Manufacturing Digital April 2026 | Page 104

TECH & AI

While talk of smart factories is everywhere, few have yet found success in scaling these technologies. To achieve this growth, manufacturers need to do more than just connect machines.

Ganesh Bukka is Vice President & Global Head Industry 4.0 at Hitachi Digital Services and has cracked the code on moving from experiments to rollout. He shares his expertise with Manufacturing Digital.
Q. HOW DO YOU DEFINE A SMART FACTORY TODAY?

» A smart factory today digitalises the core of a traditional manufacturing environment by unifying the edge-tocloud journey. Unlike conventional setups, it leverages real-time data from interconnected machines, systems and processes to optimise every stage of production – from supply chain operations through manufacturing and delivery. By creating a dynamic and responsive environment, smart factories enable manufacturers to adapt quickly to changing market demands, improve efficiency, reduce costs and consistently ensure product quality. At its core, a smart factory is an intelligent ecosystem where digital technologies seamlessly connect machines, processes and people to drive continuous improvement and business value. A strong example of this evolution is our Hagerstown Advanced Rail Digital Factory, where these principles have been put into practice to create a truly cutting-edge smart factory model. Another example is Hitachi’ s Omika Works factory, which was recognised by the World Economic Forum as an Advanced 4th Industrial Revolution Lighthouse.

Q. WHERE DOES IIOT FIT WITHIN THIS ECOSYSTEM?

» IIoT sits at the foundation of the smart factory ecosystem. It acts as the connective layer that links machines, sensors, systems and people across the shop floor and enterprise. Without IIoT, there is no reliable flow of real-time operational data to power analytics, AI models, digital twins or sustainability platforms.

In practical terms, IIoT enables data acquisition from critical assets, supports edge processing for lowlatency decision-making and integrates operational data with enterprise systems such as MES, ERP and cloud platforms. It provides the visibility and contextualised data needed for predictive maintenance, quality optimisation, energy management and connected worker solutions.
Ultimately, IIoT serves as the backbone of the smart factory, transforming standalone equipment into intelligent, connected assets and establishing the data foundation for AI, industrial edge computing and Industry 5.0 capabilities. Initiatives such as the Hagerstown Advanced Rail Digital Factory and Hitachi Omika Works, developed by Hitachi, illustrate how this connectivity translates into realworld operational transformation.
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