THE MAGAZINE FOR THE FOURTH INDUSTRIAL REVOLUTION
issue no. 4 - SEPTEMBER 2018
IN THIS ISSUE Interview with Martin Walder
Vice President of Industry, UK & Ireland
SENSORS IN MANUFACTURING Developments in sensor technologies
NOW. NEXT. BEYOND
What the factory of the future has in store
Food and Beverage
Evolution for food manufacturers
Britain’s Manufacturing Future. We’re here to enable it The Factory of the Future is coming to Britain soon and we’re here to help make it happen. British businesses are already taking their first steps to remain competitive in a world where customers demand customised products, faster delivery and shorter lead times. As leaders in drive and control solutions, we offer the digital solutions you need to maximise the opportunity of Industry 4.0. The Factory of the Future is more than just a vision, so join us on our journey Now. Next. Beyond.
WE MOVE. YOU WIN. www.boschrexroth.co.uk/FOTF
WELCOME TO THE
Industry 4.0 magazine Thank you for reading the 4th edition of the Industry 4.0 Magazine, the official magazine for The Industry 4.0 Summit in Manchester. Our lead interview is with Martin Walder of Schneider Electric who has provided valuable insights on the state of Industry 4.0 in the UK, relevance to the SME market and his role with the Engineering and Machinery Alliance. We have had a detailed look at the sensors industry and it’s role in industry 4.0. Paul Stansfield from IFM and Richard Jeffers from RS Components provide expert advice and insights on machine performance, infrastructure, I/O link and data collection and analysis. In our sector analysis we have included a guest contribution from Specpage who have provided ‘Food for thought’ on the food and beverage industry. Bosch Rexroth, the lead sponsor for our flagship event – The Industry 4.0 Summit 2019 have provided an overview on The Factory of the Future and the opportunities digitization brings to efficiencies in production. We hope you will find valuable information and knowledge in the articles and videos in this issue. We look forward to receiving your feedback on the articles in this issue and topics you would like to read about in the future.
THE INDUSTRY 4.0 MAGAZINE IS PUBLISHED MONTHLY BY GB MEDIA AND EVENTS - ORGANISERS OF THE INDUSTRY 4.0 SUMMIT PUBLISHER Gary Gilmour EDITOR Pav Baghla TEAM Matthew Pearsall Digital Manager Lyn Illsley Designer All Editorial and advertising Enquiries to Digital@gbmediaevents.com +44 (0) 207 9932300 +44 (0)1642 438225 GB Media & Events, Wilton Centre, Redcar, North Yorkshire, TS10 4RF. GB MEDIA & EVENTS LIMITED GB Media and Events Limited is a company registered in England and Wales with company number 10114934 /Industry40news JOIN OUR INDUSTRY 4.0 NETWORK ON LINKEDIN linkedin.com/groups/8646038 www.industry40.news
Kind regards, Pav Baghla, Editor The content of this magazine does not necessarily express the views of the Editor or publishers. The publishers accept no legal responsibility for the loss arising from information in this publication. All rights reserved. No part of this publication may be producted or stored in a retrieval system without the written consent of the publishers.
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Interview with Martin Walder Vice President of Industry, UK & Ireland
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NOW. NEXT. BEYOND What the factory of the future has in store
Latest news Industry 4.0
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Food and Beverage Evolution for food manufacturers
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SENSORS IN MANUFACTURING OVERVIEW Developments in sensor technologies
Industry 4.0 Summit Speech Smart factory management
Interview with
Martin Walder VICE PRESIDENT OF INDUSTRY, UK & IRELAND
Q & A with Martin Walder There’s a lot written about industry 4.0. What is your take on it and where are we heading? Many companies and governments have done a really good job in driving the “Industry 4.0” story, most notably the German government. Their campaigns have given maximum visibility to the changes taking place and created a narrative. However, many of the concepts behind the technology are not new. In fact, Schneider Electric have been on the front line in bringing the ‘Transparent Factory’ to the market since the late nineties. More recently our ExoStruxure offering that takes this even further. We are working on bridging the gap between building management, IT and power to ensure that it is all operating as part of the same connected environment. Ultimately, we are heading for a more connected space than we have ever seen – and we’re on the right path to see a more connected future. A lot of large solution providers are focusing on the SME market. Is Schneider, and what can you do for them and what can they do themselves to get started on their own 4.0 journey? At Schneider Electric, we are working with many forward-thinking blue-chips to implement connected, Industry 4.0 concept solutions. However, we do still recognise that the biggest challenge facing the UK is being able to get all SMEs onto the same curve and way of thinking. I currently sit as chairman of the Engineering and Machinery Alliance where I represent around 2000 engineering and manufacturing SMEs in Britain.
Working alongside our trade associations, we are gaining momentum in educating and encouraging the investment in the use of modern automation and digital technologies. In fact, Schneider Electric are also taking a role in this education. We have developed an extensive innovation hub that allows us to demonstrate simple, practical examples of Industry 4.0, IIoT and digitisation in action to as many SMEs as possible. Our doors are always open to visitors. If 4.0 is largely about efficiency and ironing out otherwise manual operations through automation, what do you see as the best way to achieve this? At present, there are not many greenfield plants going up in the UK. This means it’s all about upgrading and evolving what already exists today. Our message is focused around evolution as opposed to revolution. The concept here is that we need to start with small and simple examples of IIoT use cases to show the performance and efficiency gains of the technology. Not all businesses will be ready to achieve full connectivity today. However, the incremental costs for the IIoT capabilities are small, so it’s worth the investment up front. We also need to ensure that digitisation, automation and innovation are subjects on the agenda for discussion at every single board meeting. Many of our manufacturing companies have long abandoned those smart, technical and manufacturing capable engineers and it’s more vital than ever before that we start helping them to develop again to give management teams the confidence to implement new technology solutions. 5
industry 4.0 Issue no 4 - SEPTEMBER 2018
Interview
Video:
Martin Walder speaking at The Industry 4.0 Summit
At the Industry 4.0 Summit you spoke about SME’s in supply chain to the major’s and how they can use Industry 4.0 to gain efficiencies? Can you please elaborate on this? As with larger companies, SMEs can use automation and digitisation to produce components to a higher standard and at a lower cost with fewer staff. They can give themselves the flexibility to turn up and down production output to match the major demand and operate Just in Time (JIT). Digital connection of the SME to the scheduling demand of the Major can really improve efficiencies and satisfaction. More importantly, it brings the companies together more closely. How is Schneider implementing change across its own organisation? Digitisation is on the agenda for all C-suite meetings. There is a huge focus on our internal systems and factories too.
We have roughly 240 manufacturing sites and we have invested heavily in our own technology, implementing Industry 4.0 techniques to increase efficiencies and enhance productivity. We now have 11 factories acting as showcases around the world and 68 will be up to a similar standard by the end of the year. We are working hard to deploy the most capable and connected digital offer through EcoStruxure – MV/LV Power, building management, data centre, micro grid, smart factories and smart machines. From the CEO down, every team is partaking in implementing these changes. All divisions must now develop and adopt the latest technologies into the dayto-day. What’s your view of the UK governments ‘Made Smarter’ reviews? Are there things that they should have included? I think it is very good and fully support. How Is your company planning for Brexit?
“Not all businesses will be ready to achieve full connectivity today. However, the incremental costs for the IIoT capabilities are small, so it’s worth the investment up front.” 6
We manufacture in the UK through 7 factories and also bring in technologies manufactured around the world. We have been through a series of scenarios by planning and costing for each to ensure that we are ready to act – whatever the outcome.
