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Contents A6 How to use the true value of data Manufacturers could save $100 billion through data sharing

A8 How to choose a system integrator A system integrator can help end users navigate the best path toward a new optimized automation system solution

A11 How a system integrator developed a data acquisition application

A6

System integrator DMC developed a custom LabVIEW data acquisition application to leverage SystemLink as a central database for storing and serving up data for data analysis and visualization

ON THE COVER A fast and costeffective way to digitalize processes is by retrofitting new technologies to old equipment. Courtesy: EU Automation

I NSI GHTS

Insights on data sharing and system integration

T

Jack Smith Editor

he cover story in this issue of AppliedAutomation explores the topic of data sharing, explains the opportunities sharing data creates for manufacturers and the obstacles they may encounter. The article draws considerably from studies by Boston Consulting Group (BCG) and the World Economic Forum (WEF), and asserts manufacturing companies could save billions by combining their digital records. The article points out business and technical advantages. However, the author also acknowledges there are challenges. The author writes: “One involves buying and building the new computing infrastructure needed to connect machines, companies and industries, which can be costly and time consuming.” Increased data sharing capabilities also can increase security risks because it multiplies the access points through which hackers can infiltrate data infrastructures.

Each December, CFE Media publishes the Global System Integrator Report (GSIR), of which I am the editor. In addition to the system integration coverage in the GSIR, AppliedAutomation has two articles by system integrators about system integration topics. The first of these SI features (the second article in this issue) offers guidance on selecting a system integrator. The article has a thorough checklist to help guide users through the SI selection process. The third story describes how a system integrator developed a custom LabVIEW data acquisition application to leverage SystemLink as a central database for storing and serving up data for data analysis and visualization. It provided the client with a custom test executive specific to its operational processes and business needs and sent data to a server, which gave the client flexibility to manage test systems and data in ways that helped add value to the testing workflows.

Applied Automation December 2020

A5


C O V E R S T O RY

How to use the true value of data Manufacturers could save $100 billion through data sharing By Claudia Jarrett,

H

EU Automation

ow much is data worth to your business? According to a study by Boston Consulting Group (BCG) and the World Economic Forum (WEF), manufacturing companies could save billions by combining their digital records. This article explains the opportunities sharing data creates for manufacturers and the obstacles they may encounter. While big data and artificial intelligence (AI) are changing the face of industry, BCG and WEF’s research has found they also could produce benefits worth $100 billion for businesses worldwide. This conclusion is based on a survey of 996 manufacturing managers by calculating the savings their various suggestions could bring to manufacturing companies. Data sharing is considered a viable opportunity by manufacturing managers. Of those surveyed, 72% thought sharing data with other manufacturers would improve operations, while 47% believed optimized assets

are the biggest benefit of sharing data more widely. How can this contribute toward billions in savings?

Learning to save BCG and WEF’s study estimates the manufacturing industry could save $40 billion by optimizing assets through machine learning. The idea is interconnected machines use predictive algorithms to improve each other’s performance (see Figure 1). With access to performance data, machines can help reduce downtime and optimize processes. A further $40 billion could be saved by tracking products along the supply chain more effectively. If users know where a product is at any particular time, they can better plan their processes and prepare for supply and demand fluctuations. By using data to create a comprehensive picture of the supply chain, users can reduce inventory levels, stocking only what they need, and make better informed, or even automated, purchasing decisions. Both will directly benefit the bottom line. BCG and WEF’s report estimates a further $15 billion could be saved by knowing the origin and condition of products along the entire value chain. This knowledge can be invested into improved quality management by finding the root causes of faulty products more quickly and accurately. Companies that operate in highly-regulated environments, like the food industry, could realize a large part of these savings.

Obstacles to data sharing

Figure 1: Because interconnected machines use predictive algorithms to improve each other’s performance, industry could save $40 billion by optimizing assets through machine learning. Courtesy: EU Automation

A6 • December 2020

Applied Automation

While BCG and WEF’s suggested uses for data sharing clearly have their advantages, achieving those savings is not without challenges. One involves buying and building the new computing infrastructure needed to connect machines, companies and industries, which can be costly and time consuming. Instead, a faster and potentially more cost-effective way to digitalize processes is by retrofitting new technologies to old equipment (see Figure 2). One way to retrofit is through the use of smart sensors, the global market for which is growing at a 19% annual rate and is expected to reach $60 billion by 2022, according to Deloitte. Sensors can be fitted to existing machines to gather data on their performance and allow decisionmaking about production processes, in real time. A specialist supplier of industrial automation parts, such as EU Automation, can help in sourcing the retrofitting components needed to fully embrace digitalization.


