VOL 12 APR-MAY 2019 ` 100 www.industr.com/en
AUTOMATION & DIGITISATION
INDUSTRIAL ROBOTS
Also available in China, Taiwan, Singapore, Malaysia, Thailand & Hong Kong
Transforming the future
A&D - Interview
In association with
FOCUS Chemical & Process
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Additive Manufacturing
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Advt
Bipin K Chirmure, CEO & Managing Director, Stauff India (p. 17)
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Modules to isolate, convert, process and condition analog and digital signals
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Efficient and failsafe connection of field devices thanks to the process wiring connection technology realized with our Quick Disconnect connectors Comprehensive portfolio with connectors, cables and splitter boxes reduces cabling
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The RFID system BL ident® ensures increased plant efficiency and traceability of the production processes through the reliable detection of mobile containers
Identification of mobile containers and tube stations
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Interface and power supply modules
Solutions for the Chemical Industry
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The DSU35 inductive dual sensors capture the flap position of rotary actuators Easiest assembly and adjustment Ex approvals and SIL certifications
Monitoring of rotary actuators
Comprehensive fieldbus technology knowhow for chemical applications with fieldbus solutions for plants and control cabinet Tailor made system solutions with interface devices
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Monitoring of the door as well as exceedance of temperature and interior humidity Applicable up to zone 1
The modular I/O systems excom® and BL20 support application-optimized signal processing Use in the non-Ex and Ex areas in zones 1 and 2, as well as 21 and 22
The inductive sensors with removable terminal chambers are easily commissioned and maintained. High density and chemical resistance, Ex approvals, SIL certificate, extended temperature range Binary or analog position feedback of valves.
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Namur stainless steel sensors
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Distributed signal processing
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E D I TO R I A L
Automation as a strategy! It’s a known fact that for any manufacturing organisation, investment in automation is vital for establishing and maintaining global competitiveness. A better approach to automation investment begins with a strategic vision that drives a methodical approach to business improvement. Successful manufacturers look at automation from the top down, first identifying the strategic challenges of the business, and then finding ways automation can be used to meet those challenges and attain business objectives. Smart companies are taking this approach and using automation strategies to implement the right technology in the right way and at the right time and place, to get ahead of the competition. A&D India has been providing contents revolving around automation, robotics and other related topics to help the manufacturing industry leverage the information for greater productivity, efficiency, quality, safety and consistency – parameters that form the key to global competitiveness today. This edition of A&D India marks its 11th Anniversary. It has been an interesting journey filled with triumphs and challenges. The magazine kept changing and evolving, both in print and online versions, with the rapidly changing landscape of the manufacturing industry and of course with the changing reading habits of people. We would like to thank everyone who has helped A&D India become what it is today – our editorial advisory board members, editorial contributors, advertisers, partners, and most importantly our readers for their trust and confidence in the publication. I would also like to thank the team A&D India who contributed their bests to grow with the publication and make it the most desirable magazine in industrial automation, robotics and allied sectors. Please do write to us with your feedback and suggestions, and also continue sharing your knowledge and expertise with us!
EDITORIAL ADVISORY BOARD
Ravi Agarwal Director, Pepperl+Fuchs (Factory Automation) Vice President – AIA (Automation Industry Association) Raj Singh Rathee Managing Director Kuka Robotics India
Knowledge Partner
®
Progress through Research
INTERNATIONAL AUTOMOTIVE MANUFACTURING SUMMIT 2019 Manufacturing Excellence with Technology Innovations 16-17 July 2019 Pune, Maharashtra, India
For Delegate Registration, Sponsorships, Paper Presentations & other details, contact:
Shekhar Jitkar Publisher & Chief Editor shekhar.jitkar@publish-industry.net P V Sivaram Chairman - Non Executive B&R Automation President - AIA (Automation Industry Association)
AUTOMATION & DIGITISATION
Anup Wadhwa Director – AIA (Automation Industry Association) Jasbir Singh Vice President – Electrical & Instrument Essar Project Management Consultants Ganapathiraman G Vice President & GM (South and South-East Asia) ARC Advisory Group Dr KLS Sharma Advisor Automation Education & Training
Mandar Phadke CEO, Abhisam Software Former Head – Process Control Lanxess India Pvt Ltd Arcot Rajabahadur Automation Consultant Thampy Mathew Chairman, Fieldbus Foundation India Regional Sales Director, Pepperl+Fuchs (Process Automation)
Dhiraj Bhalerao (West & South) dhiraj.bhalerao@publish-industry.net +91 9820211816 Sagar Tamhane (North) sagar.tamhane@publish-industry.net +91 9820692293 Alok Kumar (Bangalore) alok.kumar@publish-industry.net +91 8861009443
Overseas Partner: China, Taiwan, Hong Kong & South-East Asia
A & D I n d i a | A p r- M a y 1 9
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CONTENTS
Market
14
Management
Interview
NEWS 34
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Interview with Michael Wilkinson, Global Segment Leader, Energy Digitalisation, DNV GL—Energy “CONTRIBUTING TO THE SUCCESS OF OUR PARTNERS”
Interview with Bipin K Chirmure, CEO & Managing Director, Stauff India
Leadership Insights 18
DIGITAL ACCELERATION IN SPECIALTY CHEMICALS
The article explores how digital technologies expand to address key drivers in specialty chemicals markets, such as accelerating innovation, optimising across the value chain and aligning with customer demands
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“LEADING WITH TRANSPARENCY!”
Mary Barra Chairwoman & CEO General Motors Company
“BUILDING THE INDUSTRY 4.0-ECOSYSTEM IN INDIA”
A post event report on the recently held Rockwell Automation On The Move (RAOTM) 2019 conference, on bringing digital transformation to the Indian manufacturing sector 58
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“DOOMED TO FAIL WITHOUT AI?”
Additive Manufacturing
Event Report 56
Chemical & Process
Professor Jörg Krüger, Head of the Industrial Automation Technology Department, Institute of Machine Tools and Factory Management, Technical University of Berlin and Director, Automation Technology Division, Fraunhofer IPK
“DIGITALISATION IS CHANGING WHAT WE DO & HOW WE DO IT”
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Focus
NEXT-GENERATION DESIGNING—THE TWIN EFFECT
The article talks about the benefits of Additive Manufacturing and its potential to change the way manufacturers develop products
Cover Story 20
INDUSTRIAL ROBOTS—TRANSFORMING THE FUTURE
The robotics industry has undergone a huge change in terms of technology and applications. In this cover story, experts from the robotics and the user industry give their insights on what the future of the robotics industry holds, the changes it has undergone and the challenges the industry brings in.
“DIGITAL TRANSFORMATION DRIVING BUSINESS OUTCOMES”
A post-event report on the Rockwell Automation conference in Bharuch, Gujarat, which discussed the various means to implement digital technologies in the process industry
ACOPOStrak
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CONTENTS
Advt
Technology
Cover image courtesy: ABB
Safety & Integration 44
FUNCTIONAL SAFETY IN MANUFACTURING
Digitalisation 52
PLANT OPERATIONS
This article explores the crucial topic of functional safety and its various dimensions in extensive detail, providing a guideline on safety considerations for all plant managers
DIGITALISATION—THE WHAT, HOW AND WHY
This article analyses and questions the need for digitalisation, subjecting it towards a larger industry perspective
Cyber Security 48
New Products 62
Process Control System; Purge and pressurisation system; Machine Learning for control systems; Rotational torch sleeves for plasma cutting torches
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Thermal SD compressed air meters; Decentralised drive units; Clamping stations with compact dimensions
EXPLORING INDUSTRIAL CONTROL SYSTEMS SECURITY & ITS SIGNIFICANCE
This article explores why it has become critical to understand and consider industrial control systems security
Columns 09 10 12 64 64
Editorial Contents Guest Editorial Highlights – Next issue Company index
Advt
High-speed diverters
Track design flexibility
Purely magnetic holding
Bipin Jirge
MANAGING DIRECTOR IFM ELECTRONIC INDIA
We, in the field of automation, are going through a very interesting period, where there are many changes happening in the industry, of which some can be very disruptive. There are new fields like, Industry 4.0, which are being seriously thought of and implemented in India. Large as well as medium scale manufacturing companies are considering the concepts to be implemented at their shop floors. On the other hand, there is also an ongoing debate about why a country like ours needs more automation, as there are many unemployed youngsters looking for jobs. But as several experts have analysed this debatable point, we must have more automation in order to create more quality jobs. In order to provide our massive Indian youth with manufacturing jobs, we must have manufacturing jobs. To do this, we should be able to take India’s manufacturing GDP percentage to 25 per cent by 2025, for which we need a huge investment in the manufacturing 12
COMMENTS & COMMENTARY
GUEST | EDITORIAL
“WE MUST HAVE MORE AUTOMATION TO CREATE QUALITY JOBS” field. To sell the produce from this large manufacturing investment, we also must be able to export, as there isn’t a market big enough at home for such a huge production. Further, we must deliver these exports at world-class quality and at a reasonable price within committed timelines. And this will be nearly impossible without automation. Industry 4.0 is a means to connect the shop floor to the management information system in real-time, so that real-time measures can be taken by the management for manufacturing operations to become more efficient. The only challenge that our industry in India, particularly MSMEs, faces is that we mostly do not know where to begin this journey and the requirements needed
to start this journey towards Industry 4.0. It will be key to start with the right kind of people/team or re-skilling the existing team in the company towards this journey. Typically, the team should know the manufacturing process, machine operation and maintenance, automation on the shop floor and software skills. We must also be aware that it will take some time to upskill the team in these areas. With these kinds of skills, we must further be prepared to invest in systems, step-by-step. The first step should be to equip our manufacturing machines with requisite devices to give us data of operating parameters of the machines, which affect the operational reliability of machines as well as the quality of work pieces produced. This, in short, will help us to improve the OEE of the machines. I am sure that with this journey towards new concepts being embraced in India, almost concurrently with the rest of the world, we, as a nation, can be a much bigger economy with quality jobs for our large young population. ☐ A & D I n d i a | A p r- M a y 2 0 1 9
MARKET | NEWS
Siemens Financial Services releases new research paper Siemens Financial Services (SFS) recently released a new research paper which focuses on digital transformation in the manufacturing industry, stating that the key point is ceasing to be one of ‘whether’ to invest in transformation, but rather ‘when’. The research has found that the potential financial value of digitalisation is estimated to be between 6.3% and 9.8% of total annual revenue by 2025. It also found that 70-80% of large companies have implemented a significant pilot project for Industry 4.0 production solutions, compared to 40-50% of small and medium enterprises (SMEs). Responding to the findings of the report, Sunil Kapoor, MD & CEO, Siemens Financial Services, cited, “Most leading manufacturers are looking for sustainable ways to invest in digital transformation so that they gain the competitive benefits of being in that early mover cohort while the forward-thinking manufacturers are using Finance 4.0 solutions to accelerate their digital transformation to maximise the market advantage.”
ABB and Ericsson join hands to accelerate wireless automation ABB and Ericsson recently strengthened their commitment to accelerate the industrial ecosystem for flexible wireless automation, which will enable enhanced connected services, industrial IoT and Artificial Intelligence technologies in the future. The partners signed a Memorandum of Understanding at Hannover Messe 2019, establishing their joint vision for future flexible production with automation and wireless communication. The MoU confirms the partners’ agreement to continue their strong research collaboration, explore improvements in manufacturing processes and automation, and discover new business opportunities for the industrial ecosystem. Expressing his views on extended partnership, Ulrich Spiesshofer, CEO, ABB, asserted, “ABB’s leadership in digital industries combined with Ericsson’s pioneering work in connectivity will open up new opportunities for customers to enhance productivity and competitiveness by digitalising their businesses.”
Givaudan opens new manufacturing facility in Pune Givaudan recently inaugurated a new flavours manufacturing facility in Pune, the CHF 60 million plant, which is the company's largest investment in India. The new 40,000-square-metre facility will enable the company to meet growing demand from customers in the food and beverage and healthcare segments. Also, it will complement the company’s existing plant in Daman, strengthening its capabilities in liquids compounding, powder blending, emulsions, process flavours and spray drying for the India, Nepal and Bangladesh markets. Sharing his focus, Gilles Andrier, CEO, Givaudan, cited, “Our new plant will enable Givaudan to collaborate even more closely with our customers to deliver differentiated solutions and great taste experiences to the dynamic Indian market.”
HMS Networks AB (publ) acquires WEBfactory GmbH HMS Industrial Networks AB (publ) recently acquired 74.9% of all shares in WEBfactory GmbH, a leading provider of web-based software solutions for the Industrial Internet of Things. WEBfactory is primarily known for its i4 suite of software products. The i4 portfolio addresses IIoT-related customer challenges, such as, data collection, analysis and visualisation, and includes, i4connected – a flexible IIoT platform; i4SCADA – a web-based software; and i4BACnet – a web-based management and operations software. Elucidating on adding a software dimension to HMS’s offering for IIoT, Staffan Dahlström, CEO, HMS Networks, explained, “The i4 software products will enable a straightforward path for HMS’ customers and partners to realise truly smart manufacturing and services.”
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A & D I n d i a | A p r- M a y 2 0 1 9
NEWS | MARKET
Konecranes adopts IIoT to bridge virtual and real worlds
Konecranes recently implemented Siemens’ digital innovation platform to accelerate its product development process and connect product and performance data together. The company is using MindSphere and the Teamcenter® portfolio to leverage the digital twin and reduce the number of physical prototypes, which helps to increase efficiency and decrease product validation time. The company’s proof of value is one of the first implementations of IoT to develop a framework that connects and synchronises the virtual and physical worlds. On this occasion, Juha Pankakoski, Executive VP—Technology, Konecranes, asserted, “With an integrated digital twin platform, we see major potential in speeding up the product development process, reducing prototypes, increasing traceability and thus, improving quality and reduce development cost.”