For more details of the Engineering and Machinery Alliance visit www.eama.info
Interview
Video:
Microsoft and Schneider Electric - Mastering the Digital Future of Industry
As Chair of the Engineering & Machinery Alliance, what are your members main concerns at present?
Is Britain ready to adopt industry 4.0. Are there are hurdles to mitigate? Whilst Britain is certainly ready to adopt Industry 4.0 and should be doing so – we really do need require more employees with the right skills to help companies to accelerate this technology.
The skills gap is a big concern for us. We need to governments support to encourage capital investment into this.
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Growth on the horizon for F&B industry Evolution for food manufacturers
Evolution for food manufacturers The breakneck speed of new technological advancements has empowered traditional food engineers and research and development teams – in fact, reputable sources indicate that the food and beverage manufacturing industry is projected to grow at a rate of more than 10 percent over the course of the next twelve months. Greater digitization – more innovative process solutions like product lifecycle management (PLM) and master data management – are creating smarter processing and higher performance for food producers. Control, transparency and traceability have emerged as crucial elements, and are possible to achieve in a comprehensive way, due to the availability of more centralized process systems.
Industry 4.0, defined as the current trend toward automation and data exchange – including IoT, cloud storage and computing and cognitive computing - has and will continue to revolutionize food manufacturing. There can be no question that placing the technological advances of Industry 4.0 at the forefront of the digital agenda in all manufacturing industries, including the food and beverage industry, is a wise move. From raw materials to processing, packaging and marketing, food producers are embracing this technology with surprisingly stellar results. Cyber-physical systems connect with software process solutions, and manufacturers can communicate across all channels with suppliers and retailers – sometimes even with end-use consumers.
Traceability Transparency and traceability within the manufacturing and labeling process present immense benefits to consumers. The capability to trace goods literally from the farm to the table with a mobile device has become a routine request from millennials in the marketplace – and ERP systems combined with RFID (Radio Frequency Identification) tags make it possible.
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End-to-end product data management (PDM) solutions offer manufacturers the ability to increase production and eliminate data entry errors while providing transparency throughout the supply chain via data sharing on collaborative platforms. Sustainability and a smaller eco-footprint are also important trends in the marketplace, which is addressed via quality maintenance and resource management at the factory level.
food and beverage industry
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industry 4.0
INDUSTRY 4.0 FOR F & B When implemented by food and beverage manufacturers, Industry 4.0 operates on two basic pillars: •
I nformation and process/product transparency
•
D ecentralized decision-making
Food manufacturers who embrace 4.0 find their organizations are better equipped to control their processes - leading to accelerated time to market, improved global regulatory compliance, clean product labels with accurate,
efficient ingredient management and more technologically responsive solutions to deliver maximum customer value at the lowest cost per unit. Process transparency extends to IoT infrastructure that affords production managers the connectivity and mobility to quickly aggerate data from multiple sources and make effective production decisions -from the factory floor, on a mobile device.
Managing, sharing and protecting data Industry 4.0 directly impacts regulatory compliance for manufacturers who participate in the global marketplace. Central product data sharing, like raw ingredients specifications and compliancerelated information is required; 4.0 technology supports platforms that make the essential information available to shareholders throughout the supply chain.
Product data management is critical for global food and beverage manufacturers; SaaS and Cloud PLM infrastructure options for global supply chains in cyberspace are quickly becoming a key asset for manufacturers who operate across international borders and must comply with regulations while protecting proprietary data. Data management is the sum of all parts, and for each part, Industry 4.0 technology is exceptionally promising.
“Forward-thinking organizations are also testing strategies like extended shelflife products to minimize food and packaging waste.”
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industry 4.0 Issue no 4 - SEPTEMBER 2018
food and beverage industry
Video:
Digitalizing the food and beverage industry
Contamination and recalls According to the Federal Food and Drug Administration (FDA), there is an average of 27 recalls in the United States every month; these recalls range from undeclared or mislabeled ingredients to broken metal shards, microbial contaminations and pathogenic bacteria. Traceability is a complicated imperative; food manufacturers must have specific processes in place to identify batches and swiftly react with the institution of a recall.
Machinery breaks – that is a simple fact; it is vital that manufactures have both master data management, lab information systems and sensor technology to address foreign objects and mark each batch with singular, unique production identification markers. Sophisticated, integrated software process solutions and sensor technologies, like active RFID, allow efficient systematic data tracking throughout the batch progression and supply chain.
Consumer-friendly devices and applications Consumers often research their product purchases on their smart phones and mobile devices. In order to motivate them to purchase their products, manufacturers and retailers should enable point-of-sale (POS) solutions that integrate with customers’ mobile devices. An emerging technology is intelligent labeling. The combination of wireless labeling, software applications and cloud platforms lets consumers scan product labels with their smart phones to 10
ensure the product’s authenticity or to obtain information regarding ratings, customer loyalty programs or product videos. It only requires a Near Field Communication (NFC)-enabled device. The data that these intelligent labels provide manufacturers contains demographic information, location, likes, social shares and real-time reviews. Forward-thinking organizations are also testing strategies like extended shelf-life products to minimize food and packaging waste.
food and beverage industry
Issue no 4 - SEPTEMBER 2018
industry 4.0
4.0 challenges
4.0 benefits
New business models require new strategies – this is a difficult concept for food producers who still rely on spreadsheets and manual data entry – but food and beverage manufacturers must lean in, invest and embrace the technology in order to thrive in the global marketplace.
Technological advancement benefits begin with digitalization; software process solutions specifically designed for recipe-based food and beverage manufacturers that provide the ability to adjust quickly and actively manage consumerdriven rapid changes for food products while increasing traceability and transparency in the supply chain – and eliminating risks associated with regulatory compliance - are the first step.
It is crucial for c-suites to understand their business case and rethink their processes to maximize outcomes and profitability. Examining the company culture and helping your entire organization understand and embrace innovative process solutions that connect all departments is difficult – but doable.
“Understanding, finding the right blend of technology and human collaboration and adapting to innovations enhances productivity and provides greater continuity for functions across all channels.”
Quality control, lab processes and specification data must be simplified and communicated vertically and horizontally to ensure the organization has streamlined operations and can achieve sustainable growth and increased ROI. Understanding, finding the right blend of technology and human collaboration and adapting to innovations enhances productivity and provides greater continuity for functions across all channels.
Video:
How Wonderware MES helps increase Food and Beverage Production
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industry 4.0 Issue no 4 - SEPTEMBER 2018
food and beverage industry
Food for thought The food and beverage industry generates 1.8 trillion dollars per year worldwide placing Industry 4.0 at the forefront of the digital agenda in recipe-based manufacturing. Rapidly changing trends and consumer behaviors, global regulatory compliance and legal requirements as well as increasing specializations deliver unremitting challenges for food manufacturers. Even though the automation of factories and processes may, in many organizations, be already put into practice,
structured integration into a holistic data concept is often missing. Digital networking of all processes can provide innovative solutions. What Industry 4.0 really means for the food and beverage industry - identifying opportunities and implementing specific measures for best practices – is that your greatest strength lies in employing your data to achieve a strategic, competitive advantage.
Article submitted by
Severin J. Weiss CEO, SpecPage | www.specpage.com Severin Weiss is widely recognized as a global expert in integrated software process solutions for recipe-based food and beverage manufacturers. He founded SpecPage in 2006. SpecPage is a multinational privately held computer software manufacturer, software supplier and IT service provider, specializing in Product Lifecycle Management, (PLM), Product Data Management, (PDM), Global Data Synchronization, (GDSN), Laboratory Management (LIMS), Enterprise Systems Management, (ERP), Environment Health Site Assessment/Materials Safety Data Sheet, (EHSA/MSDS) Regulatory Solutions for Food and Recipe Development, (RSFRD), and Global Regulatory Compliance, (GRC). The company is headquartered primarily in Switzerland and the U.S., with offices in Sweden, Germany, France, Italy, Slovakia, the Netherlands, Singapore, China and Taiwan.