Figure 2: A fast and cost-effective way to digitalize processes is by retrofitting new technologies to old equipment. Courtesy: EU Automation

risks. Data sharing multiplies the access points through Take the example of a packaging line where managers which hackers can infiltrate computers, which is why can’t understand why output is lower than normal. Smart manufacturers should implement an effective system sensors could be fitted at each stage along the line to hardening strategy, to close such loopholes. Effective data work out which process is causing faults or slowing prosharing should be accompanied by regular system hardduction. This will tell the managers where their losses are ening audits to identify system and enable them to fix the issue vulnerabilities and help install quickly and effectively. Data sharing multiplies the access software patches that secure Another example is fitting a data sharing. range of computerized numeric points through which hackers can control (CNC) machines with Better to share? sensors that supply data about infiltrate computers, which is why their performance. If a CNC By effectively using smart manufacturers should implement machine in one location productechnologies and digitalization es burn marks because of an strategies, you can not only an effective system hardening improper feed speed, the same collect useful data, but use it to type of machine at another locaimprove efficiency within your strategy, to close such loopholes. tion could automatically correct business. AI and big data have its speed to avoid the same made it possible for informaproblem — otherwise known as machine learning. By tion, such as that gleaned from smart sensors fitted to analyzing the resulting stream of data, manufacturers can manufacturing machines, to be continuously analyzed glean clues on common faults and maintenance cycles and used to optimize assets. and achieve tangible cost savings. What could data sharing be worth to your business? Data sharing also can involve sharing design specificaWhile saving $100 billion across U.S. manufacturers is a tions and tolerances with suppliers and customers. This can huge estimate, digitalization will enable manufacturers to reduce the tolerance stacking that occurs when different share data safely, securely and in ways that significantly suppliers maximize their tolerance allowances, resulting in a benefit their bottom line. final product that fails to meet the customer’s standards. Another challenge for manufacturing managers is Claudia Jarrett is the United States country manager at increasing data sharing capabilities can increase security EU Automation.

Applied Automation December 2020

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S Y S T E M I N T E G R AT I O N

How to choose a system integrator A system integrator can help end users navigate the best path toward a new optimized automation system solution Business and market knowledge

By Lynn Njaa M AV E R I C K Te c h n o l o g i e s

M

any manufacturers are leveraging new technologies, such as the Industrial Internet of Things (IIoT), cloud and edge computing, virtual reality and the like, to digitally transform their operations. Some are migrating their legacy control systems while others are looking to perform smaller system maintenance upgrades, to improve operations and reduce downtime. No matter the size, an upgrade or migration project can be complex, and the risks can be high. Navigating the best path forward toward a new optimized automation system solution often requires additional resources in the form of an external third-party partner like a systems integrator (SI) or automation solutions provider. The best choice depends on who can meet the necessary requirements in the facility. With the plethora of SIs out there — from small and perhaps independently-owned to those who have partnerships or are embedded in big engineering, procurement and construction (EPC) companies — trying to contrast and compare who can meet facility and project requirements is no easy task. In addition, some distributed control system (DCS) and programmable logic controller (PLC) suppliers offer engineering services on their specific products. All SIs have their strengths and weaknesses. Some may have extensive knowledge on their own equipment, but limited or no knowledge on equipment outside of their specific products. Others might provide a one-stop shop, but they may lack automation expertise as it is only a small portion of their business. What is the best choice? It is best engaging with an automation partner who has applied, unbiased platformindependent process control experience working across a wide range of manufacturing processes and automation technologies. Such expertise will likely result in a more successful project execution. To get started, consider the following checklist and a few other points and topics worthy of further investigation that can help guide the selection process.

A8 • December 2020

Applied Automation

• Does the SI have expertise in many vertical industries? –This is important because a benefit of having a partner with experience in many industries is they can crosspollinate solutions, best practices and engineering expertise. • Does the SI have industry expertise specific to the business? –Having industry-specific experience is important to understanding the potential return on investment (ROI), as well as understanding the potential competitive advantages. • Is the SI open-minded to the company’s culture, and do they understand its business needs? • If an SI partnership is already in the early stages, are they listening to key stakeholders? Or are they dictating to them? Do they collaborate with company personnel, or do they work in silence and present something that ends up requiring changes to it — maybe repeatedly? Well, that’s not cool.

