The Chinese Version of Industry 4.0 Using IoT and Big Data - A Case Study of INESA

Under the strategic concept of "Made in China 2025" (also known as the "Chinese Version of Industry 4.0") that has been promoted by the Chinese government since 2015, INESA Group, a large-scale, state-owned company, has been working to provide smart city solutions. INESA Display Materials Co., Ltd. (INESA Display), an INESA Group company that has long manufactured color filters for LCDs (liquid-crystal displays), is promoting the use of IoT and big data together with Fujitsu.

Taking on the Challenge of Transformation as a Model Factory in a Smart Manufacturing Project

INESA Group has been in the electronics manufacturing industry for more than 50 years. INESA Display was selected as a model factory for the Smart Manufacturing Project under the Made in China 2025 plan, and it is working to achieve digital transformation. To adapt itself to a new era, INESA Display, while continuing to manufacture, is also driving the development of information industry, and it has established a strategic goal of helping build smart cities as part of its business model, thus working to create a new industry that fuses ICT with manufacturing.

(Left) Automated manufacturing line; (Right) Automated factory with almost no employees

Processing and Analyzing Vast Amounts of Data in Real Time

INESA Display has made numerous efforts to use IoT and big data. Thus, it holds vast amounts of data on facilities, the environment, manufacturing processes, and so forth as well as generates hundreds of thousands of data items per hour. The biggest challenge for the company is to find ways to efficiently collect data and make full use of such data when making decisions on issues and carrying out improvement activities.

Using Fujitsu's unique intelligent network communications technologies, INESA Display has alleviated the slow speed and instability of communications in its existing large-scale network by building a low-cost system to automatically collect plant energy consumption data, including information on electricity, water, and gas. This system aggregates and centralizes manufacturing progress data collected through sensors and other IoT devices. To process and analyze the accumulated big data in real time while maintaining a high level of security, a big data analysis platform was built that enables warning signs of problems in manufacturing equipment to be detected.

Overview of the newly installed system

Visualizing the Factory's Overall Production Efficiency

Information collected and processed by the big data analysis platform is displayed in nearly real time on the Intelligent Dashboard (FUJITSU Enterprise Application Intelligent Dashboard). This system shows important KPIs, such as manufacturing, facility status, quality, and energy consumption. At the same time, it monitors the statuses of production lines, thus visualizing the factory's overall efficiency.

FUJITSU Enterprise Application Intelligent Dashboard

Tackling Issues Speedily and Making Improvements Aptly

INESA Display has worked to visualize the data collection process using its own originally developed dashboard. By introducing new systems, including Fujitsu's Intelligent Dashboard, processing that used to take at least 10 minutes has been substantially shortened, and factory-wide operations are visualized in nearly real time. As a result, managers can now speedily make apt decisions on issues and improvement activities by simultaneously checking videos of manufacturing lines in the factory against the Intelligent Dashboard visualization screen without having to make checks around the large factory. This greatly improves production efficiency and product quality.

As strategic partners, INESA Group and Fujitsu will spread this successful model to more manufacturing companies in China, working together to achieve the goals of "Made in China 2025" while continuing to contribute to the digital transformation of China's manufacturing industry going forward.

(Left) INESA's originally developed conventional dashboard; (Right) Video feeds of manufacturing lines displayed by Fujitsu's Intelligent Dashboard