launched a program to designate advanced factories leading the Fourth
Industrial Revolution as “Lighthouse” factories, in order to spread information about advanced efforts and to encouragecompanies to depart from the pilot phase.
⚫ 44 factories were recognized as a Lighthouse factory in January 2020, and 10 factories in September 2020.

First Lighthouse factory in Japan!

WEF recognized Omika Works as a Lighthouse factory(announced on January 10, 2020)

Excerpt from the WEF White Paper

Source: White Paper Global Lighthouse Network : Insights from the Forefront of the Fourth Industrial Revolution© Hitachi, Ltd. 2021. All rights reserved.

5Evaluated Points for Lighthouse Factory
12

3

4

5

Hardware design
and manufacturing

Software designand development

System testing

System operation andmaintenance support

Factory utilities

Highly efficient
production model

Autonomous
decentralized
framework

Comprehensive
system simulation
environment

Cyber defense drill
Environmental
testing facilities and energy management
stable operationservice

After delivery,
provide support forsafe and reliableoperation

Reduce production
lead time by 50%

Applied to 4,000
infrastructure
systems

Enhanced BCP usingPV, battery and FEMS

After delivery,
provide support forsecure operation© Hitachi, Ltd. 2021. All rights reserved.

6

1. About Omika Works
2. Past Efforts of Production Reformation
3. Challenges in Future© Hitachi, Ltd. 2021. All rights reserved.

7

Accomplishment of Omika Works so far

2020'18'11'10

Selected as WEF Lighthouse

Linking warehouse and production
Automatic transport robot

Dynamic response to production changes
Factory Simulator

Digitalization of assembly instructionsAssembly Navigation'05

Digital computerization of manufacturing sites
RFID implementation'98

Design, production processes reform© Hitachi, Ltd. 2021. All rights reserved.

8

Contribution to International Standardization Initiatives
IEC Market Strategy Board“Factory of the future”

Crowd Manufacturing
Engineering

Human Resources

MethodPeopleMaterials
AssetsMaterial

PeopleAsset

Crowdsourcing
Platform

Asset

Material

Concept

MethodFactory A

Factory C

PeopleMaterial

PeopleMaterial

Asset

MethodAsset

MethodFactory B
PeopleMaterial

Asset

MethodSecurity H-ARC
Cyber-attack
Terroristattack

Omika Works

Theft of electric
power or waterSystem layer

Human error

Natural disaster

Fault
Cyberspace

Ongoingmeasures

Physical world
Operation and management
EnergyMobility
Water

CoordinatedmeasuresRef. IEC - White Paper > Factory of the future

Organization

Manufacturingsystem

Exercises
Defense, detection
Countermeasures (damage limitation)
RecoveryConcept

Quick ResponseTime© Hitachi, Ltd. 2021. All rights reserved.

9Manufacturing floors of Omika Works: 20 yeas ago and now

20yearsago?

!

?

Started to organize shop floor andto streamline flow of materials and people
Now© Hitachi, Ltd. 2021. All rights reserved.

10Current Production System for Assemble Line of Control Panel
Think
Information

Knowledge and model

Progress andoperation monitoring

Support forwork improvement

Assembly navigation

Factory simulator

Discovery assistant
CAD

Identify the production
progress and results

Analyze and address
bottlenecks

Improve quality andefficiency of work

Carry out work levelingand resource leveling

Automatically detectdesign defects

Bottleneck work

Sense
RFID
Movements/results

Electronic
instructions

Loading

Leveling

Displayguidance
Detected!

Act

Shop floorVideo footageof work
RFID

RFID

RFID

Wiring line for control panel assembly© Hitachi, Ltd. 2021. All rights reserved.

11Current Production System for Assemble Line of PCB
ThinkInformation

Make 4M data visible and collect it.
Combine data to create new value

Knowledge and model

Production progress andoperation monitoring

Operation results
analysis

Inventory management

Facilities maintenance

Defects analysis

Make visible deviations between
production plans and results,
as well as the status of machines

Analyze bottlenecks,
machines and work

Manage parts inventory ofwarehouses and mounters

Provide guidanceon maintenancefrom running machines

Provide guidance information
about defects and solutions

Design log

Design log

SenseCollect 4M data from production shop floors
Identify activities in real time

Automaticplacementof order forelectronic parts

Shop floor

Maintenance andplacement of orders
for spare parts

Act
Combine high-value added data andknowledge, analyze problems,develop solutions, and provide
feedback to the real world

Production line for printed circuit boards© Hitachi, Ltd. 2021. All rights reserved.

