Global Lighthouse Network 2025

Lighthouse design solutions to optimize interactions between people, data and materials 1. Smart andon: a digital system that uses real-time data and alerts to signal and manage operational issues. 2. OEE: Overall equipment effectiveness – an indicator used to measure the efficiency and effectiveness of equipment. It is calculated by multiplying three factors: availability, performance and quality. 3. Tenure: refers to the length of time that an individual has been employed or has held a specific position or role. Source: Global Lighthouse Network.FIGURE 7: Miscommuni cation Inefficient meetings Task/skill mismatch Integration issuesProduction bottlenecks Data transfer errors Synchronization delaysInefficient set-up or adjustments Human error Machine downtimeHuman-to- human Shift manager does not need to spend time catching up with other teams, solving problems right awayHisensehitachi Qingdao, China GenAI-enabled digital assistant for shift handover reports to quickly address production issuesAstraZeneca Wuxi, China IoT-based “smart andon”1 integrated with skill matrixes for automated task reallocation Line lead spends less time on live production issues and more on planning for future staffing needs+16% Improvement in OEE2+31% Improvement in OEE Data is no longer siloed within sites and instead can be integrated across all for root cause analysisHaier Qingdao, China Federated knowledge graph for analysing data spread across global fragmented systems and laboratories to rapidly diagnose defectsZhengzhou Coal Mining Zhengzhou, China Genetic algorithm to synchronize workstation status with AGV tasks and routes for optimized internal logistics AGVs spend less time idling and more time out on the floor completing tasks-75% diagnostic cycle time-61% Manufacturing lead timeUnilever Tinsukia, India Unsupervised machine learning for workforce line allocation based on experience, skill, group compatibility, demographics and other parameters (e.g. tenure,3 technical skills) Shift manager no longer allocates manpower at start of shift – instead, confirms and undertakes data-driven and targeted skill gap coaching-64% human-led OEE loss1. 1. 3.2. Machine-to- machine3.Human-to- machine2. Global Lighthouse Network: The Mindset Shifts Driving Impact and Scale in Digital Transformation 14