Implementation Steps

The following is an example introduction process.
Through workshops, we identify customer issues and propose a concrete implementation approach.

STEP 1Assessment

Clarification of investment priorities and goals based on KPIs

To achieve KGI (Key Goal Indicator) targets, we analyze manufacturing site conditions from multiple perspectives to clarify issues and bottlenecks.
By combining OMRON’s operational improvement expertise and technologies with the knowledge of partner companies, we quantitatively assess the current state of equipment, processes, and operations.
We identify the KPIs (process indicators required to achieve KGIs), define the gap between the current state and the desired state, and build a scenario that serves as the basis for investment decisions, leading into the next phase of system requirements definition.

Target state

  • The priority of issues to be resolved is clearly defined from both executive management and field perspectives.
  • Agreement has been reached on the direction of improvement and target values required to enhance KPIs.

Key delivered value

  • Smart factory consulting

    Translate KGIs into KPIs and define the issues to be solved and the basis for investment decisions.

  • Field interview workshops

    Organize challenges from both IT and OT perspectives and clarify investment targets.

  • Gap analysis between current and desired states

    Visualize the gap between the current state and the desired state to identify true issues and bottlenecks.

  • KPI improvement roadmap development

    Organize investment priorities and develop an execution plan for KPI improvement.

  • Definition of improvement scenarios

    Define improvement scenarios (including solutions) to address identified issues.

Assessment

STEP 2Definition of requirements

Data utilization scenarios and system design

Design specific solutions to realize the improvement scenarios required to close the KPI gaps identified in STEP 1.
Centered on i-BELT Hub, a data utilization platform that integrates IT and OT, we define an optimal system architecture that links real-time on-site data with management indicators.

Target state

  • The data items, collection frequency, and analysis methods required for KPI improvement have been clearly defined.
  • The system architecture is designed with future expansion in mind, including additional production lines and application extensions.

Key delivered value

  • IT-OT architecture design

    Organize the overall architecture required to integrate field equipment and IT systems and enable data utilization.

  • i-BELT Hub system design and definition of requirements

    Define the configuration, required functions, and data integration requirements of i-BELT Hub.

  • Interface design

    Define connection methods and data integration approaches with existing equipment and higher-level systems.

  • Application specification design

    Define application specifications required to achieve KPI targets.

Definition of requirements

STEP 3Implementation and adoption

Implementation of data solutions and establishment of KPI improvements

The solutions designed in STEP 2 are implemented in the field, and implementation of the improvement scenarios defined in STEP 1 begins.
In addition to system introduction, we establish operational frameworks that enable field personnel to autonomously execute the PDCA cycle. Through optimization of field operations, we create successful KPI improvement experiences and ensure that the framework becomes firmly established.

Target state

  • The target values agreed upon in STEP 1 have been achieved, and problem-solving effectiveness has been confirmed.
  • Data-driven operational improvements (via the PDCA cycle) have been incorporated into daily operations and are functioning autonomously.

Key delivered value

  • Implementation of systems including data collection devices

    Build an environment where on-site data can be collected and utilized.

  • Implementation of i-BELT Hub and issue-resolution applications

    Enable operations that leverage data to improve KPIs.

  • Operational process design

    Establish operating rules and improvement processes that enable field personnel to autonomously implement the PDCA cycle.

  • Field utilization support workshops

    Support field adoption and self-sustaining operation through training and improvement workshops.

  • Report verifying implementation effectiveness

    Quantitatively verify actuals by reporting KPI improvement achievements.

Implementation and adoption

STEP 4Continuation and evolution

Continuous improvement and expansion/advancement of data solutions

The results demonstrated in STEP 3 are horizontally deployed to other production lines and sites rather than remaining one-time achievements. Leveraging the scalability of i-BELT Hub (including container technologies), applications can be flexibly added to address new challenges. Site KPIs are reconnected to KGIs, enabling company-wide data circulation and management. Build resilient manufacturing sites that continuously evolve and respond rapidly to market changes.

Target state

  • Data-driven improvement activities are continuously executed across factories and sites based on standardized concepts and mechanisms.
  • KPIs and KGIs are linked in real time, enabling investment decisions and target revisions.
  • Required applications are rapidly introduced and utilized in response to market changes.

Key delivered value

  • Continuous updates and support for i-BELT Hub

    Promote long-term data utilization through ongoing operational support.

  • Dashboards for the executive layer

    Visualize KPIs across factories and sites to support rapid decision-making.

  • Support for institutionalizing and standardizing improvement processes

    Combine data with human expertise to establish and standardize continuous improvement activities.

  • Engineering support

    Support ongoing operation and advanced utilization from both IT and OT perspectives.

  • Support for introduction of additional applications

    Applications can be flexibly added as market conditions and field issues evolve.

Continuation and evolution

Enabling the alignment between “a seamless, uninterrupted production system”
and “a fast and efficient management cycle”.

Footnote:i-BELT is a registered trademark of OMRON Corporation. All other company names, product names, and related names mentioned herein are the registered trademarks or trademarks of their respective owners.
Some product photographs and illustrations used on this website include images for illustrative purposes and may differ from the actual products. The content of this website is subject to change without prior notice for improvement purposes.