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NOW. NEXT. BEYOND: WHAT THE FACTORY OF THE FUTURE HAS IN STORE
Compare factories of 20 years ago to those of today and in most cases they won’t look too dissimilar. On the surface, you may be right, but dig a little deeper and their heart will have changed as they adjust to a more volatile global marketplace. Alongside increased cost pressures and heightened quality standards, consumers now expect customised products, fast delivery, greater flexibility and shorter lead times. As a result, efficient working practices are more important than ever – but how can factories of the future accommodate this? Of course, the digital transformation – from the configuration of networked machines and systems through to the fully digitalised value stream – will be key. With some six billion objects now IoTconnected, we’re already seeing manufacturers taking significant steps towards a digital future.
But for some, taking the leap into the digital age isn’t straightforward, with the benefits of Industry 4.0 and the process of implementation not fully understood. To understand where the benefits of digitalisation lie, Bosch Rexroth developed its own Factory of the Future, demonstrating every possibility and exploring how manufacturers can implement them step-bystep for maximum impact. Let’s explore some of the key benefits, and how close the future is. A spokesperson from Deutsche Telekom explained how Industry 4.0 contains a broad technological spectrum, including data analytics, the IoT, machine-to-machine communication and artificial intelligence.
Video:
Bosch Rexroth Factory of The Future
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“On the factory floor, real-time gathering and processing of data from sensors not only enables production quality checks at the point of manufacture, but also facilitates accurate machine and system health checks through continuous monitoring.“
Digitising your value stream In the Factory of the Future, all hardware modules and functions are represented digitally in real-time. Sophisticated software solutions collect, transfer and process data from manufacturing and logistics to analyse, simulate and improve all processes across the value stream. On the factory floor, realtime gathering and processing of data from sensors not only enables production quality checks at the point of manufacture, but also facilitates accurate machine and system health checks through continuous monitoring.
Distributed intelligence manifests itself in all technologies and gives machine manufacturers new options. From cabinet free drives which reduce cabling; low energy, intelligent hydraulic power units; to assembly workstations which provide employees with work instructions that are adjusted to the individual’s level of training and knowledge. At the same time, for factories looking to evolve gradually, older machinery can realise many of the benefits cost-effectively using a pre-configured plug and play IoT gateway.
Maximising your flexibility Setting the stage for increasing productivity in serial production, smart factories will make it possible to (re)configure production lines and facilities to fast changing requirements. Taking connected hydraulic systems as an example - sensors can be added to horizontally and vertically networked machine architectures. Predefined functions within the software can be used to control the position, velocity, distance/ force, different synchronous cylinders or pathdependent braking and improve performance by dynamically adjusting flow and pressure. Managing these functions in real-time, via the software, allows users to operate more efficient when producing small batches and reduces the retooling work for new products.
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Further improving flexibility, the increasing use of wireless technology has the potential to mobilise machines and plants. Instead of power cables, which effectively tie a machine to a specific place in the factory floor, machines will be powered by inductive charging from the floor of the hall, with the added benefit of 5G connectivity as a faster, more stable means of data transfer. This functionality simplifies conversion to new processes, making factories highly flexible. Production configures itself independently in-line with the product to be manufactured. Communication between machines and systems is mainly wireless. Production layouts are optimised and operating data is captured and analysed, producing real-time data which drives continuous improvement and virtually eliminates machine downtime.
now. next. beyond.
Issue no 4 - SEPTEMBER 2018
industry 4.0
Stepping into the future What we’ve learned in developing the Factory of the Future is that when you consider what can’t be changed, surprisingly little remains: the floor, the walls and a roof. The rest of the factory: the machines, automation topologies, equipment, communication paths, even the people and how they work together are subject to the changes demanded by modern manufacturing. The notion that a process facility is too large or too old to move towards digitisation is a common one. Whether a facility chooses to take a granular approach to getting connected, or prefers the idea of a complete digital overhaul, it is important to remember that digital technologies are highly scalable – making them relevant to any business, of any size, at any stage of the process. In fact, Industry 4.0 presents a host of opportunities for manufacturers to incrementally change how they do things. Putting sensors on key pieces of machinery to provide real-time insights into equipment health and making use of the Internet of Things to collect data, streamline operations and improve efficiency are just some of the benefits.
As one of the world’s leading suppliers of drive and control technologies, Bosch Rexroth ensures efficient, powerful and safe movement in machines and systems of any size. The company bundles global application experience in the market segments of Mobile Applications, Machinery Applications and Engineering, and Factory Automation. It enables fully connected applications with intelligent components, tailored system solutions, and services. Bosch Rexroth offers its customers hydraulics, electric drives and controls, gear technology and linear motion and assembly technology, including software and interfaces to the Internet of Things. With locations in over 80 countries, more than 30,500 associates generated sales revenue of 5.5 billion euros in 2017. To discover more about the evolution of smart factories, explore Bosch Rexroth’s Factory of the Future at: apps.boschrexroth.com/rexroth/ en/factory-of-the-future/
“Industry 4.0 presents a host of opportunities for manufacturers to incrementally change how they do things.”
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SENSORS IN MANUFACTURING
Developments in sensor technologies
Evolution Not Revolution Industry 4.0 Magazine talks to Paul Stansfield, UK National Sales Manager at IFM, about how the Industry 4.0 agenda is changing the sensor manufacturer’s business model. One of the real takeaways that emerged from the Industry 4.0 Conference in Manchester in March 2018 was the notion that capturing sensor data is a good entry point for exploring what Industry 4.0 has to offer. It’s a view which the IFM Sales Manager shares. “The concepts of Industry 4.0 are not new,” Paul Stansfield tells us. “But there has been a lack of uptake in these concepts until now. One of the things Industry 4.0 has done is made industry think about the concepts of the digital world and how to realise them; to think ‘why do we need more data?’.”
Video:
Meet the IFM experts
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Stansfield warns against the tendency to view Industry 4.0 as an “all or nothing” concept. While it is tempting to approach the topic from an IT perspective and focus on the exciting new technologies of machine learning and artificial intelligence, the reality is that really isn’t an affordable way to start for most businesses. Besides, Stansfield emphasises the machine learning must be derived from the right data. “It isn’t until you’ve got the ‘grass roots’ piece right that you know you’ve got the right data coming through in the first place,” he points out.
Sensors in MANUFACTURING
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industry 4.0
Prove the Concept Instead, IFM has been advocating a bottomup approach with its customers keen to explore the Industry 4.0 agenda – adding sensors one machine at a time and proving the concept before rolling it out further to additional machines across the facility. “For us, it’s all about proving the concept and talking about where the opportunities lie. We can start with one machine – maybe the machine that is performing the worst – do a proof of concept and, when we are ready, we can build up in a modular way. Data capture is going to become almost decentralised. Only the information derived from that data needs to be pushed to the top platform.” By way of illustration, Stansfield shares the example of a customer who retro-fitted extra sensors across its facility’s central machine services. The subsequent data analysis threw up some surprising insights into machine performance.
