Omika Works Quality Assurance Operations DX Promotion Project: Digitalization of quality assurance to improve operational efficiency and reliability

Hitachi is currently using Digital Paper.

Digital transformation has been progressing in various industries in recent years, but in quality assurance work, where quality assurance is the main mission, reliability is emphasized over efficiency, so new methods cannot be adopted unless the risk of quality degradation is completely eliminated, and digital transformation has generally been delayed. However, with concerns over a decline in the productive labor force, it is urgent to balance quality assurance with efficiency. Hitachi's Omika Works has therefore conducted a demonstration experiment of the digitalization of six quality assurance tasks, and some of them are now in full operation.

The "gleaning" spirit eliminates the risk of human error

Hitachi's quality assurance department performs quality assurance for the control panels that support social infrastructure such as water supply and sewerage, power plants, substations, steelworks, and transportation, as well as the monitoring and control systems that combine them. When a Product is completed, we check that it has been manufactured according to the drawings, and after installing it at the customer's site, we conduct a test run to confirm that the performance is being met.

Any work done by humans has the risk of human error, but in the quality assurance department, which handles quality assurance tasks, even minor mistakes can become the cause of major problems, and must be thoroughly eliminated. Therefore, an initiative was started using IT tools rather than relying on people. This project is called the "Quality Assurance Digitalization" project.

Hitachi has inherited the spirit of "gleaning from failure," which means "gathering experience from failure" to thoroughly prevent the recurrence of failure. The company's DNA is strongly rooted in the company's focus on keeping promises to customers from their perspective and thoroughly investigating the cause of a problem until it is essentially solved. Based on the premise that "people cannot avoid making mistakes," how can we thoroughly eliminate the risk of human error? This project can be said to be the creation of a system born from Hitachi's corporate culture.

Hitachi, Ltd. Control Platform Quality Assurance Division Control Platform QA Center Process Management Group

Six initiatives to improve efficiency while ensuring quality

The "Quality Assurance Digitalization" project involved six initiatives aimed at strengthening quality compliance, improving Productivity, and enhancing on-site activity.

Shift from paper to electronic data, centralize management of quality records

The purpose of introducing the inspection and Quality Control system in ① is to reduce costs in inspections and strengthen risk management and compliance. Paper documents have been replaced with electronic data, and on-site activity has been changed to using tablets. (Full-scale operation will begin in fiscal year 2023)

Simplify Stock Taking by using smartphone apps

The purpose of introducing the RPA tool in ② is to streamline routine work. For example, in the case of small fixed asset Stock Taking, we have streamlined several routine tasks, such as introducing a system that reads the two-dimensional codes on Stock Taking items using an iPhone photo app. (Full-scale operation will begin in fiscal 2024)

Strengthening compliance through automated measurement and data management

③ The system that automatically acquires quality inspection data automatically acquires measurement data and stores it in a management system, reducing compliance risks such as clerical errors while improving the efficiency of inspection work (full-scale operation from fiscal year 2022).

Generative AI makes knowledge utilization faster and more advanced

④ The knowledge information search system using generative AI instantaneously performs the activity that was previously done by searching through numerous standards and regulations. It can also handle complex matters such as presenting accumulated knowledge and know-how (currently under development).

Electronic paper improves inspection quality

The system that uses electronic paper to improve inspection quality and visualize activity(⑤) has been in full operation since fiscal year 2024. Inspection quality has been improved by utilizing the automatic detection function for missed checks on drawings.

Smart glasses improve activity efficiency

The ⑥ smart glasses display information such as activity instructions and drawings on eyeglasses-like eyewear. With smart glasses, you can activity while checking necessary information such as activity instructions in real time. You can concentrate on activity without having to go to the location of the drawings or hold the drawings in your hands.

Measures taken when introducing electronic paper that changed the atmosphere on-site regarding digital transformation

Of the six initiatives introduced above, electronic paper is the one that is being actively used for practical application. While retaining the ease of use of paper, the automatic check omission detection function can eliminate "human check omissions," and has many other benefits, such as cost reduction by going paperless and visualization of activity by managing information in real time (progress check).

When introducing e-paper, one of our concerns was that people would reject the idea of giving up the "goodness that only paper has." For example, the surface of a regular tablet is smooth, and the touch feels different to paper, which was a little unnatural. We were worried that this alone would discourage people from using it. However, e-paper reproduces the feel of paper, so there is no problem with the comfort of writing on it. It is also lighter than a tablet, making it easier to handle on-site, and the initial cost was about half that of a tablet, making it easy to introduce.

The e-paper introduced here is being developed in collaboration between E Ink Holdings Inc., a pioneer in the field, and its subsidiary Linfiny Japan, along with Hitachi (Omika Works and Research Laboratory). Equipped with a 4096-color 13.3" flexible color e-paper display using E Ink's cutting-edge technology, the e-paper terminal has built-in NFC and can be used continuously for long periods of time with ultra-low power consumption. Document management between host systems and multiple e-paper devices is possible through pen input that meets the needs of manufacturing sites and cloud/on-premises system integration using Linfiny's DCSS (Digital Paper Control Server Software).

Masahiko Niioka, who promoted this project, talks about the struggles he faced at the time to overcome the resistance of the people on-site. "We first explained the benefits of the system, such as the ability to automatically check for missed checks and record activity and activity content in chronological order. At first, we had people use it as a personal notepad and schedule manager, so they could see for themselves how good it was."

Currently, activity are feeling the benefits of not having to carry a lot of documents with them when they go to the site, but there are still areas for improvement, such as the fact that the pages cannot be turned over like paper and multiple pages cannot be viewed at the same time. This is a task for the future.

Reasons for progress in digitalization of quality assurance

Hitachi Group has a research laboratory that pursues cutting-edge technology on a daily basis. Many demonstration experiments, like this one, begin with a proposal from the laboratory saying, "We have this technology. Want to try it out?" This project progressed smoothly thanks to the joint trial and error between the R&D department and the field.

Hitachi will continue to promote further business improvements through digital transformation initiatives that transcend departmental boundaries.