HAI is a real-time process manufacturing data hub—a first-of-its-kind cloud platform for integration, contextualization and visualization of process manufacturing data. It combines high frequency time-series data with contextualized event-data.
Sourced with plant- and operations-data from any source, the system provides real-time and historic information that is contextualized, thus immediately meaningful and actionable.
The platform includes a powerful logsheet generator for visualization that is unique in its kind. It allows users to define and maintain their own smart logsheets without the help of IT-specialists.
Logsheets that present the automatically collected data, along with manual data-entry facilities, and automatic data calculations for reporting, KPI’s and AI-applications.
HAI is a real-time process manufacturing data hub—a first-of-its-kind cloud platform for integration, contextualization and visualization of process manufacturing data. It combines high frequency time-series data with contextualized event-data.
Sourced with plant- and operations-data from any source, the system provides real-time and historic information that is contextualized, thus immediately meaningful and actionable.
The platform includes a powerful logsheet generator for visualization that is unique in its kind. It allows users to define and maintain their own smart logsheets without the help of IT-specialists.
Logsheets that present the automatically collected data, along with manual data-entry facilities, and automatic data calculations for reporting, KPI’s and AI-applications.
NextGen Logsheets
Types of Data:
✔ Automatic data collection
✔ Real-time & historical data
✔ Raw data & calculated data
✔ Manual data entry
Logsheet capabilities in short:
✔ Real-time monitoring
✔ Compliance against specs
✔ Easy filtering historical data
✔ Custom logsheets per user
✔ Interactive
✔ Mobile devices
✔ Easy to configure/maintain
✔ Unlimited #logsheets
Logsheets
Data
✔ Automatic data collection
✔ Real-time & historical data
✔ Raw data & calculated data
✔ Manual data entry
Logsheet capabilities
✔ Real-time monitoring
✔ Compliance against specs
✔ Easy filtering historical data
✔ Custom logsheets per user
✔ Interactive
✔ Mobile devices
✔ Easy to configure/maintain
✔ Unlimited #logsheets
Examples of Logsheets for the Production Departments
• Automatic data collection of process control factory data (SCADA), incl. weighing scales, counters, in-line sensors, etc.
• Real-time logsheets for each operator work station throughout the factory, showing compliance of process conditions (e.g.: CCP’s like temperatures) and quality measurements (like pH or visco measurements)
• Operator manual data entry for:
◦ Start-up checklists
◦ CCP/OPRP/QCP checks
◦ Downtime allocation
◦ In-process quality control measurements
◦ Comments on anomalies
◦ Hourly controls
◦ etc.
• Real-time monitoring of process and quality compliance against specs:
◦ Ingredients quantities
◦ Output volumes
◦ Adherence to plan
◦ Energy consumption
◦ Water consumption
◦ Waste water monitoring
◦ Cleaning (CIP)
◦ etc.
• Operator Decision Support (adjustment advices):
◦ Statistical Process Control
◦ Advanced Process Control
◦ Artificial Intelligence
• Real-time Weight-control of end-products
• Connect to Inspection Lot in ERP-system & MES
Examples of Reports & Analysis for the Production Departments
• OEE Performance Reports, Downtime Analysis
• Continuous Improvement Reports & Analysis
• Daily Management System Reports
• Shift Report
• Statistical Process Control
• KPI reporting for OEE, Yield, Quality, Energy/Water Cnsumptions, Waste Water Treatment, etc.
• Environmental control records
• Statistical Process Control
• CIP (Cleaning) Reports
• Process anomalies
• Advanced Analysis and A.I./Machine learning for Process Optimization
Examples of Logsheets for the Quality Departments
• Operator Decision Support (adjustment advices)
• Automatic data collection from lab instruments, incl. weighing scales, in-line sensors, and metal detection.
• Combine lab test results with operator quality inspections and in-line measurements.
• Record laboratory test results for:
◦ Raw materials
◦ In-process quality checks
End-product quality tests
◦ Sensory measurements
• Exernal lab:
◦ Automated sample handling
◦ Test results in logsheets (to combine with other quality test results and process data)
• Inspection rounds for:
◦ Environmental monitoring
◦ Glass inspection
◦ Other internal audit rounds
• Sampling plan
• Connect to Inspection Lot in ERP-system & MES
Examples of Reports & Analysis for the Quality Departments
• OEE Performance Reports
• Continuous Improvement Reports & Analysis
• Daily Management System Reports
• Positive Release, COA, Digital Batch report, E-mark reports (weights).