Because the facility had added to the machines consuming those services over time, the services were struggling to keep up with the demand from each machine. Stansfield explains, “We worked with our customer to identify how they could produce in a certain sequence to keep demand lower – so the machine speed wasn’t affected by the constraint those services represented.” The company now has plans to increase service capacity in order to enhance throughput. This type of data capture and analysis demonstrates how sensor data can offer new – and unexpected – insights. “It so happens that it is the companies that have some performance issues, where we can really talk about what those issues are, often have the most potential in terms of the ways in which we can track performance,” Stansfield says. “Once the concept is proven, it can be escalated and can drive OEE throughout the facility.”
Manufacturing as a Service Stansfield characterises IFM’s UK market as equally split between end users and machine manufacturers/ OEMs. Given the opportunities for end users to drive improvements using sensor data as a key part of their Industry 4.0 agendas, it might be expected that this ratio might be changing. However, Stansfield admits the 50/50 split remains steady. “Many of our OEM customers are grappling with changing business models as well,” he explains. “They are being asked by their customers to provide capital equipment as a service. When you’re charging per piece made or per part delivered, you need to know about the health and conditions of your machines on a continuous basis because if the machine is underperforming, the revenue drops.”
The big piece of this work is monitoring whether the machines are being used within the specified parameters and, in many cases, IFM is exploring with its OEMs how sensor devices can be added to machines to make this data accessible remotely. Moreover, the data from multiple sites can be used to look at how to improve OEE on a continual basis – which isn’t something OEMs have necessarily prioritised before. As such, demand for sensor devices is growing on both the end user and OEM side of the business. “Sensors were on machines for control purposes only,” says Stansfield, “however, now our customers are putting sensors in place just for analytical purposes; just to bring back data to meet analytical requirements. It’s changing our business model hugely. Instead of most sensor deployment being for machine control, now we are overlapping technologies and bypassing machine control – going straight to the IT platform and just to gather data.”
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industry 4.0 Issue no 4 - SEPTEMBER 2018
5%
of the data is processed in the controller - in bytes per millisecond
Sensors in MANUFACTURING
MACHINE DATA
95%
of the data should be processed in the IT world - in megabytes per second
Protecting Machine Performance Stansfield makes the point that, when you ask people what data they are capturing, more often than not the data comes from a PLC controller. Inevitably, that data is very limited. To truly represent the physical world and do true analytics, you need more information than that. While there is a lot of intelligence in the sensors on machines, often that is not utilised; manufacturers don’t want to take up capacity on their control networks or on their PLC just to analyse data and, consequently, risk network or machine performance. Cognizant of this brake on deployment, IFM were one of the founder members of the I/O Link consortium. 18
Stansfield believes this new standard will play an important role in the Industry 4.0 journey – enabling organisations to more easily harness the information coming from intelligent sensors. Stansfield says, “As a founder member of the I/O Link consortium, IFM has played an important role in developing this important standard and we’ve been putting I/O Link technology into our sensors for over five years now. IFM analysis earlier this year estimated that there are 6 million IFM sensors already in the market with I/O Link capability. These embedded chips are our preparation for when people want to come onboard with Industry 4.0 – they cover around 80 percent of our product range at this stage.”
Sensors in MANUFACTURING
About I/O Link IO-Link is the first standardised IO technology worldwide (IEC 61131-9) for the communication with sensors and also actuators. The powerful point-to-point communication is based on the long established 3-wire sensor and actuator connection without additional requirements regarding the cable material.
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IFM is hoping this preparation will help organisations that wish to explore what intelligence they can get from sensor data. “The I/O Master is the only important bit to which people now need to upgrade to gather all the intelligence from the I/O sensors they’ve been buying for the last five years,” Stansfield says. “Probably only around five percent of that data will need to go to the machine controller. 95 percent of it doesn’t need to go to the controller; it will go straight to the IT platform. By doing this, we protect the speed and resilience of the manufacturing process.”
Only
5%
of the data is used by the PLC.
95%
of the data is lost. Stop this data loss!
Fig.1 Example of system architecture with IO-Link
I/O Link is not a fieldbus but a bidirectional point-to-point connection between a peripheral interface and a field device. •
It closes the communication gap in the
lowest field level •
It makes validation of machines and
equipment possible down to the lowest sensor and actuator level •
It minimizes the variety of existing
interfaces (PNP, push-pull, 4-20mA, 0-10V, RS232, and RS422 become IO-Link) •
IO-Link also allows bidirectional
communication with sensors which also means that sensor parameters can be changed by machine controller or IT platforms ‘on the fly’, essential for the ever increasing flexible manufacturing processes.
An I/O Link master translates the sensor data to a known industrial standard to send it directly to an IT platform on an industrial network or an IT network for processing and analysis – thereby minimising the extra traffic to the PLC controller and those elements of the network. In this way, Stansfield argues, I/O Link answers an early objection to getting started with Industry 4.0 and opens up the possibility of collecting the data necessary to truly represent the physical world virtually. “In this way we can start dividing the physical world into virtual capacities,” Stansfield says, “and these insights will improve our understanding of how well our facilities are performing over time – with sensor data driving OEE. Of course, different companies have different requirements but this is a good, low-cost starting point for everyone.” Article supplied by IFM www.ifm.com/gb/en 19
Making ‘Cost to Fail’ a Thing of the Past Richard Jeffers, Technical Director for Northern Europe at RS Components, explains how Industry 4.0 technologies are creating opportunities in new realms of the factory. Having worked in the automation-intensive brewery sector for fifteen years, Richard Jeffers has been talking about using data to drive decision-making for some time. However, an increasing awareness of Industry 4.0 concepts and associated technologies means he now finds himself pushing on an open door. “The cost of sensors is coming down and, together with the opportunity that wireless presents to avoid additional cabling costs, this is putting the opportunity to use data to drive decision-making into more hands,” Jeffers tells Industry 4.0 magazine. “That’s really exciting.”
As a leader in the automation space, RS Components is well-placed to have conversations with manufacturers about the opportunities Industry 4.0 presents. Jeffers has had detailed conversations about Industry 4.0 with more than 60 customers over the last 12 months. These conversations have made it clear that organisations are starting from very different points, Jeffers tell us. Nevertheless, there are some clear stepping stones along the Industry 4.0 journey. “In a large manufacturing facility there are probably hundreds of sensors and data from those sensors is flowing across the network. The majority of people recognise that there is already a lot of data swilling around their organisation and they want to know how they can use that data.”
Leverage existing data In these situations, Jeffers recommends organisations ask: •
What data can I get off my existing
infrastructure? •
What do I want to do with it?
•
Where are the gaps in that data (that are
preventing me from doing what I want to do)? The reducing cost and improving connectivity of sensor technology means it is today far easier to fill those data gaps.
“More often than not, you’re just going to be adding a few sensors to a piece of machinery and that data can go through your existing wired infrastructure to an existing SCADA,” Jeffers says. “If you are going to have to add 100 new sensors to get the information you need, then perhaps you wouldn’t want to put that over the existing network but, again, that depends on how much capacity you have on it.”
Richard Jeffers, Technical Director for Northern Europe at RS Components
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Two parts to the puzzle Jeffers explains that most Industry 4.0 initiatives he has encountered are focused on two areas: either preventative maintenance or process optimisation. “There are undoubtedly other areas,” he admits, “but these are the key areas for our customers and, therefore, us. What we’re most interested in is repeatable use cases.” This means investing time and research into developing models that can facilitate useful equipment and process analyses using cloudbased solutions.