12Moving Forward for Reformation

Driven by IT Evolution
Resolvethe next problem

Goal 3

Step 3
Resolvethe next problem

Goal 2

Step 2

Prepare dataResolve
one problem

Goal 1

Step 1CreativeUse of data Collection ofmeasurestechnology
and ideas 1313
information© Hitachi, Ltd. 2020. All rights reserved.
© Hitachi, Ltd. 2021. All rights reserved.

13

Moving Forward for Reformation⚫ Provide funds, organize teams, and assign right persons
just pay lip service.)
Machine performance (Don’tand tools
are constantly improving⚫ Praise good points and improve
Resolvethe next problem

Management

Goal 3

Step 3
Resolvethe nextproblem
The shopfloorsays “No.” Step 2

Prepare data

They do not accept
our solutions.
Resolve
one problem

Shop floor

The 1performance
Goalis poor.

Goal 2Fix problems
whenever they arise

Step 1

Solutions might not work out
in the beginning

Use of data Collection of Creative measurestechnology
and ideas
information© Hitachi, Ltd. 2020. All rights reserved.
1414© Hitachi, Ltd. 2021. All rights reserved.

14

1. About Omika Works
2. Past Efforts of Production Reformation
3. Challenges in Future© Hitachi, Ltd. 2021. All rights reserved.

15

Coming VUCA Era

Rapid shift tocarbon-free society

Disasters, Pandemic

Global supply chain
division

Meteoric progress ofdigitalization© Hitachi, Ltd. 2021. All rights reserved.

16Omika Works’ Challenges

CO2 Emission

０Ideally(Internal target by 2030)

Employee workplace
occupancy30％～(COVID-19 impact)

Procurement ofelectronic components
Lead time

2 times～(Disaster, supply and demandbalance)

Number of OSS used in
the product３times～(Actual results at our work)© Hitachi, Ltd. 2021. All rights reserved.

17

Approach to address challenges

Ecosystem

Acquire“Unexpected” changes occur

Dynamic
Capability

ClientSupplier

Omika Worksof future

Supplier

ClientSense - Seize - Transform
Supplier

TraditionalOmikaWorks
Correct internal changes＝Ordinary capability

for External changes

Technology
Partner

Collabcompany

ChannelCollabcompany© Hitachi, Ltd. 2021. All rights reserved.

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In pursuit of acquiring dynamic capabilities
Eco-friendly factory

People building factory• Use of green parts• Optimal operation of equipment(energy-saving)

Assign from a long-term perspective
Multi-skilled work

Omika Works
Collaborativecompany

Partner

Supplier

ClientPlatformContinuous operating factory• Visualization of supply chain production status• Quick optimal scenario planning using AI

Employee

Continual value providing
factory
Monitor the status of client equipment© Hitachi, Ltd. 2021. All rights reserved.

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DX platform for acquiring dynamic capabilities
ChangeImpactAction

SENSE

SEIZE

TRANSFORM

Parts procurement
fluctuation

Client site
incidents
Data Utilization
Platform

Quality variation

Maintenance

Procurement

Client sites
DBOmika Works

Quality
Assurance

Supplier

Supplier,
Collaborative company

Engineering Manufacturing
QA results
Document
history
DBDBDB

ManufacturingParts
DBEngineering

Suppliers
DBClient© Hitachi, Ltd. 2021. All rights reserved.

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END
Past Efforts and Future of Hitachi Omika Works,
recognized as an Advanced Factory "Lighthouse"
by World Economy Forum
Naohiko Irie
Senior Strategist,Control System Platform Division
Services & Platforms Business Unit
Hitachi, Ltd.
© Hitachi, Ltd. 2021. All rights reserved.

21