• Statistical Process Control
• Track & Trace & Complaint Investigation
• Audit compliance
• AQL reporting (Acceptable Quality Level)
• Weight control end-products
• Batch records
• CIP Reports (Cleaning)
• Process anomalies
• Advanced Analysis and A.I./Machine learning for Process Optimization
Examples of Logsheets for the Technical Department
• OEE Performance monitoring in real-time
• Logsheets provide input for:
◦ Predictive Maintenance
◦ Condition Based Maint.
• Reliability engineering
Examples of Reports & Analysis for the Technical Department
• OEE Performance Reports & Downtime Analysis
• Continuous Improvement Reports & Analysis
• Daily Management System Reports
• Statistical Process Control
• Process anomalies
• Advanced Analysis and A.I./Machine learning for Process Optimization
Examples of Logsheets for Continuous Improvement & Process Technology
• OEE Performance monitoring in real-time
• Operator downtime allocation
• Real-time KPI compliance monitoring
• Continuous Improvement: Easily provide Summarized data (KPI’s) along with Underlying data (which often explain the reason for improvement or deterioration).
• Process monitoring (real time anomalies)
• Connect to Inspection Lot in ERP-system & MES
Examples of Reports & Analysis for Continuous Improvement & Process Technology
• OEE Performance Reports & Downtime Analysis
• Continuous Improvement Reports
• Daily Management System Reports
• Statistical Process Control
• KPI reporting for OEE, Yield, Quality, Energy/Water-consumptions, Waste Water Treatment. etc.
• Mass balance
• Root cause Analysis
• Golden batch analysis
• Define & Analyze optimum process settings to obtain max. yield and quality
• Process anomalies
• Advanced Analysis and A.I./Machine learning for Process Optimization
Examples of Logsheets for Utilities
• Automatic Data Collection of detailed energy consumptions
• Automatic data collection of water levels / consumptions
• Automatic data collection of Waste Water Treatment details
• Real-time feedback on actual information re. Eergy consumptions, Water management and Waste Water treatment data
Examples of Reports & Analysis for Utilities
• Continuous Improvement Reports
• Daily Management System Reports
• Analyze Waste Water Treatment data in relation with process conditions and product quality
• Analyze energy consumption in relation with process conditions and quality
• Analyze water consumption in relation with process conditions and product quality
• Process anomalies
• Advanced Analysis and A.I./Machine learning for Process Optimization
HAI provides the shortest way from a scattered IT/OT landscape to an integrated holistic view for each workplace and each purpose.
A key success factor of HAI is the simplicity and speed of implementation through the availability of the user-centric logsheets that are available for each role in the team, thereby elevating organizations as a whole to work in a data-driven manner.
The platfom offers an accessible, manageable, and scalable path to drive your company’s digital transformation
The digital transformation helps to bring about increased efficiency, cost reductions and improved quality, and ultimately positions organizations for long-term success.
Securely (ISO 27001 certified) available as a Service (SaaS) in the Microsoft Azure Cloud, HAI needs no local infrastructure and software installation, and is available on any device and from any location.
Ready to start in the Cloud
start < 4 hrs no local infrastructure
Safe & Secure in the Cloud
ISO 27001 certified
Yearly subscription
no capital investment
Self-reliance
no vendor lock-in
HAI comes with standard connectors to a variety of data sources, for instance:
Once the connection between a data source and hai-app has been established, the system can be configured to define how the automatic data collection should take place, e.g.:
Key-users are able to adjust the configuration of the automatic data collection without the need to involve an external expert. Self-sufficiency in software management is important because it makes you independent of a vendor. This allows for flexibility, cost savings, and shorter lead times.
The NextGen interactive logsheets are a unique part of the software, cherished by users, and brilliant in its capabilities.
The logsheets are the screens where end-users view their information. What makes them special is that the logsheets combine a wide range of functionalities on a single screen, a.o. an Early Warning System to prevent out-of-spec situations.