“Ultimately, we envision a model which is ubiquitous for each piece of equipment, whichever hardware you’re using,” Jeffers explains. “Unfortunately, there is an idea that you can just plug a sensor into the cloud and the magic happens. But the reality is far from that. A cloud infrastructure isn’t an end in itself; you need the application knowledge behind it. What are you going to do locally and what are you going to send to the cloud? How are you going to send that data to the cloud? And, once it’s there, what are you going to do with it?”
Clear business case Ultimately, like any investment, Industry 4.0 initiatives must have a clear objective and targeted ROI. Jeffers says, “Industry 4.0 is sometimes mistaken for a shortcut to running your factory properly. But it isn’t a shortcut; it’s about using emerging tech to take what you’re already doing to the next level. It is the people who are already competent who are seeing the real value achieved.” He points to the example of a water treatment works he recently visited, where more than ten years of hard work on OEE has gone into improving operations. Industry 4.0 technologies have provided an opportunity to better understand onsite assets through the development of a digital twin. Subsequent analysis has resulted in a five percent reduction in chemical cost – with a value into the hundreds of thousands of pounds per year – in an already optimised system. “Digital twins don’t have to be big, complicated projects,” Jeffers says. “Anywhere there is a degree of complexity in a system a digital twin can add value by predicting performance and helping take cost out.”
Jeffers believes that as the cost of solutions come down, digital twins will enable modelling on small-scale operations in the same way that reducing hardware costs are making more analysis possible for condition monitoring to be more widely applied now. “The lower cost of sensors and cloud computing are making it cost effective to predict failure and optimise performance in areas where it wouldn’t have been cost effective before,” Jeffers enthuses. He points to the example of small electric motors where, until now, it hasn’t been cost effective to add sensors. “As well as being huge energy consumers, they would run on a cost-to-fail strategy,” he says, “Condition monitoring wasn’t cost effective. As the costs come down, cost to fail will become less attractive. And there are benefits in terms of resource optimisation and environmental benefits to be gained at the same time.” Ultimately, he says, captured data needs to be leveraged to create insights. And those insights must be actionable.
“Industry 4.0 is sometimes mistaken for a shortcut to running your factory properly.” 21
industry 4.0 Issue no 4 - SEPTEMBER 2018
Sensors in MANUFACTURING
How do I start with Industry 4.0? “I’m asked a lot ‘how can we do Industry 4.0?’. There is still a lot of confusion about what it is,” says Richard Jeffers, Technical Director for Northern Europe at RS Components. He recommends starting with a clear problem that needs solving. • •
•
W hat problem are you trying to solve? W hat is the value to the organisation of solving that problem/ is it worth solving the problem? W hat data do you need in order to solve that problem?
•
How are you going to get that data?
•
How are you going to manage that data?
i.e. what analytics are you going to do at the edge? What are you going to send to the cloud and what are you going to do with it once it gets there?
The challenge for solution providers is to create a ubiquitous model for subsequent cloudbased data analysis. Jeffers says this modelling is something with which RS Components is currently grappling: “We’re at an exciting stage; people really want to engage with us.”
Article submitted by RS Components uk.rs-online.com
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industry 4.0 Issue no 4 - SEPTEMBER 2018
sensors directory
Sensors DIRECTORY Below is a selective list of firms manufacturing and supplying sensors for the manufacturing sector. If you would like to like to include your firm in our online directory of Industry 4.0 firms please send details to digital@gbmediaevents.com.
3100 Daresbury Park, Warrington, Cheshire, WA4 4BT, UK. T: +44 1925 741547 new.abb.com/uk www.linkedin.com/company/abb
Bletchley Denbigh Road, Milton Keynes, MK1 1EP, UK T: +44 870 242 5004 ab.rockwellautomation.com/Sensors-Switches www.linkedin.com/groups/120132/about
3 Horizon Business Village, 1 Brooklands Road, Weybridge, KT13 0TJ, UK. T: +44 (0)1932 358530 www.analog.com www.linkedin.com/company/analog-devices
Kao 1 Kao Park, Hockham Way, Harlow, Essex, CM17 9NA, UK. T: +44 (0)1279 441144 www.arrow.com www.linkedin.com/company/arrow-electronics
20 Cheshire Business Park, Cheshire Avenue, Northwich, CW9 7UA, UK. T: +44 1606 812777 sales@balluff.co.uk www.balluff.co.uk www.linkedin.com/company/balluff Bosch Sensortec GmbH, Gerhard-Kindler-StraĂ&#x;e 9, Germany. T: +49 7121 35 35900 F: +49 7121 35 35909 www.bosch-sensortec.com 24
www.linkedin.com/company/bosch-sensortec
sensors directory
Issue no 4 - SEPTEMBER 2018
industry 4.0
6 Bracken Hill, Southwest Industrial Estate, Peterlee, SR8 2SW, UK. T: +44 (0)191 5180020 www.emerson.com www.linkedin.com/company/emerson
Floats Road, Manchester, M23 9NF, UK. T: +44 161 286 5000 www.uk.endress.com www.linkedin.com/company/endress-hauser-group
T: +44 (0)1698 481481 crc-techuk@honeywell.com sensing.honeywell.com www.linkedin.com/company/honeywell
Kingsway Business Park, Oldfield Road, Hampton, TW12 2HD, UK T: +44 (0)20 8213-0000 Enquiry.gb@ifm.com www.linkedin.com/company/ifm-electronic-gmbh
Great Western Court, Hunts Ground Road, Stoke Gifford, BS34 8HP, UK T: +44 (0)800 951951951 www.infineon.com www.linkedin.com/company/infineon-technologies
7-9 Beetham Road, Milnthorpe, LA7 7QL, Cumbria, UK. T: +44 (0) 1539 722 520 info@invisible-systems.com www.invisible-systems.com www.linkedin.com/company/invisible-systems
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industry 4.0 Issue no 4 - SEPTEMBER 2018
sensors directory
Avebury House, 219-225 Avebury Boulevard, Milton Keynes, MK9 1AU, UK. T: +44 (0) 1908-696-900 ukinfo@keyence.co.uk www.keyence.co.uk www.linkedin.com/company/keyence The Officers Mess, Coldstream Road, Caterham, Surrey, CR3 5QX, UK. T: +44 (0)203 026 2670 sales@lamonde.com lamonde.com www.linkedin.com/company/lamonde-automation-ltd Terek House, Phoenix Business Park, St. Neots, PE19 8EP, UK. T: +44 14 80 408 500 mail@leuze.co.uk www.leuze.co.uk www.linkedin.com/company/leuze-electronic-gmbh---co--kg Auf dem SchĂźffel 9, 58513 LĂźdenscheid, Germany. T: +44 79 44 15 03 00 info.uk@mtssensors.com www.mtssensor.de www.linkedin.com/company/mts-sensor-technologies-gmbh-&-co-kg
One Fleet, Ancells Business Park, Ancells Road, Fleet, GU51 2UN, UK. T: +44 1252 811666 www.linkedin.com/company/murata-electronics www.murata.com
Pendlebury Industrial Estate, Albion Street, Swinton, M27 4FG, UK. T: +44 (0)161 72831 33 info@murrelektronik.co.uk www.murrelektronik.co.uk www.linkedin.com/company/murrelektronik-gmbh 77 Ripponden Road, Oldham, OL1 4EL, Lancashire, UK. T: +44 (0)161 633 6431 sales@gb.pepperl-fuchs.com www.pepperl-fuchs.com 26
www.linkedin.com/company/pepperl-fuchs
Issue no 4 - SEPTEMBER 2018
sensors directory
industry 4.0
Halesfield 13, Telford, Shropshire, TF7 4PG, UK. T: +44 (0)845 881 2222 info@phoenixcontact.co.uk www.phoenixcontact.com www.linkedin.com/company/phoenix-contact
Davy Avenue, Knowlhill, Milton Keynes, MK5 8HJ, UK. T: +44 (0)1908 666 777 www.routeco.com www.linkedin.com/company/routeco
Birchington Road, Corby, Northants, NN17 9RS, UK. T: +44 (0)8457 201201 uk.rs-online.com www.linkedin.com/company/rs-components
Waldkirch House, 39 Hedley Road, St. Albans, AL1 5BN, UK. T: +44 (0)1727 831121 info@sick.co.uk www.sick.com/gb/en www.linkedin.com/company/sick-ag Vincent Avenue, Crownhill, Milton Keynes, Bucks, MK8 0AN, UK. T: +44 (0)330 311 6689 technical@smcpneumatics.co.uk www.smc.eu www.linkedin.com/company/smc Blenheim House, Hurricane Way, Wickford, Essex, SS11 8YT, UK. T: +44 (0) 1268 578888 +44 (0) 1268 763648 enquiries@turckbanner.co.uk www.turckbanner.co.uk www.linkedin.com/company/turck-banner-ltd
Triton Park, Swift Valley Industrial Estate, Rugby, CV21 1SG, UK. T: 01788 568 008 uksales@wago.com www.linkedin.com/company/wago-corporation