Program/project management capabilities • Locate a project management office (PMO) • Ensure project managers have project management professional (PMP) certification • Expect a solid and proven methodology for execution and quality control • Is a well-documented quality program in place? • Is a well-documented project audit process in place? • Can the SI demonstrate a substantial history of records? • Can they show template samples?

Planning and budgeting capabilities • Does the SI have business case development experience to get the migration or project moving forward? This is a plus if they do. • Can they help fill any justification gaps to get the project funded?


• Do they have support, expertise and tools for capital planning and for project funding? • Can the SI demonstrate experience in these practices? • Can they provide the confidence they have solid costestimating tools to stay within budget? • Will the SI provide the granularity of detail needed to gain company leadership confidence and provide it in native format so as not to “reinvent the wheel?”

Turnkey management The following elements are needed to provide a full turnkey management solution: • Front-end engineering • Design management • Integration management • Deployment management • Field services and/or construction management • Communication management • Optimization, advanced process control • Offerings for onsite and offsite specific training for a new system • Sustaining services • Staffing capabilities while maintaining the availability of project personnel

Main automation contractor (MAC) An automation solutions provider with proven services, capabilities and experience — one company to handle all controls requirements — so there is only one point of contact instead of many points of contact for cross communications. There should be no need to hire separate companies to take care of all the automation needs. The full list of automation abilities includes: Automation solutions • Process automation • Control system design

• • • • • • •

Control system integration Control system migration Regulatory compliance Data centers Building automation Virtualization Human-machine interface (HMI) design, including high-performance graphics design • Advanced process control (APC) • Field services • Technician services and calibration • Shutdown, turnaround and outage support • Installation services • Commissioning/construction management • Large-scale project execution. Enterprise integration • Manufacturing operations technology consulting • Manufacturing/enterprise resource planning (ERP) integration • Smart manufacturing/IIoT • Asset performance • Performance analytics • Manufacturing execution • Work process management. Strategic manufacturing solutions • Productivity improvements • Industrial cybersecurity • Energy efficiency • Automation strategy • Arc flash prevention. Sustaining services • Maintenance and support contracts • Site services • 24/7/365 remote management and monitoring support.

Applied Automation December 2020

A9


S Y S T E M I N T E G R AT I O N Formal customer satisfaction feedback mechanism • Can they share their Net Promoter Score (NPS) if they have one? For more information, check out Net Promoter Score. • Request references • Ask for case studies –Do they apply to the platform? –Do they apply to the industry?

• Meets all control system requirements, regardless of the control system. A single supplier that has depth of expertise in multiple DCSs, PLCs and communication protocols can make everything talk together. This benefit removes the risk of “Oh, we don’t take care of that part of the control system.” • Is focused on mitigating cybersecurity risks.

Review and understand

the most important items

Look for over promises

Track record of innovation: Problem solvers

on the list for the business,

• Find a trusted, honest partner with strong principles and work ethics. A company will discover there is no substitution for working with an SI with these qualities. • Compare pricing to promises made. • Be aware the cheapest isn’t always the least expensive. “If you don’t have time to do it once, you certainly don’t have time to do it twice.”— Unknown. • Watch out for poor design work due to a lack of time spent planning. This can be twice as costly as a good initial plan/solution/design. • Look for a crew mix of senior and junior personnel. No company can afford to give up all their superstars. Besides, who would want to pay for their rates? A lot of junior talent is out there who, with the right guidance, will perform beyond expectations. • Look for fairness and competitiveness.

• Look for consultants experienced in problem solving. Each consultant has a specific strength and, when pooled, can make big things happen. • Ensure they can look beyond the technology and help develop good business process management practices for the future. • Find someone who is strategy- and solution-focused to help meet business objectives.

but don’t ignore the rest

of the list. Take the time to investigate each item.

Familiarity with standards • An SI who understands compliance to general best practices, as well as regulations to all equipment, will help mitigate risk and keep the company compliant.

Code migration assets • Has the tools and accelerators to automatically capture and “rewrite” the code into the new system. No tool is perfect, but it can save upward of 50% of code migration time.