Mitsubishi to set up new plant in India Mitsubishi Electric will be setting up a new manufacturing facility in India focused on hybrid vehicles, motors, etc, according to Masaki Sakuyama, Chairman. The company is in the process of locating its greenfield plant in India. At present, it has manufacturing units in Pune, Bengaluru and Chennai, and a factory automation centre in Gujarat. It is also looking at tapping the potential of IoT in improving efficiencies and coming up with smart solutions across its business verticals. Also, it is keen to expand its electric equipment for rail transportation business. It already has a factory in Bengaluru to meet some of the existing needs.
Hannover Messe 2019 – Driver of industrial transformation Artificial Intelligence in industry and robotics, the potential of the new 5G mobile communications standard for industrial applications, lightweight design, and the future of work in a time of increasing digitalisation were this year's most important topics at the world’s leading tradeshow for industrial technology, Hannover Messe 2019. Make digital transformation tangible – that was what Hannover Messe 2019 promised. “More than 215,000 visitors used Hannover Messe to invest in new technologies and prepare their businesses for the future,” informed Dr Jochen Köckler, Chairman of the Managing Board, Deutsche Messe. Roughly 6500 exhibitors from around the world presented solutions for the future of manufacturing and energy supply, including more than 500 examples of the deployment of AI in industrial manufacturing, 5G applications, and solutions for the energy and mobility transitions. Robotics was also a major draw for visitors. With 160 exhibiting companies, Partner Country Sweden stood out as a high-tech nation. Nearly 40% of the show's 215,000 attendees came from abroad. The top visitor countries after Germany were China (7200), the Netherlands (5900), Italy (3400) and USA (3400). Partner Country Sweden contributed 2600 visitors. In a rich array of Hannover Messe forums and conferences, experts from industry, government and the R&D community stimulated fruitful dialogue on topics, such as, Industry 4.0, AI and the future of work. Among the supporting program's popular highlights were the Lightweighting Summit organised by the German Ministry for Economic Affairs and Energy, the Future of Work in Industry congress and the Industrial Pioneers Summit.
A & D I n d i a | A p r- M a y 2 0 1 9
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MARKET | INTERVIEW
“Digitalisation is changing what we do and how we do it” …says Michael Wilkinson, Global Segment Leader, Energy Digitalisation, DNV GL – Energy, in this interaction with Juili Eklahare. He shares his thoughts on how digitalisation plays an important role in the transition to a global low carbon economy and throws some light on its merge with StormGeo. Excerpts… What are the technological innovations that will help reduce CO2 emissions and costs in the energy sector? Every year, DNV GL releases its Energy Transition Outlook (ETO), an annual global and regional forecast of the energy transition till 2050. Through the ETO, we forecast a very substantial increase in renewable generation (primarily in the form of photovoltaics and wind energy), a shift towards electrification and a drive towards energy efficiency. Grid-connected energy storage will also play a key role. This will be enabled by digitalisation and while it will come with a necessary upfront investment cost, the long-term benefits in terms of reduced operational costs and CO2 reductions are obvious. How has the role of risk managers in large companies changed in the last few years? In a digital world where there can often be a fine line between fact and fiction, the concept of ‘truth’ and risk management become even more important. In DNV GL, digitalisation is changing what we do and how we do it. For example, we are using digital workflow management to automate what were previously offline services. We are also assessing the reliability of artificial intelligence (AI) algorithms used in industrial applications. These are just a few examples, but our business is transforming as the world changes. StormGeo and DNV GL have announced that they have signed an agreement to consolidate their fleet performance solutions under one banner. How is this merger going to be beneficial in the short-term and long-term? In the short term, we will continue to offer the services as they exist, so there will not be major changes. The existing services will be maintained within StormGeo, with all solutions brought together in the back-end, utilising an improved data infrastructure. Over the long-term, however, combining ECO Insight and Navigator Insight, with StormGeo’s own offerings, will give our customers new services. Customers will also benefit
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from having access to the largest vessel performance data set and developer team in shipping, with industry-leading analytics. This means that our efforts can be focused even more sharply on developing our role as a trusted third party in the digital space. You predict that 80% of global electricity will be generated from renewable energy sources. To what extent and how does digitisation play a role to make this predictability come true? We strongly believe that digitalisation has an important role to play in the transition to a global low carbon economy, which will include innovations like, digital platforms that allow electricity system operators to dynamically purchase generation to match demand, rather than upgrade their physical infrastructure. It will be using AI to improve the forecasting and predictability of renewable energy sources and allow a greater proportion of wind and solar generation. It will be communications networks that allow dynamic price signals to trigger charging and discharging of electric vehicles. Moreover, other digital technologies, such as, blockchain, will be used to allow peer-to-peer energy trading, which is a radical shift compared to how the electricity system currently operates. All of these developments are happening right now in trials and pilots around the world. What does DNV GL have planned for itself next? We recently formed our new Digital Solutions business area, comprising of 1000 technology experts. We are also creating digital services that enable customers to improve operational assets, such as, WindGemini—our wind farm digital twin, and Smart Cable Guard—our digital distribution network cable monitoring system. Besides, we are investing in Veracity, which is our industrial data platform that helps connect datasets together and allows customers to get value from their data. Furthermore, we are deploying AI and machine learning experts to work in tandem with our domain experts and solve some of our customers’ most challenging problems. ☐
A & D I n d i a | A p r- M a y 2 0 1 9
MARKET | INTERVIEW
“Contributing to the success of our partners” …says Bipin K Chirmure, CEO & Managing Director, Stauff India, in this interview with A&D India magazine. He further elaborates on how it is significant to contribute to the benefit of people, machinery and environment and provide customised solutions. Excerpts… What are your most sought-after products/technology solutions in the global and Indian markets today? With our advanced technology for high pressure components, systems & services, we make hydraulic applications more efficient, reliable and safe. Thus, we contribute to the benefit of people, machinery and environment. As a leading international provider of coordinated solutions, we contribute significantly to the success of our business partners. What would be the big strategy / technology breakthrough your company will be pursuing this year, aimed at creating a big business impact? We have introduced our new concept of STAUFF LINE (hydraulic port-to-port technology). In addition to our high pressure hydraulic components, we are also offering STAUFF Pipe work support technology approach to support original equipment manufacturers with the supply of customdesigned and ready-to-install hydraulic lines from connection to connection and also provide supplemental services that create added value. What is your company’s approach towards meeting the customisation requirements in today’s competitive business world with varied customer demands? Establishing cordial & successful working relationships with our customers always starts with the expert advice provided by our professional employees. In addition to our tasks as a company engaged in development and production of standard/customised solutions, we increasingly see ourselves as a solution provider to our customers.
How does your company assess the disruptive power of new technologies at an early stage and build a sustainable plan so as to respond to the technological disruptions, in the short-term and long-term? Stauff India is tuned in to the needs of the domestic market and together, with the benefit of an experienced and highly motivated team of employees and the use of innovative technology, enables the company to offer a sophisticated product range which will satisfy the requirements of each and every customer in various segments. Would you like to brief about any of your customer success story which you feel is very remarkable and worth mentioning here? Stauff India has successfully completed prestigious projects for Metro rail coaches and defence in India. We continuously support the growing requirements in mobile hydraulics segment by introducing the concept of two bin system. Stauff has introduced new products for the offshore oil platforms and have also bagged the NACE International – Corrosion Innovation of the year award. In your opinion, what is an industrial trend/concept/ myth which you would like to demystify within the Indian manufacturing sector? The Indian customers always insist on low cost products & their price preference over quality is a big myth. Stauff India has been steadily & successfully supplying quality products to various segments and end users over a period of the last 20 years. We are very much optimistic of the future and expect higher growth in various segments. ☐ Advt
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LEADERSHIP INSIGHTS
Leading with transparency! Mary Barra
CHAIRWOMAN AND CEO GENERAL MOTORS COMPANY
The newest CEO of General Motors, Mary Barra is known to be one of the leading women in the auto industry and is the highest ranking woman in the automotive industry. Barra began as an 18-year-old co-op student at General Motors Institute of Technology. She then worked through different parts of the organisaiton, starting from engineering, and later continued to communications, human resources and product development, developing strong skills in every area. With such a holistic approach to work, it was no surprise when she became the CEO at GM in 2014. Shortly after she became the CEO, the company went through a rough patch due to a global abasement involving a defective ignition switch that led to at least 124 deaths, compelling the company to recall 2.6 million cars. Despite this setback, Barra decided to get to the bottom of the issue and conducted an internal enquiry that resulted in 15 employees getting fired and instating new policies. She went on to tell her employees that she never wants the company to put this incidence behind itself. Ever since, she has raised the bar by pushing for transparency. She is someone who believes that for an organisation that ultimately aims for 18
DO EVERY JOB YOU’RE IN LIKE YOU’RE GOING TO DO IT FOR THE REST OF YOUR LIFE sustainable change, benefits must be greater than effort. She cites, “Do every job you’re in like you’re going to do it for the rest of your life, and demonstrate that ownership of it.” One of the most important responsibilities of a leader is to bring in smoothness at an organisation, especially where all seems to be going haywire. Setting a bar in this domin, Barra also took the role of a Product Chief at GM, where she discovered that the product development process was in frenzy; there were 30 different platforms and a lot of inadequacy and poor quality. She got into action in no time, setting the product line right, bettering its quality and productivity, and aligning the product with customer needs in a better way. In fact, bringing this order in the product development process is one of the chief reasons as to why she was selected as the next CEO.
In spite of developing excellent skills through sundry departments and eventually becoming the CEO, Barra’s search for knowledge and interest in continuous learning did not end, leading her to attend the Harvard Business School program. Apart from this pursuit for excellence, Barra is also currently in talks with the US government and has stated her commitment to help with growing job opportunities in the country. Apart from creating 700 new jobs, the leading global automotive giant, under Barra’s leadership, is also setting new industry standards by taking a lead in building an all-new electric vehicle, which was originally planned to be manufactured in China. With such path-breaking vision, it is no wonder that Mary Barra is an inspiration to budding entrepreneurs worldwide.
Juili Eklahare FEATURES WRITER A & D I n d i a | A p r- M a y 2 0 1 9
C O V E R S TO R Y | T E C H N O L O G Y
INDUSTRIAL ROBOTS Transforming the future
Industrial robots have become a routine in most factory settings around the world, helping to bring about the highest productivity and quality. At the same time, the robotics industry has undergone a huge change in terms of technology and applications. In this cover story, experts from the robotics and the user industry give their insights on what the future of the robotics industry holds, the changes it has undergone and the challenges the industry brings in.
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Juili Eklahare Features Writer juili.eklahare@publish-industry.net
A & D I n d i a | A p r- M a y 2 0 1 9
T E C H N O L O G Y | C O V E R S TO R Y
“Integration is the key to robotics automation” “Robotics today is not just about measures of productivity and quality. It’s also about helping factories be more agile to efficiently introduce new products faster and meet the demands of high mix low volume manufacturing and shorter product lifecycles.” Subrata Karmakar Head – Robotics & Discrete Automation ABB India
If you look at the use of robots today, what would the market penetration look like in India and globally? Smart Manufacturing is not just a buzzword today but has become an absolute necessity in the overall manufacturing process. Today, industries require robots not only for faster production and better quality output, but also for process optimisation. The demand today is shifting in such a way that the global industry and that in India will not be able to think without robotics and automation. What is the greatest challenge facing the global robotics industry today? Robotics is one of the fastest growing industries and has created numerous opportunities across the value chain. Like any growing technology, it has to keep pace with the changing customer requirements and create value for its users. There are challenges on the way, for example, to create precise AI for reproducing and matching all facets of human intelligence. Better power source is another topic for mobile robots where improving the battery life is a major issue. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? Robots, as machines, are quite stable and ‘smart’ and we have not come across any robot malfunction situations. Its parts may fail, which could cause breakdown. Integration is the key to robotics automation. Often, integrators fail to understand the importance of using all robot features for safety and quality. In addition, end-users sometimes bypass many options due to ignorance or overlook. This can cause line stoppage, accidents or quality issues. Most importantly, using robotics or any automation in the manufacturing
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industry requires a change in culture and behaviour, without which automation will not succeed. End-users have to be smarter than the robot in order to make it more efficient and productive. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? Robotics, today, is not just about measures of productivity and quality. It’s also about helping factories be more agile to efficiently introduce new products faster and meet the demands of high-mix low-volume manufacturing and shorter product lifecycles. Besides, Machine Learning and Artificial Intelligence are further changing the game. Customers now want to simulate human intelligence processes by machines. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? Automation creates better and ultimately, more jobs. When we look at the three countries with the highest level of robotics adoption (Germany, Japan and South Korea), it should be noted that they, in fact, have some of the lowest rates of unemployment. The evolution of automation counterintuitively created more jobs in sectors where it was not expected. For example, when Automatic Teller Machines (ATMs) were introduced, people expected the number of people working in banks to reduce. However, it resulted in an increase in the number of bank branches. Robots can free up people for more rewarding tasks and take over jobs that are dangerous, repetitive, and hazardous. The future of Smart Manufacturing will bring about a paradigm shift in the way man and machine work. ☐
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C O V E R S TO R Y | T E C H N O L O G Y
“Increasing use of robots helps to upskill manpower” “Future robots should be able to “learn” from smooth operations and generate alerts in case any of the operating parameters cross the standard learnt values. Other future readiness requirements in robot technology are connectivity with data logging servers and cordless teach pendants.” Vikas Sawhney General Manager - Engineering Bajaj Auto
If you look at the use of robots today, what would the market penetration look like in India and globally? The average robot density in the world is around 85 per 10,000 employees. Taking regions into consideration, the penetration is 106 for Europe, 91 for America & 75 for Asia. In India, the robot density is close to 3 per 10,000 employees, but it is about 85 in the Indian automotive industry. What is the greatest challenge facing the global robotics industry today? The cost of robotic automation might be viable in developed countries with high cost of manpower. However, in countries like India, robotic automation is not preferred due to ample availability of low-cost manpower and the requirement of skilled manpower to operate them. Also, the time required for setting up robotic automation catering to the safety aspects results into higher lead times. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? Robotic malfunctions in the industry are largely due to the lack of training and technical knowhow. Power quality & failure are other major contributors to malfunctions. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? Collaborative robots have features, such as, stopped stage monitoring, speed and separation monitoring, hand guiding
& force limiting. Text alarm messages on the teach pendant screens, along with troubleshooting steps, can help with the ease of restoration. The role of robot programmer is to anticipate the probable mishandling by the operator and then set program speeds, limits and paths to avoid damages. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? Future robots should be able to “learn” from smooth operations and generate alerts in case any of the operating parametres cross the standard learnt values. Other future readiness requirements in robot technology are connectivity with data logging servers, open protocols (OPC UA), standard architecture and cordless teach pendants. What are some misconceptions of a robot and its use in the factory? The use of robots leads to job loss is a major misconception in the industry. Dull, dirty & dangerous work should be done by robots. The spared manpower can be utilised for safer, valueadding operations. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? The increasing use of robots helps to upskill the existing manpower, helping them to lead a better life and in turn, boost their morale. ☐
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Flexi Soft: THE MODULAR SAFETY CONTROLLER THAT CLEVERLY INCORPORATES ADVANTAGES.