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Latest news PTC Named a Leader in Industrial IoT Software Platforms by Top Independent Research FirmPTC Noted Among the Most Significant Industrial Internet of Things Software Platforms PTC has been named a leader in the Industrial IoT software platforms market for its ThingWorx®Industrial Innovation Platform, according to a new evaluation from Forrester Research. In the Forrester evaluation, entitled “The Forrester Wave™: Industrial IoT Software Platforms, Q3 2018,” PTC was the among the top five highest ranked in the current offering category and among the top four in the strategy category. Forrester evaluated the current offering, strategy, and market presence of PTC and 14 other vendors. Each company was evaluated according to a comprehensive set of 24 criteria, grouped into three high-level categories: current offering, strategy, and market presence. Participating vendors all had a significant focus on the industrial domain and its use cases, native support for key industrial protocols, and a strong international presence. Within that context, PTC was deemed a leader by Forrester. Regarding PTC’s standing in the evaluation, Forrester notes: “PTC fuses device connectivity strength with augmented reality vision … and the company offers rich capabilities spanning design, manufacture, service, and operations, combining these in accessible end-user applications.”
The report cited partners among ’key differentiators,’ and PTC has built strategic relationships with several of the esteemed companies within the Wave’s Leaders and Strong Performer categories, as well as hundreds of other complementary partners and resellers. “We are proud to be named a leader in this independent evaluation, and we believe that being included in this Forrester report validates our strategy and market success,” said Iain Michel, general manager, ThingWorx business unit, PTC. “In our view, this recognition is yet another testament to the strength of our innovation platform and the acceptance by companies around the world looking to capitalize on the immense opportunities created by the Industrial Internet of Things.” The recognition from Forrester continues a long string of industry recognition from press and industry analysts around the world, including 451 Research, Compass Intelligence, Experton Group, Gartner, IDC, IoT Analytics, Berg Insight, IoT ONE, and Quadrant Knowledge Solutions. Most recently, PTC’s ThingWorx has been awarded IoT Evolution Product of the Year.
ThingWorx is the centerpiece of PTC’s Industrial Internet of Things technology portfolio, and it exemplifies PTC’s commitment to IIoT innovation. ThingWorx is comprised of a rapid application development platform, connectivity, machine learning capabilities, augmented reality, and integration with leading device clouds. These capabilities combine to deliver a comprehensive IoT technology stack that enables customers to securely connect assets, quickly create applications and experiences, and innovate new ways to capture value. Over 1,000 companies, including Elisa, Heidelberg, Sysmex America Inc., and Vodafone, are using the ThingWorx platform to support their IoT strategies and to create new business value in a smart, connected world. 28
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Latest news
Issue no 4 - SEPTEMBER 2018
industry 4.0
With Solomon AI-based 3D vision, robotic accomplishment of complex tasks gets real
Chairman Johnny Chen said, Solomon’s suite of AI-based machine vision solutions can significantly enhance productivity of robots by making them more ‘intelligent’ and flexible. Manufacturers around the world are gearing up to adopt Industry 4.0 in which computers and automation will come together in an entirely new way. Robotics connected remotely to computer systems equipped with machine learning algorithms, such as Solomon’s suite of AI-based machine vision solutions, can enhance productivity by enhancing the monitoring of advanced manufacture processes. Take random bin picking for example. The seemingly simple task is not quite as easy for robots. Yet, Solomon’s AccuPick 3D system is able to perform bin picking with high recognition rate and ease of use thanks to its 3D scanner capable of generating high quality point cloud at high speed. The system is capable of recognizing complex shapes objects with maximum efficiency and precision. AccuPick’s motion planning module is specifically targeted for applications requiring robot arms to maneuver inside of an outsized bin in industries ranging from automotive components, electronics, food packaging, machine tending, and warehouse de-palletization. The system is able to work in complex environment while remaining compatible with major robot brands, such as Universal Robots(UR+ certified), Fanuc, Staubli, Yaskawa, Kuka, ABB and more. Advanced tasks such as sealing, assembly, welding or inspection can also be equally difficult or time consuming
for robots. Solomon’s 3D vision guided robot solution, Solmotion, takes complexity out of these seemingly challenging tasks as it recognizes unique features to determine the three-dimensional position and orientation of a workpiece with precision and speed. All it takes is for the Solscan 3D scanner to take a snapshot of the workpiece, before the software immediately matches and calculates the required routes for robot to move along. Applications include sealing of automotive parts, gluing of footwear parts, quality inspection of metal or plastic injection objects, welding of motors, to name a few. In industrial setting, defects and features with irregular patterns such as hard-to-define scratches, stains, cracks and many other types of flaws, Solvision, Solomon’s AIbased machine vision software, can further solve inspection problems. The software deep learning requires no tedious writing of codes to inspect various types of defects. All it takes is a few samples to label the defect types for machines to learn, simplifying inspections tasks and saving significant amount of engineers’ time to write the programs. Another advantage of Solvision is its seamless integration with different robots, six-axis or SCARA, Solomon’s 3D Solscan scanner and software, so inspected objects can be automatically separated accordingly.
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Why manufacturers should transform into Connected digital enterprises in Industry 4.0?
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industry 4.0 Issue no 4 - SEPTEMBER 2018
Latest news
TCS Recognized as a Leader in Worldwide Manufacturing Customer Experience IT Strategic Consulting & Systems Integration by IDC MarketScape Tata Consultancy Services’ Global Footprint, Innovation Accelerators, and CX Roadmap and Methodologies Cited as Key Differentiators Tata Consultancy Services (TCS), (BSE: 532540, NSE: TCS), a leading global IT services, consulting and business solutions organization, has been recognized as a Leader in two IDC MarketScape reports for Worldwide Manufacturing Customer Experience, covering IT Strategic Consulting as well as Systems Integration.1 According to the IDC MarketScape: Worldwide Manufacturing Customer Experience IT Strategic Consulting 2018 Vendor Assessment, “Among the strengths that surfaced from this evaluation of TCS are the company’s use of innovation accelerators within CX for manufacturing engagements as well as its depth of experience in full time employees with CX or manufacturing experience. TCS has a high penetration rate of non-IT key sponsors of customer experience projects, indicating its ability to work with business leaders to identify the strategic impact that technology can have on customer experience.” “Progressive manufacturers in a Business 4.0™ world are focusing on connected products, operations and customers to provide contextual service and greater customer experience,” said Milind Lakkad, Executive Vice President & Global Head – Manufacturing Industry Solutions Unit, TCS. “Our positioning as a leader is a testament to the investments we have been making in building deep capabilities in this area, and our Business 4.0 vision that is driving our strategy around CX offerings.”