Technical breadth and depth of portfolio and expertise • Offers broad expertise of most process control systems • Provides access to leading-edge technology • Offers continued education and mentoring within the organization to expand versatility of resources on all control systems and stays current with new technologies • Has diversity and bench strength — in other words, is there just “a guy” that can help or are there several to many resources in case “the guy” is busy?

A10 • December 2020

Applied Automation

Financial stability and backing • Is the trusted resource too small and might disappear overnight if they win the lottery or begin to have financial trouble? If so, then what? • Does the SI have many locations with several resources in various places to call on when needed? This is the checklist, which will require further review and input from key stakeholders to ensure a successful systems integrator selection process. Now for some more key takeaways. Review and understand the most important items on the list for the business, but don’t ignore the rest of the list. Take the time to investigate each item. Any one of these items can rear its ugly head on an upgrade project or migration. And the thought of, “If I’d only known,” is a terrible feeling and will result in sleepless nights. Think through the risks of each item and consider whether stakeholders have the appetite for the worst-case scenario. There is at least one systems integrator that can check all the boxes on the list to fulfill company requirements. The trusted partner can realize all of the company’s needs with one phone call. Finding a knowledgeable, systems integrator who can lead the company to future success is worth the time and effort. Lynn Njaa is a senior consultant for MAVERICK Technologies. MAVERICK Technologies is a member of the Control System Integrators Association (CSIA).


D ATA A C Q U I S I T I O N

How a system integrator developed a data acquisition application System integrator DMC developed a custom LabVIEW data acquisition application to leverage SystemLink as a central database for storing and serving up data for data analysis and visualization By Ryan Yu,

D

DMC

home. This remote capability now offers more options on how to view and access the data. While this project was completed prior to the COVID-19 pandemic, the system enabled engineers to access data anywhere they can access their network. The client had an existing data acquisition system that suffered from the following data management issues:

eveloped by National Instruments, SystemLink is a software platform designed to help companies manage devices, software and test data on a centralized SystemLink server. SystemLink provides a wide variety of powerful, • Local data storage built-in management tools that make it easier for users to manage their fleet of • No backups were taken, so data test hardware and gain key insights into was at risk their test systems. SystemLink provides flexible options for data storage in the Figure 1: The API relies on HTTPS and • The data was not secure and there form of data files and tags, which make SystemLink’s system management feawere critical security vulnerabilities it simple to upload test data onto the ture to validate and securely transfer SystemLink server. Once the data is in files. Courtesy: DMC • The database grew unmanaged over the SystemLink environment, a wide time, so it suffered from slow data variety of data analysis and data visualwrite and export speeds ization tools become available to the user, allowing one to maximize the information gained from the test data. • Off-the-shelf data acquisition software could not supThis case study highlights a recent project where DMC port the data throughput and acquisition rates required developed a custom LabVIEW data acquisition application by changing industry requirements to leverage SystemLink as a central database for storing and serving up data for data analysis and visualization. • Operators were bottlenecked in their daily tasks due to The solution DMC delivered provided the client with a the single user-access point on the one PC hosting the custom LabVIEW test executive specific to its operational local data processes and business needs. At the same time, the LabVIEW application sent data to a custom-configured • The database offered limited data management tools, SystemLink server, which gave the client the flexibility to so getting insights from the data was difficult manage test systems and data in ways that helped add value to the testing workflows. • Data was aliased according to the physical channel it Assessing the situation was acquired on, so handwritten notes were needed to associate a physical channel with the meaningful This solution was implemented for the client’s qualmetadata of the test ity assurance testing lab. The lab is large, and units are spread out. The client wanted to replace one computer • Data was cumbersome to visualize and response for data management with a server allowing remote rates for the interface were slow. access through the web on the same network or from