When design engineers become euphoric, there must be a good reason. Perhaps the latest safety controller from SICK? It is so safe and intelligent that a new word had to be invented for it: Flexi Soft. A solution that is flexible, scalable and easy to program using custom software – yet soft on the budget. And if the same engineers test the unlimited ability of the Flexi Line communication concept to network modular machines, they will be left speechless by its advanced capabilities. The same is likely to happen when they see that Flexi Loop makes it possible to cascade safety switches and sensors within a machine in a way that both saves money and supports diagnostics. We think that’s intelligent. www.sick.com/flexisoft
C O V E R S TO R Y | T E C H N O L O G Y
“Robots will take away labourintensive, repetitive, unsafe jobs” “A popular misconception among factory owners/managers is that deploying robots in their shop-floors will instantly solve all their production issues related to quality, productivity and labour problems. However, deploying robots requires a lot of preparation.” Ajay Gopalswamy Chief Executive Officer DiFACTO Robotics and Automation
If you look at the use of robots today, what would the market penetration look like in India and globally? The automotive industry (including the tier 1, 2, 3 suppliers) is the largest user of robots in India. But when it comes to consumer goods, electronics, medical industry, etc, we are largely dependent on imports. Consequently, the use of robots in these industries is low. Globally, the use of industrial robots is spreading rapidly among non-automotive industries and into non-traditional areas (energy, farming, buildings, etc). The growth in these areas is very rapid in high-tech economies like, Korea, Singapore, USA, Western Europe, Japan and even China, which is preparing itself for the upcoming labour shortage. What is the greatest challenge facing the global robotics industry today? Execution, deployment and technical support are some of the greatest challenges faced by the global robotics industry today. Given the fragmented nature of the industry, skill development in robot systems deployment is the need of the hour in order to enable large-scale usage and meet user expectations. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? There are various reasons for a robot to malfunction, such as, faulty hardware/software, lack of understanding customer needs, improper maintenance, lack of skilled automation manpower, etc. For a properly designed, executed and maintained automation system, the uptime of the system should be better than 95%. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? Most modern robots do have self-diagnostic features. Companies deploying industrial robots should have well-trained production and maintenance teams to carry out regular checks on wear parts and conduct routine maintenance procedures to prevent catastrophic failures from occurring. 24
The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? It is becoming easier and more intuitive to program robots. Collaborative robots enable humans and robots to work together, thereby creating a safer and friendly production environment. Conventional robots mounted on Automated Guided Vehicles (AGVs) enable them to be deployed over a larger area. What are some misconceptions of a robot and its use in the factory? A popular misconception among factory owners/managers is that deploying robots in their shop-floors will instantly solve all their production issues related to quality, productivity and labour problems. However, deploying robots requires a lot of preparation – these include a clear problem statement, understanding which tasks can be automated and which cannot, budget and resource allocation and justification of the investment, an automation roadmap, setting small and achievable automation milestones, selecting the right automation partners, and persistence in the face of initial set-backs. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? Robots will take away labour-intensive, repetitive and unsafe jobs. This will enable human resources to be employed in more productive and value-added activities. The robot industry will create opportunities for automation system designers, technicians, programmers, maintenance crews, integrators, sales and service personnel. This will require large scale re-skilling, including investment in training. Embracing and preparing for the robotics revolution would be the most prudent approach in order to propel India into the group of high-technology manufacturing nations. ☐ A & D I n d i a | A p r- M a y 2 0 1 9
C O V E R S TO R Y | T E C H N O L O G Y
“The global robotics industry is currently facing a transition” “ The use of robots will create more and better-paid jobs. They improve the quality of work and give workers more autonomy and job satisfaction, while also making jobs safer.” Junji J Tsuda President, International Federation of Robotics Representative Director & Chairman of the Board, Yaskawa Electric Corporation
If you look at the use of robots today, what would the market penetration look like in India and globally? India is one of the strongest growing economies among the Asian emerging markets. In 2017, with a record of 3,412 new units installed, it ranked 14th in the global annual supply, following Thailand and Spain. In terms of operational stock, it ranked 13th, following Canada, Spain and Singapore. Between 2012 and 2017, India saw a compound annual sales growth rate (CAGR) of 18 per cent. The country’s automation potential is illustrated by a rather low robot density figure. 85 industrial robots per 10,000 employees in the automotive industry – the main customer industry – is less than a fourth of Indonesia’s density of 378 units and far away from China’s 505 units. The automotive industry will remain the main driver of the increasing robot installations in India. Numerous new projects are announced by the international and domestic car manufacturers aiming to expand production capacities. Moreover, OEMs increasingly require local supply of automotive parts. What is the greatest challenge facing the global robotics industry today? The global robotics industry is currently facing a transition from internal combustion engines to electric vehicles in its largest customer market, the automotive industry. This is linked to a current slowdown in investments. Moreover, its second largest market, the 3C industry, is facing declining smartphone sales. Political headwinds also result in restraints to investments. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? There are usually no separate statistics on incidents with robots
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in factories. In general, thanks to high safety precautions, the rate of incidents naturally is low. Accidents are usually caused by human errors, often overruling safety measures. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? For stable operation, sensors will be the key factor to control quality of manufacturing and maintain the machine running without any unpredictable failures. Additionally, AI is the great accelerator to enhance the capability of sensors and analysis of data, where humans are needed to train those systems. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? The three biggest trends in the robotics industry are: • Collaboration: Humans and robots in shared workplaces without fences open up new possibilities and concepts in production and non-industrial areas • Simplification: Simplification will be critical to SMEs, but also important for large global manufacturers • Digitalisation: Big Data is allowing people to make better decisions about factory operations Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? The use of robots will create more and better-paid jobs. They will improve the quality of work and give workers more autonomy and job satisfaction, while also making jobs safer. Of course, we have to contribute to pave the way for the transition. Companies and governments must collaborate to ensure workers have the skills that are in demand. Currently, the lack of qualified employees is holding back the necessary growth. ☐
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C O V E R S TO R Y | T E C H N O L O G Y
“Humans and robots would coexist harmoniously” “ Industrial robots are getting more advanced, with the influx of new technologies like, AI, Machine Learning and Big Data.” Pulak Satish Kumar Director and COO Puresight Systems (iRobot India)
If you look at the use of robots today, what would the market penetration look like in India and globally? The robotics industry in India is expected to register strong growth numbers in the upcoming years. Robots are being deployed in various sectors, ranging from manufacturing to agriculture. The defence sector, too, is considering the idea of introducing a robotic force. As for the global market, robotics is witnessing unprecedented growth, with a sudden spike in demand for consumer robots. It won’t be an exaggeration to say that we are steadily moving towards a world where humans and robots would coexist harmoniously. The global surgical robotics market is also fast-expanding. What is the greatest challenge facing the global robotics industry today? Despite the advancements made in the field of robotics, the industry is still at a nascent stage. This is mainly because of factors, such as, lack of cognizance, lack of multipurpose robots, high cost of implementation, safety concerns and general misconceptions. These challenges are preventing the robotics industry to reach its maximum potential. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? The incidents of robot malfunctions in a factory are not frequent, but they are not uncommon either. There could be many possible reasons, including technical failure, control panel issues, power disruptions, human errors and even environmental factors. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? While taking self-diagnosing in robotics into account, it is always there as an alert system. If the robot is facing anything wrong, it gives an automatic alert, which can be in any form
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like, an LED blinking, an alert sound or some digital text showing up on the screen. When it comes to industrial robots, the staff should be trained so that they can identify any signs of failure. Also, only authorised personnel should have access to these robots. Similarly, domestic robots should be handled with care and the owners should ensure that the robots are maintained properly. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? Earlier, robots were designed only for industrial usage. Today, companies are equally focused on developing consumer robots and companion robots that exhibit some human values. At the same time, industrial robots are getting more advanced, with the influx of new technologies like, AI, Machine Learning and Big Data. What are some misconceptions of a robot and its use in the factory? The main misconception is that robots are evil and can turn against humans, especially, in a factory setting, where robots could go haywire and harm humans. Another major misconception is that robots will cause mass job destruction or unemployment. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? Contrary to popular belief, the rise of robotics will create more jobs than destroy. Of course, some jobs will become obsolete. However, this doesn’t mean that humans will be left without any jobs. Instead, their roles will evolve and workers will need to upgrade their skill-sets. In any case, it’s safe to say that there wouldn’t be a time in the future where we wouldn’t require human intervention. ☐
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Behind every expert is a strong team. The future will bring many technological challenges. We have the right experts for every future challenge.
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C O V E R S TO R Y | T E C H N O L O G Y
“Human-robot collaboration is the next wave” “ With strict adherence to industry safety regulations, robot malfunctions are becoming rare. On the contrary, robots can be used as the eyes and ears of the manufacturing environment in order to spot production glitches and lead through for predictive maintenance.” Vijay R Seelam CEO Svaya Robotics
If you look at the use of robots today, what would the market penetration look like in India as well as globally? India has a very low robot penetration compared to industrialised countries. Globally, the robotics market is growing at a healthy rate and India, with its fast-growing economy and rapid manufacturing growth, is well-placed to mimic these secular trends to become the next big robotics market. What is the greatest challenge facing the global robotics industry today? The greatest challenge for the robotics industry today is the perception that it replaces humans. It is a misplaced apprehension of the fact that countries with high robot penetration are enjoying resurgence in manufacturing and continue to add more well-paid manufacturing jobs. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? With advancing technology and strict adherence to industry safety regulations, robot malfunctions are becoming rare. On the contrary, robots can be used as the eyes and ears of the manufacturing environment in order to spot production glitches and lead through for predictive maintenance. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? With embedded sensors and machine learning, modern robots could self-diagnose problems and resolve them or warn for predictive maintenance. Furthermore, as robots become more intelligent and safe, they can work alongside humans to learn
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and avoid problems in real-time. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? Force sensing, vision, real-time computing and Machine Learning technologies are enabling robots to have a more humanistic perception, i.e. be intrinsically safe and contextually intelligent to work in unstructured environments and work safely alongside humans or other robots. What are some misconceptions of a robot and its use in the factory? Some misconceptions about robots are that they are expensive, suitable only for all-out automation and require experts to operate. New human-robot interaction technologies are breaking these barriers and making it possible for robots to be flexible, affordable and easy to operate by anyone enabling smaller and efficient factories. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? Robots cannot replace humans but can become collaborators to augment human ability. Robots are evolving to be a great humanising force, relieving humans from menial, repetitive and sometimes dangerous jobs, and instead focusing their creative energies on problem-solving. Human-robot collaboration is the next wave, where both robots and humans inform and affect each other. ☐
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C O V E R S TO R Y | T E C H N O L O G Y
“AI and deep learning are the latest trends in robotics system” “ Displacing labour by robots is feared by most bluecollar professionals, but that is not the case with cobots. By working in collaboration with humans, they increase efficiency and lead to the company’s growth, thereby enabling it to hire more employees.” Pradeep David General Manager – South Asia Universal Robots
If you look at the use of robots today, what would the market penetration look like in India and globally? India’s manufacturing sector is growing year-on-year as its people take a step in the direction of Industry 4.0. The benefits of cobots include a small footprint, ease of operation, deployment within a few minutes that can be in almost any application and their ability to serve as tools that enable humans to optimise their performance at work. Once set, they can be deployed with minimal to no human intervention in utmost safety. What is the greatest challenge facing the global robotics industry today? One of the challenges that the global robotics industry faces is the high capital expenditure associated with acquiring this technology that can only be used for a certain hardwired application. Cobots counter this challenge as they can easily be re-programmed and re-equipped with a wide selection of endeffectors and supplementary equipment to meet the changing needs of the enterprise. As they do not need to be pegged down in a designated location, they can be re-deployed virtually anywhere in the company’s operational grounds. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? The frequency of incidents depends on different cases and there can be a multitude of reasons for the same. The most common issue faced is that when the standard pattern is changed, a process can easily take several days, which can result in the robots hitting obstacles. This is caused by process variability, in which robots cannot recognise objects in their way or due to improper programming. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? Each cobot records event logs of the performance of its tasks that are automatically connected to cloud-based platforms to 32
