Hitachi Global Storage Technologies Wins
Managing Automation 2007 Progressive Manufacturing Award

Processes Improved and Best Practices Shared
Hitachi’s once-isolated manufacturing sites now operate under common processes and standards.  Top performers can share best practices with the other sites, and the improved processes can be easily implemented using Camstar’s MES.

Manufacturing IT is more streamlined and effective because it supports a single, configurable MES.  Knowledge and procedures are transferable to all sites, and upgrades and improvements can be applied throughout the organization in a timely manner.  The total cost of system ownership is lower, and the value delivered is higher.

Lower Cost of System Ownership
Deploying Camstar’s MES was remarkably cost-effective.  Because the project team worked at all sites and could use established knowledge, and because the manufacturing model in the system was easily transferred to each site, the cost of roll-out to each subsequent factory was at least 30% to 50% lower than the first.

Hitachi’s decision to implement Camstar’s MES solution in all sites has strong long-term advantages.  It eliminates the many variations and skills required to use and support the application. It allows Hitachi to develop excellent collaborative and financial partnerships with its choice vendors. 

Tools for Continuous Improvements
Manufacturing sites now have the tools they need to quickly make process, product and efficiency improvements.  The sites report specifically that:

• Detailed and consistently accurate visibility of WIP, components and test results improved inventory accuracy and planning functions
   
• Integration with SCADA and ERP (SAP) systems eliminated manual and double data entry, allowing operators to focus on manufacturing
   
• Visualization of asset (equipment) utilization helped reduce lead times

Quickly configuring new products and processes in the manufacturing model facilitates ramping new product introductions to volume – a necessary requirement in an industry with rapidly changing technology and high customer expectations.

The Hitachi Project
At five manufacturing facilities located throughout the world, Hitachi manufactures hard disk drives (HDDs) at the rate of 160 million units per year.  Rapid growth is expected in the next few years due to high demand for storage not only for business use but also for consumers who want to store more and more video, photos and music.

Hitachi’s various manufacturing sites are widely dispersed globally.  Before implementing Camstar’s MES, the plants used different systems, many of which were developed internally, and whose varying capabilities were strong in some areas and weak in others.

It is important to note that the deployment in each site had to be complete and reliable, as it replaced existing systems that the plants depended on.  Production down time was not an option.  The new and old systems ran in parallel for a short time until data accuracy was verified and the required high-transaction volume was proven.

Camstar’s MES is installed at each site for optimal performance, appropriate autonomy and ease of integration with the SCADA systems.  Each site also integrates Camstar’s solution with the corporate ERP system, SAP.

The Payoff
Hitachi has realized benefits in the rich functionality of Camstar’s MES with streamlined and efficient manufacturing and assured high quality products; all of which has reduced expensive scrap and rework, and shortened cycle times. Hitachi has gained real-time visibility and control necessary to optimize production processes across multiple unique manufacturing sites.  Camstar’s MES enables the organization to rapidly implement new products and changes to the manufacturing process. Standardized process definition and management make it possible to quickly increase volume by rolling out and scaling new processes globally. The natural outcome is increased customer satisfaction.