Applied Automation December 2020

A11


D ATA A C Q U I S I T I O N Four-step approach

HTTPS and SystemLink’s system management feature to validate and securely transfer files (see Figure 1). The tag feature is useful for storing slower speed data such as metrics and health data. The tag viewer in the web user interface (UI) makes it easy to view the latest tag data as it is being updated live and the tags are great for monitoring and tracking ongoing tests. The aggregate feature enables historical recording of tags values that can be viewed through the tag viewer, as well. Features such as keywords and properties allow the user to attach metadata STEP 1: Test the executo the tags for easier orgative app. DMC worked to nization and filtering during develop a test executive searches. The tags toolkit that would fit well into its provides the tools necesexisting testing workflow. sary to create, configure DMC began by designing and interact with tags in the a flexible test executive for LabVIEW environment. configuring and controlling For this project, DMC the data acquisition hardcreated the SystemLink ware. This was a LabVIEW Figure 2: Tags were created dynamically from the custom Tag driver to calculate test application that ran on local LabVIEW application so that by the time they were published metrics and post them to computers (nodes) connectto the SystemLink server, they were ready to be consumed SystemLink tags for general ed to the data acquisition by end users who were looking to understand their tests. test monitoring. Tags were devices. These “nodes” proCourtesy: DMC created dynamically from the vide a local interface to the custom LabVIEW applicadata and allow operators to tion so that by the time they were published to the server, configure hardware settings, configure data acquisition they were ready to be consumed by end users who were parameters, start new tests and view live results in high looking to understand their tests (see Figure 2). resolution. To send data from the nodes up to the SystemLink server to leverage the different features it provides, STEP 3: SystemLink server setup. An important DMC developed a code module called the “data desconsideration of integrating SystemLink into any projtination.” The data destination is an object-oriented ect is the specification of the server itself. The perforclass designed to be a generic and flexible application mance of the server depends on the CPU, RAM and programming interface (API) for the test executive to drive selected for the server hardware. Data throughstore acquired data in different locations. SystemLink put, the duration of tests and data retention periods data destinations were implemented to allow the test should be considered to calculate how much disk executive to automatically send data to the SystemLink space the SystemLink server needs to accommodate server in the form of data files (for high-speed data) and the data collected in the lifetime of a system. SystemLink tags (for calculated data and metrics). DMC worked with the client to calculate the hardware specifications needed for a high performing data storage solution. It also benchmarked the file transfer and tag STEP 2: SystemLink data destinations. SystemLink writing features using a SystemLink test server to ensure has two options for data storage, files and tags. The the application would meet or exceed the client’s requirefile storage on the SystemLink server is enhanced and ments. The final proposed server hardware was designed optimized by its software. The server provides a cento last for years of testing and high-speed data collection. tralized and secure option for storing data files and the SystemLink File Transfer toolkit can be used to programmatically transfer files from a custom LabVIEW STEP 4: SystemLink features. Once test data is application to the server. DMC developed a SystemLink stored on the SystemLink server in the form of data files technical data management system (TDMS) driver based and tags, SystemLink’s data management tools become on this API to save and format high-speed test data to available to the user. The web interface allows simulTDMS files and transfer them automatically to the clitaneous multiuser access to the tools and stored data. ent’s SystemLink server during testing. The API relies on The web interface also can be configured to require

The client searched for a solution that could gather highspeed test data from its fleet of remote NI cDAQ devices and store the data in a secure and centralized location. The client also wanted a solution to accommodate multiuser remote access and provide tools for organizing, searching, analyzing and reporting the data. Based on these requirements, DMC designed a four-step approach that leveraged SystemLink’s data management tools to accomplish these goals.

A12 • December 2020

Applied Automation


user authentication at different user levels for security purposes. The TDMS test data can be accessed and viewed in the web interface using the file viewer tool, which also provides additional filtering and data manipulation features. Tag data can be viewed through the tag viewer and can be used to create test dashboards or queried by the test monitor to produce test insights. SystemLink’s systems manager tool allowed DMC to set up asset management for the client’s test nodes. This unlocked the ability to push software updates to the nodes through the web interface and easily track metrics such as connection status and CPU usage. Calibration tracking also can be configured for managed assets to notify users based on calibration schedules. The asset management provided the user with the ability to ensure configuration conformity across assets and view the status of an entire fleet of test systems in one place. Overall, DMC provided the client with a solution delivering the following features that resolved many of the issues with the previous data management system: • Centralized data storage on a server with backup options • Secure data transfer

• Improved data storage security • Multiple data storage methods for both slow and high-speed data • Simultaneous multiuser access • Access to a broad selection of data management and analysis tools.

Final thoughts With the test executive and SystemLink integration, DMC was able to deliver a fully featured data acquisition and data management system to its client. The system allowed the client to centralize its data and rely on the tools to secure, manage and analyze the data. SystemLink updates the old data storage infrastructure into a, server-based infrastructure that updates the data management quickly and easily. Ryan Yu is a systems engineer at DMC. DMC is a member of the Control System Integrators Association (CSIA).

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Applied Automation December 2020

A13


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