track the cobot’s work, efficiency and any abnormalities that may occur and cause malfunctions. Since cobots cannot selffix, they create new tasks for the human employee counterparts to monitor cobot logs and make sure everything is in place by tracking every activity of theirs. In case the productivity decreases or there is abnormal behaviour, the cobot software will alert the human employees, who can promptly tweak the programming or operational conditions accordingly. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? AI and deep learning are the latest trends in robotic system. The latter has enabled countless successes on a number of applications. In the field of robotics, it improves industrial robotic efficiency as the robot can detect things themselves and understand data physically and logically. What are some misconceptions of a robot and its use in the factory? Displacing labour by robots is feared by most blue-collar professionals, but that is not the case with cobots. By working in collaboration with humans, they increase efficiency and lead to the company’s growth, thereby enabling it to hire more employees. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? While low-end jobs are being eliminated, increasing automation does not have to impact employment negatively. Instead, the introduction of cobots almost always results in net job creation. Human employees are being unburdened from performing repetitive tasks that may hurt them or present some ergonomic risk, which cobots can perform with optimal speed, accuracy, cost and with no safety hazards. ☐ A & D I n d i a | A p r- M a y 2 0 1 9
T E C H N O L O G Y | C O V E R S TO R Y
“Safety is a key topic in the robotics sector” “One of the greatest challenges facing the global robotics industry is the collaboration between robots and humans. If the necessary safety requirements are fulfilled for the designated task, human-robot collaboration allows the support of humans by robots, without safety fences.” Patrick Schwarzkopf Managing Director VDMA Robotics + Automation
If you look at the use of robots today, what would the market penetration look like in India and globally? The sales of industrial robots in India reached a new record of 3,412 new units installed in 2017. This is an increase of 30 per cent compared to the previous year (2,627 units in 2016). Between 2012 and 2017, India saw a compound annual sales growth rate (CAGR) of 18 per cent. What is the greatest challenge facing the global robotics industry today? One of the greatest challenges facing the global robotics industry today is the collaboration between robots and humans (workers). If the necessary safety requirements are fulfilled for the designated task, human-robot collaboration allows the support of humans/ workers by robots, without safety fences, i.e. robots and workers sharing a common workspace. What do you think about robot malfunctions in a factory? How frequent are the incidences and what are the possible reasons? Safety is a key topic in the robotics sector. Therefore, robot safety standards, on a worldwide level, created by international technical experts within the International Organization for Standardisation (ISO), have high value and quality. In order to avoid injuries and harm for humans, it is essential to meet and fulfill the relevant safety requirements when using robots. Accidents with robots occur rather rarely. In such cases, they are mostly caused by human failures and not by technical malfunctions of the robot. Can a robot self-diagnose a malfunction and avoid causing any damage? What role can the human play here? Due to intelligent machine systems, faults can be recognised
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before they appear and machines can be maintained before a breakdown occurs. This allows cost efficiency. Predictive Maintenance is closely linked to topics like, Industry 4.0, the Internet of Things and Big Data. The robotics industry has undergone a huge change in terms of technology and applications. Can you highlight the latest trends? The latest trends in the robotics industry are human-robot collaboration as well as easy programming of a robot. Easy programming makes it convenient to adjust the use for different applications, i.e. it provides more flexibility to production processes. What are some misconceptions of a robot and its use in the factory? A misconception of a robot and its use would be that they are a total replacement for human labour. Robots are important to perform tasks which are stressful, monotonous and unhealthy for humans. By taking over such tasks, robots support human labour. But other tasks remain important for humans when it comes to higher qualified tasks. Do you think the increasing use of robots will affect human jobs? If all the repetitive tasks become automated, what happens to the low-end jobs? Automation and the increasing use of robots will change human jobs. If robots take over low-end jobs, further education and qualification for higher-qualified jobs becomes very important. When we look back in the past, it can be seen that in sectors with a high increase of robot use and automation, new jobs were created instead of leading to a decrease in them. ☐
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MANAGEMENT | INTERVIEW
“Doomed to fail without AI?” Professor Jörg Krüger, Head of the Industrial Automation Technology Department, Institute of Machine Tools and Factory Management (IWF) at the Technical University of Berlin, and Director of the Automation Technology Division at Fraunhofer IPK, is making the necessary wake-up call for Artificial Intelligence (AI). He gives his pessimistic view of AI and new value creation models. Excerpts… How and when did you first come into contact with AI? That was in 1992 when I was exploring the use of artificial neural networks in the diagnosis of machine tool axes. Today, I am fascinated by the tremendous advances made in deep learning (part of machine learning based on neural networks and large amounts of data) and convolutional neural networks (according to Wikipedia, a machine learning concept inspired by biological processes), some of which already exceed human capabilities in pattern and image recognition in the processing of audio and video data. What do you think of the pessimistic views on AI? Some aspects are becoming ever more complex and so I understand the scepticism regarding the inscrutability of these systems. We need to create simpler automation structures that facilitate better understanding of and control over the complexity of machine learning. The issue is whether production engineers can trust a self-learning system enough for them to deploy it in production. Education
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and training often don’t adapt quickly enough to such rapid developments in re-search. This means that only with a considerable delay are we able to acquire the skills necessary to master this complexity and build confidence in these new technologies. All this, of course, fuels the notion that humans will eventually be pushed aside. And then the production engineers find themselves confronted with a mountain of Big Data - what should they do with this? It depends very much on what kind of data you are talking about and what the production engineer’s objective is. One user, for example, wanted to use image recognition to identify and manage 50,000 to 60,000 parts in a warehouse. Previously, a warehouse worker would do the work of identifying and sorting the parts using a catalogue. We only had a limited number of images taken of each part, not enough to map a neural network structure. However, we found that by using pre-trained networks based on non-industrial image data in combination with a limited amount of industrial component data, it was possible to achieve acceptable recognition rates for providing assistance functions even from an early stage. The AI system then works as a semiautomatic assistant that displays the five most likely parts to the warehouse worker. Thanks to this assistance, he now works much more efficiently and accurately. But this only works if you know the processes very well. That’s why my message is: don’t just invest in
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INTERVIEW | MANAGEMENT
Professor Jörg Krüger is Director of the Department for Industrial Automation Technology of the Institute of Machine Tools and Factory Management (IWF) at TU Berlin and Director of the Division for Automation Technology of the Fraunhofer Institute for Production Systems and Design Technology (IPK). His research is focused on automation systems for flexible production. Together with his team, he develops innovative systems for human robot collaboration in assembly as well as new methods for machine vision, data mining & cloud-based control in production.
hardware and software, you also need to make systematic use of The Simple Economics of Artificial Intelligence. Here, automation the “domain knowledge” of the production staff. People must also or production engineers view the opportunities of AI from an learn to evaluate processes in the factory economic perspective in order to discover and decide which tasks AI can take over. the digital gold dust in their own company. The inclusion of domain knowledge from Completely new value creation models production is crucial in order to identify and niches suddenly emerge for small WE NEED TO CREATE SIMPLER new areas of value creation potential businesses, especially for start-ups. quickly and systematically. AUTOMATION STRUCTURES THAT What role will sensors play? FACILITATE BETTER Smart assistance is one aspect, but what “Sensorisation” is usually the first step UNDERSTANDING OF AND else does AI have to offer? in acquiring data for learning. The more CONTROL OVER THE COMPLEXITY powerful and cost-effective the tools The data generated by companies is digital gold dust for me. In my experience, for machine learning are, the more OF MACHINE LEARNING many companies are not yet aware of just valuable the underlying data becomes. what value creation potential it holds. Especially in the field of sensorisation, Machine learning tools are becoming increasingly powerful. great progress is being made in research and development in In production, we should now be systematically combining relation to Industry 4.0, a good prerequisite for taking the next data with domain knowledge in order to refine processes and step towards machine learning in production. make them more efficient. I’m interested in tackling this issue with colleagues from WGP (Wissenschaftliche Gesellschaft für What are you most interested in seeing at EMO Hannover Produktionstechnik - German Academic Society for Production 2019, not only in your capacity as a production engineering Engineering). For example, we should no longer be focusing on researcher interested in AI? increasing recognition rates with the help of machine learning I’ll certainly be interested in seeing the exhibits being presented methods as we did in the past. Instead, we should be analysing the by our WGP colleagues. For example, I heard that an institute potential of existing production data for machine learning more will be showcasing something very exciting in the field of pattern systematically than before and exploiting the resulting potential recognition on machine tool drives. It should also be worthwhile for raising production efficiency levels more systematically. checking out the stands of some machine manufacturers and I recommend watching the YouTube video by the Canadian automation companies. ☐ scientist, Ajay Agrawal or reading his book Prediction Machines: Courtesy: VDW
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I MA G E CO URT ES Y: Siemens
CHEMICAL & PROCESS | FOCUS
Digital acceleration in specialty chemicals Digital technologies enable opportunities that do not stop with operations but expand to address key drivers in specialty chemicals markets, such as, accelerating innovation, optimising across the value chain and aligning with customer demands. The journey towards digitalisation started a few decades ago in the process industry, when companies began to upgrade from analog and paper-based systems to digital instrumentation. Early solutions for chemical companies included replacing manual adjustments to production units with distributed control systems (DCS) and the use of computer models to predict behaviour in reactors. What began as disparate point solutions solving singular and local challenges has expanded to include solutions that can deliver productivity improvements and cost savings across the entire business. Digital technologies can now guide improvements at all stages of an asset lifecycle – from unit design and operations optimisation (including production and supply chain) to maintenance programs. Many tools are
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Paige Morse Industry Marketing Director AspenTech
further refined to meet the specific needs of chemical producers, across the broad mix of raw materials, technologies, production processes and markets. The interest in digital tools is truly accelerating as many companies realise the power such tools can deliver and see rivals eagerly adopting the new solutions and capturing the benefits. In this competitive industry, companies cannot afford to be left behind. Producers of specialty chemicals face particularly demanding challenges due to the complexity of operations and the increasing variety and number of products their downstream customers require. Specialty chemicals require greater efficiency in innovation and new product introduction compared to commodity chemicals.
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FOCUS | CHEMICAL & PROCESS
50% 45%
46%
49%
47% 42%
40%
36%
43% 34% 28% 23%
Operational efficiency
Productivity and growth
Profitability
Innovation and R&D
Advanced manufacturing
Customer engagement
Oil and gas: For productivity gains and cost controls
Key benefits of employing digital technologies
Chemicals: For both short-term results and long-term strategic thinking
“2018 Oil, Gas, and Chemicals Industry Survey.” Deloitte, October 2018
Enabling technologies unlock hidden value The global chemicals industry has been in a sustainable upcycle for several years now. Innovation, sustainability, and supply chain remain the key high priority strategic areas for the sector. Applying digital technologies is becoming a strategic imperative in many industries, including the chemicals sector. BASF’s website states that “digitalisation presents big opportunities for us. Using digital technologies and data, we are creating additional value for our customers and increasing the efficiency and effectiveness of our processes.”
Chemical industry response is lagging Although many chemical companies are actively working to use digital technologies in their business, by most accounts, the industry is lagging. In 2017, the Deloitte report, “Digital Transformation: Are Chemical Enterprises Ready?” stated that “most chemicals enterprises lack a digital roadmap or strategy”. The authors cited several possible reasons for the slow progress – from the challenge of large capital projects to the lack of confidence in and knowledge of digital technologies. In its 2018 update, Deloitte reported some progress but still rated the chemical sector as a 5 on a scale from 1 to 10, even as 85% of executives believe that the chemical industry is moderately to highly digitally mature. At the same time, Deloitte reports that chemical executives acknowledge the value of deploying digital technologies to achieve operational efficiency and productivity, while also addressing key challenges in R&D and in complex manufacturing environments. These challenges are typically leading concerns for specialty chemical companies. Chemical companies are similar to oil & gas companies in operational efficiency and productivity concerns but have greater need for innovation and advanced manufacturing. The challenge for many companies is gaining enough understanding to harness the advantages that are possible with digital technologies. Organisations struggle to learn the terms, correlate with current and future assets, harness data to ensure
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safe and secure operations and leverage advanced models to develop greater business expertise.
Leaders are gearing up for change Leading companies are introducing new organisational approaches to digitalisation, as they see value across their portfolios and align their organisations to best capture the advantages. Evonik established a digitalisation subsidiary and named a Chief Digital Officer in 2017 and has since moved to invest 100 million euros in developing and testing new digitisation technologies. Wacker Chemie has launched a new program to advance digital transformation across its supply chain. In its 2018 annual meeting, President & CEO, Rudolf Staudigl acknowledged the value, stating that “digitalisation will help us satisfy customer needs even better. It is a topic that encompasses the entire supply chain, from product development & manufacturing right through to customer service.” In 2018, Dow added Chief Digital Officer to its Chief Information Officer title to reinforce the company’s emphasis on digital tools. In her role as CDO & CIO, Melanie Kalmar leads a team of executives, business-line presidents and functional vice presidents to develop Dow’s digital strategy. In heavy asset process industries like, chemicals and refining, leaders are embracing an asset optimisation strategy to enhance the entire asset lifecycle using digital tools. Asset optimisation has always been about digital technologies. Now, it is accelerated through new developments like Artificial Intelligence, Machine Learning and multivariate analytics and further enhanced with concepts like innovation, vertical integration and asset lifecycle.
Value opportunities in digitalisation In the specialty chemicals market, digital technologies can effectively address the following emerging priorities – accelerating innovation, optimising across the value chain, and aligning with customer demands. Innovation allows businesses to meet customer demands while also staying ahead of competitors.