In the logsheets, we can see:
As a result, manufacturers unlock all data from their primary production process (process data, quality, utilities) and present this as meaningful information in the form of logsheets. Custom-generated logsheets can be created for:
Key users without IT knowledge can configure logsheets themselves after a short training, using a simple configuration menu. Therefore, no IT knowledge is required!
Depending on the size and diversity of a production site, there can be anywhere from twenty to over a hundred logsheets. Every data point from the database can be found in one or more logsheets.
In HAI, the automatic data collection leads to (near) real-time visualization in a logsheet. This means that all collected data is always visible in real-time!
Contextual graphical information helps answer the "why" and "how" questions, providing a deeper understanding of the data.
Uncover powerful insights by trending the data in any type of chart, combining related data from different sources to understand correlations, deviations and patterns. Investigate historical trends, or alternatively present real-time trending to identify deviations as they occur.
Create automatic real-time reporting by defining calculated parameters and presenting them in a logsheet. Examples of logsheets that contain calculated variables are Batch reports, Yield calculations, Mass balance reports, Loss calculations, Line speed calculations, OEE calculation, Recovery, First Tme Right rates, and other KPI’s.
Some other examples:
Create ad-hoc reports and analysis by applying advanced filter options (without the need to define queries), and simply export the results to for instance MS Excel for further processing and analysis.
Apply Statistical Process Control (SPC) or Statistical Quality Control (SQC) as part of the HAI-LOGSHEET, to identify process- or quality-deviations before they occur. This helps operators to understand when they need to take action to prevent non-conformances.
Calculate your Process Capabilities (CP or CPk) to understand to what extent the factory can meet the (customer-) specifications.
A Golden Batch is defined as the time-based profile of the process parameters that were recorded for a particularly succesful batch, in terms of duration and quality.
HAI facilitates the definition of a Golden Batch and operator real-time monitoring of the current batch versus the Golden Batch.
Moreover, Process Technologists use Golden Batch Reporting and Analysis to maximize process efficiency.
Calculate your Overall Equipment Effectiveness (OEE) metric to identify the percentage of planned production time that is truly productive. In other words: the performance of a production line or shift. Apply a special operator front-end to allocate down-time reasons and view real-time OEE metrics and downtime analysis.
Define the data-points that will be used by external visualization or analytics programs. Once that the Analytics Base Tables are defined, there is no need for manual interaction to let the data flow.
This feature is often used to create dashboards in Power BI, or provide data for advanced analytics purposes.
Define your high volume (high frequency) data, to be stored in a time-series Influx DB database and make sure all high frequency data remains available for the sake of batch release, track and trace, and research issues. Use the high-volume data for trending, reporting and analytics. Define the period that the high-volume data needs to remain accessible.
In parallel, an aggregated version of the high-volume-data will be stored, contextualized with other data, and remain available at all times in the event-based database.
High frequency data is often used for certain processes that need detailed monitoring (Critical Control Parameters), e.g. for a Pasteurization Process)
Having a structured, real-time contextualized database in HAI, the possibility of applying solutions with Artificial Intelligence come within reach. That’s why HAI includes advanced analytic features and even features for Artificial Intelligence and Machine Learning. Alternatively, you may wish to connect a real-time data stream from HAI to your own Analytical Program.
This could for instance be used to discover how process conditions affect the quality of your end-product, or it could be used to develop a predictive model.
Once, such a model has been developed and tested, it can be put to use in the HAI-LOGSHEET, which makes the model part of the daily operations. Through a continued (user)feedback loop to the original AI model, there is a continuous improvement cycle for the model.
Unlock the power of your data, by applying the Advanced Analytics Capabilities to discover and develop advanced control models that are incorporated as a Smart Factory App as part of the HAI-LOGSHEETS. The app supports plant personnel with for instance process adjustment advices.
A Smart Factory App has been developed to improve sustainability, quality and yield in cheese production (1% yield improvement reflects an amount in the range of 100,000 – 500,000 euros a year). More information: https://hai.nl/news/hai-wins-with-team-notilyze-sas-hackaton-2023/
Another appealing example is a Smart Factory App to reduce energy consumption (and CO2 emissions) on a destillation process, while optimizing for quality and yield. More information: https://hai.nl/news/winning-the-worldwide-sas-hackaton/
Use the alarm module to define in which situations an alarm should be raised for whom, and what workfow applies to this particular alarm.
Never miss an alarm, and never doubt on what actions need to be taken.