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TCS works with the world’s leading manufacturers, including a third of all Fortune 500 manufacturing companies, helping them embrace business innovation and advance their growth and transformation agendas. Leveraging its manufacturing domain expertise, business knowledge, and transformation capabilities, TCS provides a comprehensive portfolio of services and offerings around customer experience management spanning digitalization strategy, ecommerce transformation, front office transformation, analytics and insights, digital marketing, customer portals, contact centers, and customer journey orchestration. Industry specialists and customer experience experts with rich hands on industry expertise work closely with teams of designers across a global network of design studios to build next generation customer experience management solutions. By leveraging digital technologies such as Big Data analytics, mobility, social media, artificial intelligence, robotics and cloud, TCS helps global enterprises reimagine their customer experience journey. Innovation accelerators such as augmented/virtual reality, artificial intelligence, IoT and natural interfaces further help in assessing end-customer perception and ensuring an overall superior customer experience. “Our industry depth, contextual knowledge, comprehensive portfolio of services, investments in accelerators, and continuous focus on innovation make us the partner of choice for organizations looking to reimagine their customer experience systems in a Business 4.0™ world,” added Milind Lakkad.
Latest news
Issue no 4 - SEPTEMBER 2018
industry 4.0
Honeywell Connected Plant Helps Visualize And Optimize Energy Use At Turbocharger Plant In Japan
First deployment of Asset Performance in Asia reduces energy consumption at Honeywell Transportation System’s Kodama plant Honeywell (NYSE: HON) today announced the implementation of Honeywell Connected Plant Asset Performance at its Kodama turbocharger plant located in Saitama, Japan. The newly-deployed cloud-based technology allows Honeywell’s Transportation Systems business to remotely identify, analyze and optimize energy consumption of the overall plant as well as all connected field devices. This is the first deployment of the solution in Asia. Asset Performance connects assets and equipment to the cloud and applies analytical models from Honeywell and its partners to monitor and predict future asset performance, helping customers avoid critical asset failures and unplanned shutdowns. The Connected Plant technology is vendor-neutral, and can be tailored and rapidly deployed through pre-configured templates based on Honeywell’s extensive industry experience. As a centrally-managed Software as a Service (SaaS) solution, it requires minimal infrastructure and reduces maintenance costs. “Just as we strive to offer automakers innovative technologies for both traditional internal combustion engines and advanced hybrid electric powertrains to help meet more stringent global environmental standards, we must also optimize our own energy consumption during production,” said Yasuhiro Kinoshita, country leader of Honeywell Transportation Systems, Japan. “With Asset Performance, we can monitor asset performance details and for example detect air leaks in the manufacturing units, which directly allows us to reduce energy usage and avoid excess cost.”
At the Kodama plant, Asset Performance operates in three stages: • Data
is collected from nearly 70 different field devices such as power meters, flow meters and air compressors and is securely transported to the cloud-based environment of Asset Performance.
• The
Asset Performance solution combines process data with asset data to provide analytics and key performance indicators (KPIs) that provide insight to plant management into asset performance and energy consumption, enabling proactive actions to ensure the highest level of reliability and manufacturing performance.
• With
the help of its robust analytical results, Asset Performance helps Transportation Systems better forecast the plant’s energy consumption and integrate with their third-party ISO 50001 energy management solution.
“This is another great example of how Honeywell Connected Plant can bring existing facilities to the next level of data-driven optimization,” said Shinichi Sakata, business leader of Honeywell Process Solutions, Japan. “With our global industrial domain expertise and more than 60 years of experience in Japan combined, we can help businesses like Transportation Systems manage asset performance and operate more strategically and efficiently.”
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industry 4.0 Issue no 4 - SEPTEMBER 2018
Latest news
Dell Technologies Announces New IoT Solutions to Automate Powerful, Actionable Insights
Provides scalable, secure, manageable and open infrastructure - spanning edge to cloud - so customers can realize value today and build a foundation for the future •
ew solutions include hardware and software N engineered to work together to support computer vision and machine intelligence from edge to cloud
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New Dell Technologies IoT Solution for Surveillance speeds time to realize return on investment with flexibility and customization
•
New IoT Connected Bundles, created through the Dell Technologies IoT Solutions Partner Program, offers channel partners new revenue streams
Dell Technologies’ Edge and IoT Solutions Division is announcing new solutions and bundles to simplify deployment of secure, scalable solutions for edge computing and IoT use cases. With these solutions, Dell Technologies is combining tools from its broad portfolio with technology from Intel and partners in the Dell Technologies IoT Solutions Partner Program. This will drive workloads for computer vision – enabled by imaging sensors – and machine intelligence – characterized by structured telemetry from sensors and control systems. Dell Technologies has collaborated with Intel, who has helped advance these solutions with their computer vision and analytics technologies.
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“Workloads and use cases for computer vision and machine intelligence require different combinations of tools, but the computing infrastructure elements are the same,” said Joyce Mullen, president, Global Channel, OEM and IOT Solutions at Dell Technologies. “Dell Technologies provides a scalable, secure, manageable and open infrastructure – spanning edge to cloud – so customers and partners can realize value today and build a foundation to support these workloads and case studies in the future.” Cameras provide rich information about the physical world, but the deluge of video data creates too much data for humans to cost-effectively monitor for real-time decision making. Applying analytics, such as Artificial Intelligence, to these data streams automates powerful, actionable insights. Events driven by computer vision and analyzed together with telemetry from machines – including data that imaging sensors cannot provide, such as voltage, current and pressure – results in even more powerful insights. Because of rapid evolution in the IoT market and the fast pace of innovation required to stay competitive, many customers now require an ‘IT grade’ infrastructure. This should include a security-first perspective to support scalability, data diversity and the increasingly complex needs of connected devices.
Latest news
Issue no 4 - SEPTEMBER 2018
industry 4.0
Integrating Dell Technologies solutions to enable computer vision By enabling computer vision with Dell Technologies IoT solutions, customers can more accurately, efficiently and effectively “see” relevant information pertaining to areas such as public safety, customer experience, and product inventory and quality. Surveillance is the first use case to which Dell Technologies has applied computer vision, so customers can more cost-effectively monitor events in the physical world and automate decision-making. The IoT Solution for Surveillance is specifically built to transform and simplify how surveillance technology is delivered with an easy to deploy and manage hyperconverged, software-defined solution. Available later this year to purchase as a package, the engineered, preintegrated solution will provide a consistent foundation from edge to distributed core to cloud. It will also be ready to run on day one with customer data to speed the return on investment. The solution is currently available as a reference architecture to align systems and build a framework for computer vision learning and adoption for other use cases.
Additionally, it is flexible to adapt to changing technologies or industry regulations to meet data needs today and in the future. •
Reduced risk – Dell EMC Surveillance Validation Lab tests hardware and ISV software solutions together in extreme simulations to ensure it will stand up in the real world.
•
Integrated security – The built-in security measures include micro-segmentation (NSX-T) and the ability to push over-the-air (OTA) updates and security patches in real time to all surveillance devices from camera to cloud. It also will include holistic management capabilities across IT and operational technology (OT) concerns through a combination of VMware Pulse IoT Center and Software Defined Data Center.