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CHEMICAL & PROCESS | FOCUS
Week 1 STEP 1: Aggeregate Data
STEP 2: Demand Planning Week 2
MFG Template (capacity plan)
Supply Chain
Product Lead Times & Inventory Report
Manufacturing
MKT Template (product launch, trials) Sales Opportunities with (*75%) into SAP
Marketing Sales
Customer Focus Report in SAP with 12 month unconstrained forecast
Finance
Frozen 45-day production plan STEP 3: Supply Planning
Proposed 12 month production plan Constrained 12 month demand forecast
Multifunctional Repeat Monthly
Frozen 45-day production plan
Week 3 STEP 4: Reconciliation & Balancing
Preliminary
Proposed 12 month production plan Constrained 12 month demand forecast Latest Estimate (LE) Frozen 45-day production plan
Week 4 STEP 5: Executive S&OP Meeting
Final
Proposed 12 month production plan Constrained 12 month demand forecast Latest Estimate (LE)
Specialty chemical manufacturers are continually looking to innovate and enhance product performance at lower cost – often with fewer or alternative raw materials. Digital technologies can boost productivity and reduce errors by easing the transition from laboratory to plant production processes. Manual procedures, hand-written reports and paper-based systems are still common for critical activities such as, recipe execution, quality monitoring and raw material management. These isolated tools limit visibility into data and often delay responses to potential quality issues and regulatory requirements. Through digitalisation, companies can gain insight that allows for improvements in quality and consistency. For example, modelling tools can be used to better predict and control behaviour in plant reactors. When assessing the entire value chain for specialty chemicals producers, technology solutions enable monitoring, execution and control of the manufacturing process. In addition, planning and scheduling tools offer important capabilities that boost responsiveness and related profitability. Rapidly changing market and customer demands force frequent changes in production schedules. According to some producers, adjustments of 25 to 45% each month are not uncommon. Scheduling tools deliver the best value when linked with manufacturing execution systems, often referred to as vertical integration, so commercial systems are synchronised with process automation. Improved scheduling tools help companies make better business decisions as variations occur by incorporating key constraints, such as, storage limitations, throughput rates and variable lead times – while minimising excess inventory and offspec production. Better scheduling capabilities can also boost asset utilisation. At the same time, schedulers can see the impact of their decisions and make adjustments to avoid problems along the supply chain before they happen. With targeted plant scheduling tools, the scheduler can rely on the model to inform decisions such as, batch size determination, resource selection and batch sequencing and disposition. The technology enables better asset utilisation and improved customer service by
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Revised sales and operations planning process at Criterion
clarifying the profit opportunities and the extra costs in less than optimal operations. The next step is vertical integration, which links manufacturing systems to scheduling. These systems can give visibility to storage tank levels, for example, so scheduling tools can decide when raw materials should be put in tanks and when they should be emptied. This link can also alert the scheduler if processes are taking longer than expected, allowing for adjustments across the production plan. The scheduler can proactively identify optimal solutions in real-time. Aligning with customer demands is crucial for success in specialty chemical markets. Models of manufacturing assets can be used to automate identification and evaluation of a variety of production scenarios across a variety of timeframes. These models represent the full complexity and options possible, including production rates, constraints, efficiencies, set-up times, sequencing and site logistics. Specialty companies cite an 8 to 12% increase in on-time order fulfillment when these tools are applied. Meeting customer needs includes ensuring that assets operate well and produce the targeted products. Leading companies are using multivariate tools to analyse inter-related operational data to identify and eliminate sources of process variability. Businesses apply this analysis to batch and continuous processes to ensure more production that meets specification.
Benefitting from digital acceleration The tools, services and solutions specialty chemical producers need to manage their complex operations and achieve new levels of reliability and profitability are accessible to companies now. The first step is to consider the primary challenge for your business and identify relevant digital solutions. Adopting such tools will set you on a path towards a more holistic approach to achieving the highest possible financial return over the entire asset lifecycle. Aspen Technology has been working with leading chemical manufacturers for nearly 40 years, accelerating the digital transformation of the industries by optimising their assets to run safer, greener, longer and faster. �
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Beckhoff
EtherCAT
Mitsubishi Electric CCLink
Schneider Electric
Modbus, CANopen, Modbus TCP
Net/IP, Modbus Plus, Modbus-RTU, ModbusTCP, CC-Link, ControlNet, CANopen, CompoNet, Interbus, FIPIO, EtherCAT, FIPIO, Lon works, AS-Interface, FL-net, USB, Bluetooth and others.
Rockwell Automation
DeviceNet, ControlNet, EtherNet/IP
Siemens
Anybus Gateways ®
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A D D I T I V E M A N U FA C T U R I N G | F O C U S
Next-generation designing— The twin effect With Additive Manufacturing and digitalisation, business and manufacturers are seeing umpteen opportunities in their business models. However, a large chunk of Indian manufacturers have still not taken the digitisation route. Therefore, it becomes imperative for them to understand the operational advantages of Additive Manufacturing that saves time, cost and other resources. The article talks about the benefits of Additive Manufacturing and its potential to change the way manufacturers design and develop products. With exponential growth on the horizon for Additive Manufacturing and digitalisation, traditional business models are getting disrupted. 3D printing or Additive Manufacturing (AM) is set to literally reconstruct the process of rapid prototyping to repairing components. Projected to grow five-fold from US$ 2.2 billion in 2012 to an estimated US$ 10.8 billion in 2021, according to a study by the Agency for Science, Technology and Research, the disruptive technology heralds an exciting time for manufacturing. With digital 3D design data enabling manufacturers to modify components layer by layer, it opens a multitude of
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Frans Adamowicz Solutions Director – Industrial Machinery & Heavy Equipment Industry Siemens PLM
design possibilities across industries, such as, aerospace and engineering. For example, Singapore has already taken great strides in AM adoption with the establishment of the National Additive Manufacturing Innovation Cluster (NAMIC) in 2015, that has boosted digitalisation efforts in the maritime and health sector respectively. Traditional manufacturing in the past was unforgiving due to the lack of resources and conventional capabilities available. Specific parts required special tooling that made it rather costinefficient for manufacturing SMEs and companies to produce. The process was all the more tedious, as engineers back then
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F O C U S | A D D I T I V E M A N U FA C T U R I N G
NGD Collaborative Design
used traditional Computer Aided Design (CAD) workflow tools that resulted in disjointed and broken designs due to the incompatibility of the CAD applications. With AM, it is possible to create innovative lightweight parts that have honeycomb or complex structures at a lower cost. Should a product prototype require reworking, a new design can be programmed onto AM equipment and be produced in a relatively fast manner. A traditional assembly line with conventional printing or manufacturing methods may not be as swift or precise, and would require a lot of time, material and labour just for reconfiguration, making it highly inefficient for producing small prototype parts.
Slower momentum While it is clear that AM has an edge over conventional assembly, uptake in Asia Pacific has been particularly slow in comparison to its other regional counterparts. The United States represented about 37 per cent of globally installed AM equipment, with China and Japan following behind at 10 and 9 per cent, respectively. This was also followed by a lack of strategy on handling legacy systems and equipment, according to a study conducted by ARC Advisory. Despite its barriers to entry, AM could produce unstoppable momentum for the growth in the region. Forecasted to grow at a rate of 18.6% in Asia Pacific between 2015 to 2025, according to a Frost and Sullivan study, AM’s multifaceted benefits are too huge to ignore. Research from McKinsey also strengthens this claim, forecasting that the overall growth impact made by AM could be much higher,
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following current momentum, which could reach $250 billion by 2025. As we transit towards a digital society, how are Asia Pacific manufacturers able to deliver products with AM in a smarter fashion amongst today’s bustling competition and resolve the issue of legacy equipment?
Better business efficiency As with the adoption of ‘smarter technology’, Additive Manufacturing, manufacturers need to change the way they view product design. For example, re-designing the original product model, which was made in mind with previous traditional methodologies, could help cut down on part wastage and reduce processes, in turn saving precious time and cost. This can be further aided by digital twins, which integrates physical and digital models into a simulated environment that improves business operations and outcomes. The virtual representation of a product or object is showcased on a digital platform that enables manufacturers to pinpoint potential issues or opportunities throughout the product lifecycle—from the start of product design to modernisation of systems and plants. The twins, which consist of both the physical and digital copies, are connected to each other and can develop a common object memory that should be ideally set from the first prototype onwards. So, by implementing digital twins within the design process, the simulated environment will help both, designers and engineers to visualise more accurately. With many emerging manufacturing techniques that are becoming as precise as conventional manufacturing methods, design now
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A D D I T I V E M A N U FA C T U R I N G | F O C U S
NGD Predictive Modeling
needs to be thought out a lot more differently than it was in the past. More companies need to shift that mindset into play, as simulated environments will take greater precedence into the future, in line with CAD inputs, such as, mesh geometry and the generative design. While its American counterparts might be ahead of the game, we foresee that Asia Pacific will quickly catch up and capitalise on AM’s benefits in the near future. Companies that have yet to tap onto the strengths of digital twins and AM equipment system should assess its potential. As today’s engineers in the SME sector and large organisations are accountable for a wider range of responsibilities, they each face same issues of tight timelines, making it all the more imperative for manufacturing companies to deploy digital solutions to tackle the problems of today and in the future.
Manufacturing ahead in India 3D printing or Additive Manufacturing is in a very early stage in India, when compared to its global counterparts. However, it will be the next industrial revolution, which will probably change and impact the way we build and create. According to research conducted by 6WResearch, India’s 3D printing market is projected to grow at around 20 per cent CAGR during 2014-19. It is believed that every single industry will be revolutionised by 3D printing. There is a growing interest in several industrial sectors, including automotive, aerospace, manufacturing, and healthcare, realising its potential operational benefits in enhancing the overall efficiency of the production cycles. They have already begun to reorganise their work to
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integrate Additive Manufacturing (AM). Of course, aerospace and automotive industries are the early adopters, since India is one of the largest and fastest growing markets globally. We will get to witness a lot of consolidation happening in the market, which will give a clear direction to the industry. Rising influence towards lightweight and functionally integrated parts in the automotive and aerospace industry to reduce environmental impact, along with biodegradable implants for medical treatments should drive Additive Manufacturing (AM) with metal powders market growth. Increased usage of AM in the fabrication of end-use products in automotive, aerospace, oil & gas, dental restorations, and medical implants should propel technology demand. According to industry estimates, India ranks among the top three growth economies and manufacturing destinations of the world by the year 2020, with the potential to reach US$ 1 trillion by 2025. The development of 3D printing in India will, likewise, depend on how industries in other sectors embrace 3D printing or additive technology in the coming years. Since there is a growing demand for customisation in the product market, 3D printing technology is effective in reducing product cycle time for new innovations. To summarise, the manufacturing sector is at the cusp of change. The next decade is going to be all about tapping the potential of emerging technologies like, Artificial Intelligence and IoT and simplifying the manufacturing process further. Companies over different divisions need to take a more proactive approach and invest heavily in emerging technologies, such as, Additive Manufacturing in order to increase productivity and overall competitiveness of the Indian manufacturing sector amongst global peers. ☐
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E X P E R T ’ S V I E W | S A F E T Y & I N T E G R AT I O N
Demystified!
Functional safety in manufacturing plant operations
Safety is a very important aspect of manufacturing plants and operations and needs to be taken seriously by all plant builders and owners. Keeping in mind the several types of plants or lines which have controllers of different makes, this article explores the crucial topic of functional safety and its various dimensions in extensive detail, providing a guideline on safety considerations for all plant managers.
S
PV Sivaram Chairman—Non-Executive B&R Industrial Automation Sivaram.Pv@br-automation.com
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afety is an aspect of a plant or of a machine that becomes prominent when it is absent. It is subject matter of several standards, defined by various regulatory bodies, who define terms in a legally accurate manner. A discussion on this topic can be referred to in the ‘Machinery Directive 2006/42/EC’ of the European Union or an equivalent from other bodies. This is key because for actual implementation issues, the legal definitions refer to the standards documents published by the authorities. The objective of functional safety is achieving freedom from unacceptable risks of physical injury or of damage to the health of people either directly or indirectly through damage to property or to the environment by the proper implementation of one or more
automatic protection functions, often called safety functions. These aforementioned statements contain several terms, which have a standard meaning and also a specialised meaning in the context of Functional Safety (FS), which will be further investigated.
What is hazard, risk and safety? A hazard is a potential source of harm to humans or machinery or to the environment. This harm could be in terms of injury or death of humans, loss or damage to machinery or could even be pollution of the environment. Hazard, and its consequent damage could arise out of random hardware faults, systematic design mistakes or human
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S A F E T Y & I N T E G R AT I O N | E X P E R T ’ S V I E W
The SIL categories can be compared in a compact manner by this table
Preferred category (CAT) EN954-1
Performance Level (PL) EN13849
Safety Integrity Safety Integrity Level Level Undetected (SIL) (SIL) errors per hour IEC61508 IEC62061 No specific safety requirements
CAT 1
PL a
CAT 1/2
PL b
SIL 1
SIL 1
< 10
CAT 2/3
PL c
SIL 1
SIL 1
< 3 * 10
CAT 3
PL d
SIL 2
SIL 2
< 10
CAT 4
PL e
SIL 3
SIL 3
< 10
-5 -6
-6
-7
errors. On the other hand, risk is the probability of occurrence of harm due to the hazard combined with the potential magnitude of the harm. Functional safety refers to the management of all operations and events within an industry in order to protect its employees and assets by minimising hazards, risks, accidents and near misses.
CAT. It is significant to note, however, that a system having a higher grade of safety does not necessarily mean higher quality. The SIL categories are indicative of robustness in detecting errors, meaning that they react to most errors appropriately, thereby ensuring safety of the machine and the person.
Safety-instrumented system
It must be noted that an SIL level is meaningful for an entire machine or plant. The SIL level of the entire plant or machine is derived from the individual SIL levels of components and the various modes of failure (single and compounded) along with associated risk.
Traditionally, safety has been implemented using cut-off relays. In case of a situation leading to a hazard, the relay should operate and bring the equipment to a safe condition. A Safety Instrumented System is also called now and then as an Emergency Shutdown System. In parallel to the regular control system, and largely independent of it, a safety system with its own controller and sensors is implemented to take care of reactions to safety violations. The safety system or ESD is specified to have higher availability so that a failure of any component in the emergency system does not compromise the safety of a plant. This approach is favoured by process plants, for example, in the oil & gas or nuclear plants.
Smart Safe Reaction A standard way to react to an unsafe situation, referred to as a ‘Safety Event’, is to stop the machine or remove power to the dangerous parts. However, safety reaction should always be tailored to the requirement of the process and the event, keeping loss of production to a minimum. This sort of a reaction is called a Smart Safe Reaction. For instance, when a safety door is opened, the system instead of going to a stop, can go into Safe Direction of Rotation, combined with Safe Limited Speed.
What is SIL? Safety Integrity Level (SIL) is defined as a relative level of risk-reduction provided by a safety function, or to specify a target level of risk reduction. SIL is a standardised measure of safety of a system defined in terms of ‘undetected errors per hour’ in the system. There are other equivalent measures, namely, PL or Performance Level and Preferred Category or
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When is a machine SIL-3 compliant?
What are the applicable standards? Safety concerns itself to reduction of unacceptable risks to life and limb of humans. Therefore, it is a topic for much regulation from authorities. Voluminous standards are available to define the terms, parameters and the acceptable levels or limits. It is key to understand that standards are continuously being improved and published. In addition, there are several country and industry-specific requirements.
Integrated safety In case of production machinery, Integrated Safety is favoured as it brings many benefits. It provides an independent controller for safety with its own safety sensors for presence of detection. It also avoids double wiring of sensors, which in itself is a source of errors. Integrated safety is a strategy by which rigid safety reactions can be replaced by flexible reactions, which take into account machine status modes like start-up, maintenance mode or production mode. Integrated Safety is a state-of-the-art strategy and it is the way forward.
Maximum productivity To avoid the painfully high costs of stopping production, machinery needs to have availability designed from the start. Intelligent safety technology plays a critical role in preventing downtime and production outages.
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E X P E R T ’ S V I E W | S A F E T Y & I N T E G R AT I O N
Safe motion functions ensures versatile and complex motion applications are handled with ease
Custom configurations The general approach taken with series-produced machinery is to equip it with a suite of customisation options. This approach places special demands on the safety technology that cannot be met by traditional safety solutions. Smart Safe Reaction can be designed to provide desired safety levels for all machine variants.
Line integration In a production line, machines from vendors must interact. With integrated, network-based safety technology, the entire line is able to react to safety events in a coordinated way. Safe communication is provided by bus-independent safety standards.
Virtual safety This is the next extension to the approach of Integrated Safety. The intelligence needed for achieving Safety Functionality can be integrated into the IO module itself. Or the IO acquisition can be integrated into the safety CPU. This provides a viable option for even small machines and for different add-on units to a machine.
STE is primarily tasked with creating the test specification, as well as testing, verifying and validating the safety application created by the SAE. The functional application engineer programs the main controller to meet the functional requirements of the machine. • Rugged and controlled means of replacing IO modules: Safe IO modules come equipped with an electronic data sheet so that they can identify itself to the controller. If the controller program is expecting a different module type at that location, it can flag a violation. • Robust check on updating programs on controller: Safe PLC have their program saved on a SafeKey, a memory device. This key has a locking mechanism, thus inadvertent removing during running operation is not possible. Strict version and revision controls are implemented. • Program platform to support all of the above: From above, it is clear that one should look for a programming platform, which can support the above activities. It is not possible just by administrative controls to achieve the highest safety.
How is safe PLC different from regular PLC?
Safe motion
Safety equipment needs to be rugged and have high availability. The challenge on this equipment is that the probability of getting a wrong diagnosis or a wrong action should be minimal. Safety is definitely more important than the commercial concerns yet we cannot throw productivity concerns to the winds. There are several aspects to this, as discussed in the following: • Rugged HW design: The controllers are designed with a dual independent redundant microprocessors, exchanging data via shared memory so that a single error or fault will not lead to any dangerous situation • Robust programming of Safety Application: Safety Programming is done in a Team generally with 3 people. The SAE is primarily tasked with creating the safety application in accordance with the customer's specifications based on the Safety Requirement Specification (SRS). The
All machinery has moving parts. Motion is controlled by various means, usually by drives. These drives nowadays are intelligent and many safety related functions can be realised using the processors inside these drives. One important requirement is that it is not always safe to turn-off the drive, leaving an uncontrolled motor. So, we prefer a mode called STO or Safe Torque Off. It is also needed that in systems having multiple drives, we achieve a synchronised stop if the conditions permit. It is equally important to prevent an unwanted or premature restart.
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Conclusion Safety is a very important topic and needs to be taken seriously by all plant builders and owners. Since many a plant or line will have controllers of different makes, it is recommended to insist on bus independent protocols. ☐
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Safe control. Stay on course. Succeed.
An automation project can be compared to a regatta: if the crew doesn’t work together, you won’t reach your destination. To ensure that you stay safe and successful on course with your automation project, Pilz offers innovative control systems, editors and network components from the automation system PSS 4000. Control your application using a centralised control system or distribute control functions over various parts of your plant. Use our proven control technology for safety and automation and rely on our Industrie 4.0compatible automation system PSS 4000.
Pilz India Pvt. Ltd
Pune 411042
+91 (0) 20 49221100
info@pilz.in
www.pilz.in
CYBER SECURITY | TECHNOLOGY
Exploring industrial control systems security & its significance Over the past few years, there has been a growing interest in the subject of industrial control systems (ICS). These systems have widespread use in various industrial sectors and many of them are legacy systems that are decades old and vulnerable to cyber-attacks from various entities. In this context, this article explores why it has become critical to understand and consider ICS security. ICS refers to a broad class of systems that measure and monitor, control and/or automate processes in a wide range of industries and sectors. Industrial control systems (ICS) are of various types, such as, DCS (Distributed Control Systems), SCADA (Supervisory Control and Data Acquisition Systems), PLCs (Programmable Logic Controllers) and SIS (Safety Instrumented Systems). All of them are used to monitor and control processes in all kinds of industries and sectors. Many of these systems are legacy systems that have been designed and architected during a time when cyber security
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Mandar Phadke, CEO Abhisam Software mandar.phadke@abhisam.com
threats were almost non-existent. The only way to sabotage these systems is for a perpetrator to physically access them. This is because generally, these systems are typically located in control rooms that have very good perimeter security and restricted access. These systems consist of either analog or digital hardware input cards, processors that run proprietary embedded software and communications utilising various kinds of proprietary or standards-based buses. Typically, these legacy systems have operator and engineering stations (basically computer terminals) that have some kind of modern operating
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CYBER SECURITY | TECHNOLOGY
system based on some flavour of UNIX or Windows (not necessarily the latest version, one can find many that still run on obsolete versions like, Windows CE and Windows XP). The operations personnel, such as, manufacturing plant operators, control and monitor the plant or offshore platform/building/ ship, whichever is the equipment under control via these stations. Engineering stations are used to configure the controllers, graphics displays, historical trend displays, etc. The operator stations are from where one can start/stop pumps, open/close valves and monitor and control other aspects, such as, a reactor or a distillation column.
System architecture The system architecture consists of lower levels of electronic hardware that comprises of signal conditioners, amplifiers, isolators and so on, that gather analog and digital signals coming from the plant and send it via DCS controllers to the operator stations, where they are displayed in the form of graphical user screens. The commands from the operator stations, likewise, travel from the operator stations via the DCS controllers and so on, until it operates a valve or a motor or pump. Some operations are done manually while others may be done via control logic that uses the Proportional Integral Derivative (PID) or similar algorithms to sense changes in parameters and automatically adjust the outputs so that the parameter remains near the desired value, called the set-point.
Legacy control systems At the time that many of these systems were designed and built, the personal computer was a novelty, available only in a few homes and the internet was just beginning to become popular. Over the next two decades, there were several developments. The internet became commonplace, as did computers, laptops and mobile phones that were connected to the internet. Likewise, business IT systems also became modern. They moved from old mainframes, running COBOL and DB2, to newer systems like, SAP and Oracle-based systems. The management of many of these manufacturing companies saw value in connecting these business IT systems with the older legacy control systems. Many of the business IT systems had web interfaces. However, either the managers were not informed properly or did not budget for security of the older control systems. It is also possible that the people in charge of Management Information Systems (MIS) had little clue of even the existence of these legacy control systems or their vulnerabilities. Now, suddenly, legacy ICS were connected to the internet and thus,
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became vulnerable to cyber-attacks. However, this was not just restricted to systems that were directly connected to the internet. Even those ICS that were modernised were done so in a very superficial way. To save on upgrade costs, only the operator and engineering terminals were “upgraded” or “migrated” to better looking systems, with plant graphic displays and trends having thousands of different colours, the ability to use pointing devices like, mice and the ease of having USB ports and CD and DVD drives for software backup.
Vulnerable to attacks However, this became the vulnerable point of these systems because now, malware could enter the system via these means and there was no mechanism that could detect and remove it. There have been several cases where such malware entered the ICS via uncontrolled use of USB drives, quickly leading to panic situations like, blank screens, slow actions and so on, which ultimately led to shutdown of the plant, associated downtime and emergency situations. These upgrades, in fact, increased the attack surface of these systems because now, malware could also enter the ICS via insecure serial connections, misconfigured firewalls and so on. Sometimes, the IT staff employed to maintain these systems had no idea of how fragile these industrial control systems really were (having little RAM and storage, not much processing power either, as compared to business IT systems) and discovered it the hard way after having inadvertently shutting them down while working on them. Meanwhile, the news that these systems were old and prone to being attacked got through quickly to unreliable sources and they could now find these systems with insecure internet connections, which could be breached. This led to many more attacks on these systems.
ICS Security: A critical aspect There are thousands of these legacy DCS, SCADA and SIS systems that are prone to being attacked from various entities, such as, general cybercriminals, cryptocurrency miners, hackeractivists called hacktivists, various terrorist groups and even rogue states. An attack on these systems can cripple critical infrastructure of any country and cause chaos and disruption. Since it will be an enormous task to replace this old insecure automation architecture with a completely new one, such as, an Industrial Internet of Things-based solution, which is next to impossible, it has become critical to understand ICS security, carry out a risk assessment of these systems and protect them. ☐
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23 - 28 January 2020, Bangalore, India
I MA G E CO URT ES Y: Sight Machine
D I G I TA L I S AT I O N | T E C H N O L O G Y
Digitalisationâ&#x20AC;&#x201D;The what, how and why While the buzz on digitalisation in the industrial sector is undeniable with the rapid pace of innovations in todayâ&#x20AC;&#x2122;s market, we take a close examination of what, how and why we are digitalising. On that note, this article analyses and questions the need for digitalisation, subjecting it towards a larger industry perspective. With an exposure to a plethora of seminars and conferences on the topic of digitalisation as well as listening to a multitude of experts on the same, it is easy to become disoriented. Their bold predictions make it appear as if the future were just around the corner, leaving us rushing to put the necessary processes in place. However, when the microphones are switched off and the hype dies down, we hear many complaining about a digital delusion that offers little benefit to either manufacturers or users. Quickly incorporating a supposedly smart function into a device, rushing into a Big Data project or sticking sensors wherever you can fit them is no way to prepare for a future that we know is going to be different. Things that sound like vital projects often turn out to be rubbish. Digitalisation has also led to a flood of data that even experienced programmers struggle to deal with. Using digitalisation in a way that actually benefits
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Georg Stawowy, Chief Technical Officer LAPP Holding AG
our customers requires us to completely change processes, products and the way we think in our work.
Digitalisationâ&#x20AC;&#x201D;Means to an end Looking for an instance of how digitalisation is not an end in itself, we can consider an example of Amazon. The second most valuable company in the world is often held up as a shining example of digitalisation. While this may be true, it is only half the story. In reality, Amazon is essentially a giant logistics company. We do not order from Amazon because we like their online store but because they can deliver pretty much anything almost always within 24 hours. It is this service that customers want. The fact that amazon is building its own package collection
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SAFETY
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D I G I TA L I S AT I O N | T E C H N O L O G Y
Digitalisation means smart software that can predict the near future and guide processes to make sure all gates have the right staff at the right time to avoid delays
stations, or their plan to even deliver packages with drones show the company’s real strengths. None of this would be manageable without digitalisation, of course, but digitalisation is only the tool for creating a fast and efficient supply chain— the speed and efficiency are what makes the company successful. Airports are another good example. Here, digitalisation means smart software that can predict the near future and guide processes to make sure all gates have the right staff at the right time to avoid delays. Digitalisation is not a matter of more computers and greater bandwidth but of processes. It is not an end in itself but rather the means for delivering new, specific customer benefits.
Radical action for customer benefit At LAPP, when we think about digitalisation, we focus squarely on these customer benefits. Just like in Amazon, logistics and supply chain processes are important tools for creating these benefits. Our customers can order thousands of products online and configure our connection solutions themselves (cables, connectors, accessories, fully assembled systems). Our global network of production facilities and warehouses ensures short delivery times. An even faster delivery service would not provide our customers with much additional benefit at present. Identifying products via QR codes, however, is a different matter. This is an area where further digitalisation would be useful. When it comes to customer benefits, we believe in radical action. Industry 4.0 and Smart Manufacturing, aside from being excellent ways for companies to advertise their excellence, also mean shorter innovation cycles. While this creates pressure to come up with the next disruption in the industry, it is an
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important aspect of becoming competitive. We do not become a leading player by resisting change. Thus, we have mastered solutions and technology in the field of connections. This is why we are expanding our product range, diving deeper into applications and giving our staff the expertise they need to advise customers. Our goal is to convey power and data quickly and reliably from A to B, in every kind of machine network and for all protocols and standards. This is our promise as a connection specialist.
Driving constant development Digital giants like, Facebook and Google are all about fast disruption. However, change does not always have to be disruptive—many improvements occur as a result of constant development. Industries like, mechanical engineering are less focused on technology for technology’s sake than they are on applications. The pace of change is often overrated, including when it comes to digitalisation. We need to stay calm in the face of digital transformation, even if this is not a widespread mindset. The opinion of Peter Drucker is of special significance in this regard, when he stated that there is nothing so useless as doing efficiently that which should not be done at all. This is why we closely examine what, how and why we are digitalising. From Industry 4.0 to Artificial Intelligence, technology is undoubtedly developing at a breakneck speed. However, genuine progress moves at a snail’s pace. If all we do is follow technical trends, there is a good chance that we will just be running fast in the wrong direction. ☐
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SMART MANUFACTURING MANUFACTURING SMART
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EVENT | REPORT
Building the Industry 4.0-ecosystem in India On a global scale, with the emergence of a myriad of smart solutions that aid industrial production, Industry 4.0 is considered to be the transformational technology in manufacturing. In order to keep up with the current trends of automation and data exchange in manufacturing technologies, Rockwell Automation recently held the Rockwell Automation On The Move (RAOTM) 2019 conference, which conferred on bringing about this digital transformation to the Indian manufacturing market. A post event reportâ&#x20AC;Ś With the onset of Industry 4.0 on the global market, the call for a profound shift towards progressive technologies in the Indian industries is undeniable. Thus, industrial automation and Artificial Intelligence have been the irrefutable forerunners in discussions as India endeavours to triple its combined factory output in gross value added (GVA) terms to $1 trillion by 2025. Having realised this, Rockwell Automation recently held Rockwell Automation On The Move 2019
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Suchi Adhikari Senior Sub-editor & Correspondent suchi.adhikari@publish-industry.net
(RAOTM) annual conference, which emphasised the acute need and explicated what the oncoming Industry 4.0 signifies across the manufacturing sector.