•
reater reliability with scalability from hundreds to G thousands of cameras/sensors – The solution offers an automated, fault-tolerant approach to scaling from 300TB to 50PB+ on Dell EMC Elastic Cloud Storage for private, on-premise, off-premise or hybrid needs. High availability and zero data loss will be guaranteed with vSAN RAID 5/6 across flash and disk. Additionally, ESXi Enterprise Plus enables high availability and disaster recovery services.
Built on world’s leading cloud infrastructure, the Dell Technologies IoT Solution for Surveillance will offer: • Rapid return on investment – The open architecture allows for customization with immense choice of technology, purchasing and configuration.
Dell Technologies IoT Solutions Partner Program creates new revenue opportunities for channel partners The Dell Technologies IoT Solutions Partner Program is an award-winning, multi-tiered program supporting technology and services partners from the edge through the full Dell Technologies solution stack. Through this program, Dell Technologies has identified several partners demonstrating strong use case focus and clear return on investment to create the new Dell Technologies IoT Connected Bundles. The bundles include sensors and licensed software from partners tailored for specific customer use cases, together with various combinations of Dell Technologies infrastructure spanning edge gateway, embedded PC and server hardware. This is in addition to complimentary software like VMware Pulse IoT Center for securing, managing and monitoring these solutions at scale. Sold fully through the channel, IoT Connected Bundles are validated, market-proven solutions that channel partners can deliver to their customers as turnkey offerings. With these solution bundles, channel partners have a new value proposition to offer their customers, as well as a new potential revenue stream. With a clear, repeatable and accelerated path to return on investment, channel partners can enter the IoT market knowing the solution will work and deliver predictable results fast.
The IoT Connected Bundles include: •
LM: compliance-aaS for HVAC, refrigeration and power E systems
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5 Systems: self-contained and powered surveillance for V safety and security in outdoor spaces
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I MS Evolve: energy savings for grocery retailers while improving food quality and safety
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odius: advanced Data Center Infrastructure M Management (DCIM)
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elco: video surveillance tailored for the requirements of P K-12 education
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ixel Velocity: efficient remote monitoring of field P assets in oil and gas operations
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ctionPoint: predictive maintenance in midmarket A manufacturing
•
oftware AG: digital manufacturing intelligence suite S for larger-scale operations
Over time, additional bundles will be available through further curation in the Dell Technologies IoT Solutions Partner Program.
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Industry 4.0 Summit Speech Smart Factory Management
At our 2018 Manchester conference Kari Terho, Head of Smart Factory Management at Finnish company Elisa, explained how Elisa has been making its own factories smarter; sharing insights and first-hand experience about Elisa’s Industry 4.0 system. We grabbed a few minutes with him to find out more about the company’s journey.
Elisa is the leading telecom provider in Finland but, in recent years, twenty-five percent of its revenue has come from IT services. A big part of these IT services is factory digitalisation and Terho explains that Elisa has been delivering Industry 4.0 solutions to enterprise customers in Finland and the Nordic countries for the past five years. “We are a huge factory ourselves, we have approximately five million devices in our network,” Terho says, “and we monitor everything in real time. We analyse more than a hundred thousand transactions per second:
every call, every data browsing, every visit to a website. So we know what is happening in our network – and we know what will happen.” In fact, Elisa is so good at knowing what will happen, 75 percent of all internal incidents were handled through its predictive maintenance programme before anything happened. “What we are doing internally has real value and we are working to deliver that knowledge and experience to our enterprise customers,” Terho continues, “because every factory is wondering ‘how can I predict?’. If an enterprise can predict 75 percent of all future incidents, its productivity will rise sharply.”
“If an enterprise can predict 75 percent of all future incidents, its productivity will rise sharply.”
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How Can I Predict? Achieving this goal is a three-step process, says Terho.
1.
2.
3.
Data
Understanding
Prediction
Data is the starting point. We need to collect data from the whole factory and make it visible.
Once we have the data, we can start to manipulate it, so we can understand why things are happening. Why is there an unplanned stop in my production? Why do I have material losses? Where are they coming from?
Then, when you have that understanding, you can start to predict. When you understand what is happening and why it is happening you can start to predict what will happen; to make anomaly detection and use machine learning tools.
Terho says there is a big appetite in his native Finland in this type of solution and the Industry 4.0 agenda. “Gartner research has shown that 50 percent of Finnish enterprise customers are already using IIoT or smart systems. By comparison, in the rest of the world that figure is only 25 percent,” he says. “But the biggest different is that only 17 percent of Finnish enterprise customers are saying there is no need for Industry 4.0. In the rest of the world, 40 percent of enterprises think there is no need. So, in that sense, Finland is ahead.”
As a small, traditionally tech-savvy country that has grown some big tech brands, Finland has a strong track record in embracing new technology, and Terho thinks there is a cultural driver behind these high acceptance figures. “We like to test new things,” he says, “When people say ‘you should do this because you can increase your productivity’ or ‘improve your cashflow’ the Finnish mentality is ‘ok, let’s try it’ and I think that is critical for speed and agility.” 35
industry 4.0 Issue no 4 - SEPTEMBER 2018
Smart Factory Management
Speed and Agility Terho argues that, wherever you are, speed and agility are vital if Industry 4.0 projects are to succeed. Rather than spending months wondering whether to do something or not, or paying consultants to ask those questions for you, Terho asserts the only way to achieve success is to test and test again. “Don’t spend more than two or three months,” he says. “Test it; run proof of concepts. If it works, then scale it. If it doesn’t work, do another test.” It’s an approach Elisa has been putting into practice for the last seven years. Despite delivering increasing data across its network over this time, the total number of incidents have come down and predictive maintenance resolves the vast majority of the rest. The telecoms provider’s own Industry 4.0 projects are ongoing. Terho makes the point that Industry 4.0 is a journey, not a destination: the opportunities for improvement continue.
“We’ve trained a massive amount of people on the platform we provide, so there is a big eco-system of learners and universities and we are part of it.”
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Today, Elisa is exploring these future opportunities not only at its factory but through its work at the European 4.0 Transformation Center in Achen. Elisa is the only Nordic company that partners with the center and Terho is on the steering group. “German industry has invested and is investing €2 billion to building up digital transformation know-how,” he says, “and the 4.0 Transformation Center will play an important role in that – not just in Germany but across Europe.” Elisa is adopting a similar approach in its own market; providing software solutions to Finland’s Universities for training purposes, so all of them can have an IoT and IIoT programme. Terho says, “We’ve trained a massive amount of people on the platform we provide, so there is a big ecosystem of learners and universities and we are part of it.” By attending our conference in Manchester, Terho hopes to inspire the same enthusiasm around what Industry 4.0 can do here in the UK.
Smart Factory Management
Issue no 4 - SEPTEMBER 2018
industry 4.0
Video:
The finnish experience of Smart Factory Management by Elisa
About Elisa Elisa is a telecommunications, ICT and online service company operating mainly in Finland and Estonia. The company was founded in 1882 and today serves more than 6.2 million consumer, corporate and public administration organisations, making Elisa is the market leader in mobile and fixed network subscriptions in Finland. With a proven track record with large industrial customers, Elisa is participating in the European 4.0 Transformational Center in Aachen, together with other technology leaders. The centre focuses on helping manufacturers realise agile digital transformation. Elisa Smart Factory Management enables digital transformation in manufacturing; brining clarity to complexity. With real-time data, advanced analytics and 3D visualisation, users can spot deviations in real time, simulate changes, optimise processes and establish “golden operation� benchmarks. Find out more: elisa.com/iot/solutions
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