Leaders in Industry 4.0 development As the torch bearers, who have taken a firm stance to be the guiding light for developing the Industry 4.0 ecosystem
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among Indian manufacturers, RAOTM 2019 witnessed the congregation of industrial pioneers who gathered at India’s largest industrial automation event to facilitate national collaborations and deliberate upon global competition. Catering to these subjects of importance, the 2019 conference played host to over 25 note-worthy exhibits and 50 fascinating technology sessions. Additionally, at Rockwell Automation’s RAOTM 2019 Annual User Group Conference—in which industry partners and customers are invited to showcase and discuss the latest digital transformation solutions and business opportunities— yet another ambitious feat of Rockwell Automation was announced. As it was observed that rigorously centered efforts are required to fulfill such an impressive target, the company has taken the lead to amplify its partner network in India. This will further allow local manufacturers to access a joint network of companies, which will be roped together with the aim of undertaking collaborative efforts. These efforts will be directed towards developing, implementing and supporting the bestin-class manufacturing solutions across industry verticals.
“Globally, digital-induced disruption is inevitable.” He further cited, “To maintain and improve global competitiveness, Indian manufacturers need to accelerate the adoption of Industry 4.0. While India has a lot of catching up to do in this respect, it can accelerate digital transformation by leveraging its strengths in the IT services sector and tapping the entrepreneurial spirit seen in the start-up sector.”
The thematic triad
The exhibits and sessions at the conference also displayed new products and showcased the solutions support by Rockwell Automation and its partner companies. Subsequently, Rockwell Automation also announced that it will host the thought-provoking conferences of RAOTM in the cities of Bangkok, Thailand; Tianjin, China; and Jakarta, Indonesia. Throughout the event, the discussions were centered on themes of prominence, which were The Connected Enterprise, Data Analytics and Augmented Reality and Innovation. The Connected Enterprise focused on the new analytics and digital solutions, that can help transform data into understandable information. This, in turn, would empower Partnerships in solution development users to confidently make more informed decisions in the As the world’s largest company dedicated to industrial entirety of the industry – from the plant floor to the enterprise. automation and information, Rockwell Automation has laid its The Data Analytics and Augmented Reality emphasised paramount focus on developing smart solutions. With an Rockwell Automation’s expansion of its portfolio by tapping analogous need for Smart Manufacturing solutions in the into its partnership with PTC. This will translate into help Indian industries, previously the company had affirmed delivered to customers in order to increase productivity and partnerships with global developers of vital solutions, such as, plant efficiency, reduce operational risk and provide better L&T, Cisco, Microsoft, Endress+Hauser, and Wipro system interoperability. Furthermore, the innovation segment Infrastructure Engineering. paid attention to the availability of pristine technologies to the In his engaging address at RAOTM 2019, Dilip Sawhney, customers. This would help better comprehend how new Managing Director, Rockwell Automation India, spoke on technologies will change manufacturing and production, venturing in partnerships towards the emergent era of Industry including Artificial Intelligence, Augmented Reality, wearables 4.0. He elucidated, “We want to take the lead in building India’s and other disruptive technologies. first industry 4.0 ecosystem of partner companies that will Thus, the RAOTM 2019 expounded the remarkable scope create solutions for The Connected Enterprise, which can for Industry 4.0 in the Indian manufacturing sector, while analyse machine conditions in advance in order to avoid highlighting the urgency to adapt to newer technology and breakdowns and enhance productivity, but also improve on smart solutions. With its offerings of industrial automation quality and compliance parameters.” and Artificial Intelligence, the conference also discussed the Consequently, John Watts, Regional Marketing Director— role of globally driven competition and the requirement for Asia Pacific, Rockwell Automation, expounded on the need for partnering with solution developers to build Indian Industry assimilation of Industry 4.0 in the manufacturing segment. 4.0 ecosystems. ☐
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EVENT | REPORT
Digital transformation driving business outcomes With the emergence of Industry 4.0, global industries have adopted digital aids to set themselves on the forefront of global competition. With ideas to propagate these digital technologies in the process industry, the Rockwell Automation Conference discussed the various efficient means to implement such technologies & how to overcome the challenges presented. A post event reportâ&#x20AC;Ś India has seen a subtle growth in its industrial sectors regarding the reception of Industry 4.0 but with its average level of digitisation of approximately 10% across various sectors, it is still far behind compared to global industries. However, the interest levels from enterprises for digital technologies is undeniable in our country. This is especially true for Bharuch in Gujarat, which has a noteworthy industrial base in significant sectors like, chemical, petrochemical, textile, pharmaceuticals and shipbuilding and offers a prolific mix of industrial sectors.
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Suchi Adhikari Senior Sub-editor & Correspondent suchi.adhikari@publish-industry.net
In this context, the Rockwell Automation Conference on â&#x20AC;&#x2DC;Digital Transformation Driving Business Outcomes,â&#x20AC;&#x2122; was held recently at Bharuch, to discuss the various challenges, opportunities and benefits of adopting pristine technologies.
IT and OT convergence The event commenced with the warm words of the welcome address delivered by Abanibushan Bera, Regional End User
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Manager - Western Region, Rockwell Automation. Shortly after, the first session began with a remarkable presentation on ‘Why Businesses need to digitally transform – Your Future is Here’ presented by RN Mohanty, President—Technology, Pidilite Industries. This was followed by another attention-grabbing address given by Abhay Dubey, Industry Manager—Rockwell Automation India & Asia Pacific, who explicated the topic of the Connected Process Plant and shared with the audience its trends and a few success stories. The session then turned its attention towards IT and OT convergence. Under this topic, AK Agarwal, CEO—BDMA and S M Thakor, Additional General Manager, GNFC, and Chairman, IT Forum, BDMA, acquainted the audience with this IIoT convergence in their presentation, ‘Two Worlds converging in Industrial IoT’. Highlighting the importance of the asset management and maintenance, Bharat Sridhar, Principal Consultant—Digital Manufacturing I4.0, ITC Infotech, propounded on its enhancement through the strategic use of data in his presentation. The challenges and opportunities in mobility, infrastructure and cyber security in process-centric industries were all consequently addressed by Jagdish Pranami, Deputy GM— Electrical and Instrumentation, SRF. This ultimately gave way to the concluding remarks for the first session put forth by P Raghu, Industry Manager—Chemical, Oil & Gas, Rockwell Automation India.
Driving business outcomes The second session of the fastidious conference commenced with the much-awaited panel discussion on the theme of ‘Digital Transformation Driving Business Outcomes’. The main objective of this discussion was to elucidate on how digital transformation can make a difference in operations and in turn, in the business. The esteemed panellists for the discussion were Jagdish Pranami; Kantilal Malvania, GM—Project Instrumentation, Grasim Cellulose; Abhay Dubey and Sandeep Redkar, Business Manager, Process Solutions, Rockwell Automation India. The panel discussion was moderated by Suchi Adhikari, Senior Sub-editor, A&D India magazine. To place a company in a league where it can compete globally, the key is to embrace solutions that will help steer an organisation towards its maximum potential and growth. As competing globally is an important aspect in today’s market
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for any venture, the moderator rightfully pointed out that digital transformation must be seriously considered by all, the big corporate companies as well as the SME sector. Consequently, the panel deliberated on the issues of a comprehensive roadmap towards digital transformation implementation, the various aspects involved in executing it and ways to ensure ROI in the long-term. The discussion was initiated with the topics of technology adoption levels in digitalisation in the industry with the implementation of advanced industry concepts, such as, industry 4.0 and IIoT. Over its course, themes such as, the short-term and long-term challenges in digitalisation, the prospects of supply chain and security were also discussed.
Technology adoption levels Opening the discussion on technology adoption levels, Kantilal Malvania cited, “This is just the initialisation, not the globalisation.” He emphasised the adoption of technology on each level by addressing the various digital machines used in a plant for digital printing, online data monitoring with the intranet, etc, which can be controlled and monitored remotely by connecting it to the main network. He also addressed the initial challenges but affirmed, “Everything is available online today. Every market and production is designed, defined and monitored remotely.” To deal with the long term challenge of infrastructure, Malvania explicated the initiation of the digital training systems to train the people, feed an ideal data into the database of servers, and achieve operational excellence through it. Following this, Jagdish Pranami brought to attention the average level of digitisation in various industries and commented that it should be at a higher level than the present level of 7% to 10%. Addressing the challenge presented by infrastructure, he mentioned how combining data from all the plants could pose a challenge to adopt IIoT, in case every plant has a different language, which can be resolved by networking. Subsequently, he explicated that assets and their management is very important and initially, the companies had not been well-aware or sincere about its safety.
Global perspective The global perspective on the adoption of Industry 4.0 or digitisation was put forward by Abhay Dubey. While many
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EVENT | REPORT
The conference proved to be a greatly insightful one, with its exchange of perspectives, from the end-users to the solution providers
multinational companies have a high degree of adoption—having a specific digitalisation department, which will only focus on the digitalisation aspect—it is unclear as to what kind of investments and what kind of returns they are going to get back. Additionally, he spoke on skill upgradation and highlighted that it is a continuous process. He explained, “In your digitisation journey, it is extremely important for your staff to be upgraded as far as their skills are concerned,” and also laid importance on developing the right mindset and culture in the company to aid digitisation. As digitisation requires a substantial amount of investment, Dubey also quoted the factors, which according to him would achieve the ROI required, “I would sum it up in three factors— one would be the people, second would be the processes around it and third would be the technology.” On the implementation roadmap of digitisation, he stressed that it can attain success if the blueprint is undertaken in small baby steps. He suggested, “Have a proof of concept done, have a pilot on a small project before you jump on to the entire blueprint or put the whole investments together.”
Further, suggesting a roadmap, he observed, “You will have process engineers to help you along the way—what are the specific measurements that will help to model that peak hour performance properly and derive some observations out of that.” The session reached its conclusion with an indispensible addition from Suchi Adhikari on the objectives of operational productivity, global competency and sustainable operations. She added, “Gain an understanding of what is important to you and start taking baby steps towards a greater objective of achieving a digital enterprise.” Digital transformation must be considered as a possible solution, which will help access Big Data, analyse the data, provide insights on hidden inefficiencies and help to streamline the ventures towards its maximum growth and potential.
Technologies and transformations
The final session for the conference focussed on the technologies and transformations that come with implementing digitalisation. The vision of Industry 4.0 in the chemical and process industry was expounded on by Ramesh Cyber security Dham, AGM—Industry 4.0, UPL. Taking up the topic of Next, Sandeep Redkar spoke briefly about cyber security and infrastructure required with the onset of digitalisation, Ankur explained the importance of drawing a base document on how to Pancholi, Product Manager—Large Control, IO & Network tackle threats and understand specifically the cyber security Security, Rockwell Automation India, spoke on ‘Secure threats to counter in the solutions that you implement, which can Network Architecture for the Digital Plant’. thus, be cost-effective. He spoke about the stages of ensuring data The latter half of the session saw the presentation on ‘What to security and shared, “Security has to be prevalent across the Expect from a Modern DCS in Digital Era’ delivered by Sandeep system; it is not a point solution.” He further addressed the Redkar. This was followed by the presentation on ‘Rethinking importance of automation systems as it takes away the uncertainty Motor Control in a Digital Age’ by Jayesh Joisher, Power Control, of how the production was done and gives a genealogy for every Area Manager, Rockwell Automation, who imparted invaluable product, and explained, “A manufacturing execution system can knowledge to the audience, as the conference drew close to its look at all the different aspects, right from the material coming in end. The final session concluded with the conclusive remarks for to the finished goods going out and trying to give one uniform the event given by Komal Shah, Channel Sales Manager— picture of how production is operating in your plant.” Western Region, Rockwell Automation India. Thus, the On the topic of investment regarding IIoT, Redkar elucidated conference proved to be a greatly insightful one, with its exchange the three aspects which stand out—the first one is productivity of perspectives, from the end-users to the solution providers, and yield and quality improvement, the second maintainability and highlighted the benefits for industries with the inculcation of Predictive Maintenance, and the third the use of AR and VR. digital machinery in its plants. ☐
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PRESENTING ARC’S SEVENTEENTH INDIA FORUM
Driving Digital Transformation in Industry and Cities J U LY 4 - 5, 2 0 1 9 • B A N G A L O R E
To navigate successfully through today’s global wave of digital transformation and make disruptive technologies work for them, manufacturers, municipalities, utilities, and all other organizations will need to roll out just the right mix of technologies at just the right time. They will need to drive and manage change in processes, people, ecosystems, and technologies while putting cybersecurity at the forefront. There are countless ways to conduct your digital transformation journey, multiple technologies and suppliers to evaluate, and endless choices to make along the way. Embedded systems, networks, software platforms, augmented reality, and machine learning may play a role as you begin to improve uptime, optimize operating performance, enhance service and the customer experience, and re-think business models.
FEATURED TOPICS: IMPROVING ENERGY EFFICIENCY ADVANCE CONTROL STRATEGIES SMART GRID AND SMART CITIES COLLABORATION AT THE USER AND DEVICE LEVELS MANAGING LEGACY AND AGING INFRASTRUCTURES 3D TRAINING AND SIMULATION SOCIAL MEDIA ADVANCED ANALYTICS AND BIG DATA CLOUD COMPUTING
ARC Advisory Group’s Seventeenth India Forum for process IMPACTS OF MOBILE COMPUTING and discrete industries is a not-to-be-missed event for all ENTERPRISE AND PLANT ASSET stakeholders – technology solution providers, end users, MANAGEMENT industry trackers, decision and policy makers, and the media. In an advanced automation and information-driven SUPPLY CHAIN MANAGEMENT INCLUDING world, terms such as Industrial Internet of Things (IIoT), SERVICE LIFECYCLE MANAGEMENT Smart Manufacturing, Industry 4.0, Digitization, and Connected Enterprise, are clearly moving past the hype stage CYBERSECURITY AND SAFETY to the point where real solutions are emerging backed by strong associated business cases. This is the age of digitization. TO REGISTER:
Space Is Limited! Call India +91-80-2554-7114 or USA +1-781-471-1000, Register on-line at www.arcweb.com/events/arc-industry-forumindia/or Email: ramang@arcweb.com.
Vision, Experience, Answers for Industry
TECHNOLOGY | NEWS
Process control system
Purge and pressurisation system
B&R Industrial Automation recently introduced the new version R4.2 of the APROL automation platform, which provides a powerful and convenient system for managing online parameters. APROL DisplayCenter displays a clear overview of online parameters and facilitates the commissioning of measurement and control loops. The online parameters can be dragged and dropped to other systems. The different APROL DisplayCenter views allow a clear display and uncomplicated modification of the online parameters. The faceplate view offers a well-structured user interface while the system logic is displayed in the control module view. Parameters can be entered, and control modules can be enabled in the list view. Depending on the requirements, the appropriate view can be selected, or one can switch between the views. The new operating dialog boxes not only provide a better overview of the parameters, but also allow existing online parameters to be transferred to other measuring points. To ensure seamless traceability, when online parameters are fed back into the APROL project engineering tool—CaeManager, a new version is automatically created with the comment, ‘Online parameters imported’.
Pepperl+Fuchs recently introduced an advanced Bebco EPS® purge and pressurisation system, designed for Class I or II/Div. 2 and Zone 2/22 locations. The 7500 series Ex pzc/Type Z purge and pressurisation system can be fully automatic or manual and purges a common enclosure of hazardous gas or dust to maintain positive pressure. It effectively reduces the classification within the protected enclosure to a non-hazardous area. The 7500 carries ATEX and IECEx certifications and is UL listed. It operates within an extremely small footprint of only 5.8” × 3.8” × 1.9”. Also, it includes intelligent automatic monitoring and control of Bebco EPS 7500-Series enclosure pressure with dilution and Type Ex pzc/Type Z continuous flow functionality. The system makes automatic adjustments and provides an alarm output for reliable protection. It is designed in marine-grade chromate aluminium. The 7500 uses universal AC/DC power and is available as both a panel mount and external mount. The large touch screen enables quick and easy setup while also providing status LEDs, a bar graph for pressure, and multiple program selections.
B&R Industrial Automation | Pune Email: office.in@br-automation.com | Tel: +91-20-4147 8999
Pepperl+Fuchs | Gurgaon Email: fa-info@in.pepperl-fuchs.com | Tel: +91-9650530027
Machine Learning for control systems
Rotational torch sleeves for plasma cutting torches
Beckhoff recently offered a Machine Learning (ML) solution that is integrated into TwinCAT 3 software. Building on established standards, TwinCAT 3 Machine Learning brings to ML applications the advantages of system openness familiar from PC-based control. In addition, the TwinCAT solution supports Machine Learning in real-time, allowing it to handle even demanding tasks like motion control. Inference can be performed directly in real-time with a TwinCAT Machine Learning integrated TcCOM object. With smaller in TwinCAT 3 software networks, system response times of less than 100 µs corresponding to a TwinCAT cycle time of 50 µs are supported. Through integration with control technology, the multi-core support provided by TwinCAT 3 is also available for Machine Learning applications. All the fieldbus interfaces and data available in TwinCAT can be fully accessed as well. This allows ML solutions to use immense amounts of data. These capabilities provide machine builders and manufacturers with an optimum foundation to enhance machine performance, e.g. through prescriptive maintenance, process self-optimisation and autonomous detection of process anomalies.
Hypertherm recently introduced three new torch sleeves for XPR plasma cutting torches and lead sets. The sleeves allow the torch and lead sets to remain axially fixed while the torch holding device rotates 360 degrees in either a clockwise or counterclockwise direction. The new sleeves – available in short, medium and extended lengths – are ideal for bevel or 3D/robotic cutting applications when using either an XPR170 or XPR300 X-Definition plasma system. An outside diameter of 76 mm (3”), allows for an increased wall thickness and eliminates compression caused by clamping. Pre-sealed, high—precision bearings reduce axial play by 90 per cent and radial play by 81 per cent. This keeps out dirt and other particulates associated with plasma cutting and greatly extends the life of the sleeve and lead system. A combination of engineering advances and refined high definition plasma processes help X-Definition class XPR rotational plasma deliver unmatched plasma cut quality on mild torch sleeves steel, stainless steel and aluminium. Laboratory testing shows ISO-9013 Range 2 cut quality on thin mild steel and extended ISO Range 3 cuts on thicker metals.
Beckhoff Automation | Pune Email: a.phatak@beckhoff.com | Tel: +91-9975547774
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Hypertherm India | New Delhi Email: yaseer.wajahet@hypertherm.com | Tel: +91-11-40521201
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NEWS | TECHNOLOGY
Thermal SD compressed air meters
Decentralised drive units
ifm has recently launched the new thermal SD compressed air meters, which are ideal for fast and reliable identification of leakages in compressed air systems. The modern sensor does not only measure the pressure but also the temperature and the volumetric flow so that it can also be used as a quantity meter. The user needs only one sensor which saves hardware, installation and maintenance costs. The integrated pressure measurement has decisive advantages in many applications. The pressure loss at dirty filter Thermal SD compressed air meter systems can, for example, be monitored. Timely maintenance of the filters can contribute to cost reduction. Very high pressures can lead to an increased wear of components, which can also be reliably detected. Also, the compact compressed air meter can visualise the measured values directly on site on the built-in TFT display. The staff always has an overview of the 6 bar and 12 bar compressed air systems. Plus, four different individually adjustable graphic layouts are available for the visualisation. The SD also has an IO-Link interface and can be integrated in higher-level systems.
Nord Drivesystems recently offered LogiDrive systems that are service and maintenance-friendly plug-&-play technology and feature ultimate efficiency and reliability. The decentralised drive units consist of an energy-saving IE4 synchronous motor with a rated power of up to 5.5 kW, a twostage helical bevel gear unit and a NORDAC LINK frequency inverter mounted close to the motor. The entire system has a LogiDrive systems modular design, so that all components of the drive technology can be individually serviced. Among other offerings by the company are the extruder flange option, which can be customised to the customer’s shaft and optimally matched to the customer’s demands with several bearing variants. This gives plant constructors, manufacturers and processors of plastic and rubber the opportunity to develop safe and highly reliable drive units that are very versatile at the same time. Also, a drive unit with extra safety, the PROFIsafe interface module, is introduced. It provides comprehensive safety for the reliable operation of plant and machinery.
ifm electronic India | Kolhapur Email: info.india@ifm.com | Tel: +91-231-2672770
Nord Drivesystems | Pune Email: india@nord.com | Tel: +91-20-39801200
Clamping stations with compact dimensions Schunk recently introduced the miniature clamping stations from the VERO-S NSL mini 100-25 series, which ensure high clamping forces in a compact design. The powerful 1-way, 2-way, and 4-way clamping stations are particularly designed to the requirements of modern small parts production. Each clamping module achieves a pull-down force of 6,000 N due to a patented dual stroke system VERO-S NSL mini 100-25 and activated turbo function. Since the rigidity has also been increased, significantly higher tilting moments can be absorbed. On similar lines, the VERO-S NSL mini 100-25 clamping stations enlarge the SCHUNK VERO-S mini modular system. They precisely mount a wide variety of clamping devices from the SCHUNK NSE mini range and enable quick set-up procedures. The alignment grooves present at the bottom, simplifing the placement on the machine table in the longitudinal and transverse direction. In addition, the 2-way and 4-way clamping stations are equipped with centre holes and alignment edges. Optionally, the clamping stations can be provided with additional screw holes.
Statement about ownership & other particulars about A&D, as required to be published in the first issue every year after the last day of February 1. Place of Publication: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 2. Periodicity of Publication: Bi-monthly 3. Printer’s Name: Shekhar Jitkar Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 4. Publisher’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 5. Editor’s Name: Shekhar Jitkar Nationality: Indian Address: 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 6. Names & addresses of individuals who own A&D and partners or shareholders holding more than 1% of the total capital in publish-industry India Pvt Ltd, 302, Sarosh Bhavan, Dr Ambedkar Road, Camp, Pune 411 001 Details of the shareholders of publish-industry India Pvt Ltd who are holding more than 1% of the paid up equity share capital of the company as on 29-05-2019: a) publish-industry Verlag GmbH, Machtlfinger Strasse 7, 81379 Munich, Germany b) Kilian Mueller, Machtlfinger Strasse 7, 81379 Munich, Germany I, Shekhar Jitkar, hereby declare that all the particulars given above are true to the best of my knowledge and belief. Dated: April 29, 2019 Sd/SHEKHAR JITKAR Signature of the Publisher
Schunk Intec India | Bengaluru Email: info@in.schunk.com | Tel: +91-80-405 38999
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H I G H L I G H T S | C O M PA N Y I N D E X | I M P R I N T
Highlights – Jun-Jul 2019 IMPRINT
Automation & Drives
Publisher / Chief Editor ShekharManufacturing Jitkar Efficient
shekhar.jitkar@publish-industry.net Senior Sub-editor & Correspondent Suchi Adhikari suchi.adhikari@publish-industry.net Features Writer Juili Eklahare juili.eklahare@publish-industry.net Content Developer (Online & Print) Namrata Singhania namrata.singhania@publish-industry.net
» Fieldbuses and Networks Many different fieldbus networks still continue to dominate industrial automation and process control. One of the dilemmas that have obstructed the quick adoption of fieldbus technology has been the absence of standardisation. The next issue discusses the challenges in this sector and how they can be overcome.
» Power & Energy Over the coming decades, digital technologies are set to make energy systems around the world more connected, intelligent, effective, dependable and viable. Digitalised energy systems in the future may be able to recognise who needs energy and deliver it at the right time, in the right place and at the lowest cost. The following issue finds out how digitalisation is refining security, output, availability and sustainability of energy and power systems.
» Test & Measurement Although test & measurement profiles differ from organisation to organisation, it is important that measurements are precise and measure what is achievable. Test and measurement equipment supports the product design process, allowing engineers to confirm their design is working the way they want and find out where the problems lie. The next issue explore the latest developments and trends in this sector.
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COMPANY INDEX Name . . . . . . . . . . . . . . . . . . . . . . . . . Page ABB . . . . . . . . . . . . . . . . . . . . . . . . . . 14, 21 Abhisam Software . . . . . . . . . . . . . . . . . . . . 48 ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 AspenTech . . . . . . . . . . . . . . . . . . . . . . . . 36 B&R Industrial Automation . . Cover, 10, 11, 44, 62 Bajaj Auto . . . . . . . . . . . . . . . . . . . . . . . . . 22 Beckhoff Automation . . . . . . . . . . . . . . . . 1, 62 Contrinex Automation . . . . . . . . . . . . . . . . . 53 Delta India . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Deutsche Messe . . . . . . . . . . . . . . . . . . . . . 15 DiFACTO Robotics and Automation . . . . . . . . 24 DNV GL . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ericsson . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Fraunhofer IPK . . . . . . . . . . . . . . . . . . . . . . 34 General Motors . . . . . . . . . . . . . . . . . . . . . 18 Givaudan . . . . . . . . . . . . . . . . . . . . . . . . . . 14 HMS Industrial Networks . . . . . . . . . . . . 14, 39 Hummel Connector Systems . . . . . . Back Cover
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Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Hypertherm India . . . . . . . . . . . . . . . . . . . . 62 ifm electronic India . . . . . . . . . . . . . 12, 27, 63 igus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 IMTMA . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 Innovista Sensors India . . . . . . . . . . . . . . . . 13 International Federation of Robotics . . . . . . . . 26 Konecrane . . . . . . . . . . . . . . . . . . . . . . . . . 15 Kubler Automation . . . . . . . . . . . . . . . . . . . 31 LAPP Holding AG . . . . . . . . . . . . . . . . . . . . 52 Lapp India . . . . . . . . . . . . . . .Back Inside Cover Maxon precision motor India . . . . . . . . . . . . 49 Mitsubishi Electric . . . . . . . . . . . . . . . . . 15, 19 MurrElectronik India . . . . . . . . . . . . . . . . . . 29 Nord Drivesystems . . . . . . . . . . . . . . . . . . . 63 Pepperl+Fuchs . . . . . . . . . . . . . . . . . . . . . 62 Phoenix Contact . . . . . . . . . . . . . . . . . . . . . 25 Pilz India . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Puresight Systems (iRobot India) . . . . . . . . . . 28
Name . . . . . . . . . . . . . . . . . . . . . . . . . Page Rittal India . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rockwell Automation . . . . . . . . . . . . 55, 56, 58 Schunk Intec India . . . . . . . . . . . . . . . . . . . 63 SEW-EURODRIVE India . . . . . . . . . . . . . . . . 43 Sick India . . . . . . . . . . . . . . . . . . . . . . . . . 23 Siemens Financial Services . . . . . . . . . . . . . 14 Siemens PLM . . . . . . . . . . . . . . . . . . . . . . 40 Stauff India . . . . . . . . . . . . . . . . . . . . . . . . 17 Svaya Robotics . . . . . . . . . . . . . . . . . . . . . 30 Technical University of Berlin . . . . . . . . . . . . 34 Turck India Automation . . . . . .Front Inside Cover Universal Robots . . . . . . . . . . . . . . . . . . . . 32 VDMA Robotics + Automation . . . . . . . . . . . 33 VEGA India Level and Pressure Measurement . . . . . . . . . . . 5, 6, 7, 8 Yaskawa Electric Corporation . . . . . . . . . . . . 26
Board of Directors Kilian Müller (CEO – Worldwide) Hanno Hardt (Head – Marketing & Business Development) Frank Wiegand (COO – Worldwide) Shekhar Jitkar (Publisher / Chief Editor) Subscription Cover Price: `100 Annual Subscription Price: `1000 AandD.india@publish-industry.net Tel: +91-7410006435/36 Printing Vikram Printers Pvt. Ltd., Parvati Industrial Estate, Pune-Satara Road, Pune - 411009, Maharashtra, INDIA Copyright/Reprinting The publishing company holds all publishing and usage rights. The reprinting, duplication and online publication of the magazine contents is only allowed with written permission from the publishing company. The publishing company and editorial staff are not liable for any unsolicited manuscripts, photos and illustrations which have been submitted. Internet https://industr.com/en/ Digital edition http://issuu.com/publishi/docs
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