newtek nº 110 | IoT + Industry = An ongoing revolution

NEWS Sustainable and adaptable workplaces for the industry of the future

INTERVIEW “Operation and maintenance: once a support, now the essence of the business”

SCIENCE, TECHNOLOGY AND KNOWLEDGE

PROJECT A pioneering solution for agricultural spraying

SEPTEMBER 2019 | No. 110 ENGLISH EDITION

IoT + Industry =

An ongoing revolution

INTRODUCTION As is the case with many other areas, digital transformation has also reached the area of industrial maintenance. As we now “predict” instead of “prevent, significant changes have resulted in how companies address maintenance issues.

On the other hand, the increased use of sensors and devices connected to the environment (the Internet of Things) in diverse sectors such as health, infrastructures, digital homes, automotive, aeronautics, machine tools and agrofood, among others, have given rise to new business opportunities and services characterised by a higher added value.

In this edition of Newtek, IK4-TEKNIKER describes how the organisation is addressing operation and maintenance to meet challenges based on Industry 4.0 and also looks into the development of IoT technologies seen from complementary perspectives and capabilities.

Don’t miss it!

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INDEX

THE EXPERT’S VIEW

C04 Predictive

maintenance: from data to the indicator

INTERVIEW

C06 “Operation and

maintenance: once a support, now the essence of the business”

NEWS

C08 MOM: an industry 4.0

ecosystem C10 Sustainable and adaptable workplaces for the industry of the future

PROJECT

C12 Data exploitation and

management for wind turbine predictive maintenance

PROJECT

C14 A pioneering solution

for agricultural spraying

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THE EXPERT’S VIEW

THE EXPERT’S VIEW: Virginia Giao Director of the IK4-TEKNIKER Operation and Maintenance Business Unit

Egoitz Konde Industrial Maintenance Coordinator at IK4-TEKNIKER

Predictive maintenance: from data to the indicator

IK4-TEKNIKER has made available to all customers its expertise, equipment and technology to advance towards a predictive maintenance strategy that will enhance plant performance, optimise operations, give products more added value and, consequently, improve business outcomes.

The emergence of new technologies in the industry has not only made it possible to optimise production processes but has also helped to upgrade equipment maintenance practices. Nowadays, and thanks to real-time information analysis and monitoring, it is possible to anticipate potential failures and incorporate actions geared towards increa-sing system availability, reliability and service life, thus optimising OEE (Overall Equipment Efficiency) and reducing operating costs.

A maintenance strategy defines what, when and how to proceed. In the past, three scenarios applied subject to whether you were dealing with a breakdown (reactive maintenance), with a scheduled maintenance plan regardless of plant status (preventive maintenance) or were influenced by online data (condition-based maintenance). Nowadays, a fourth stage has been added that allows maintenance actions to be optimised by constantly monitoring equipment and processes by means of real-time data analysis, i.e., predictive maintenance.

RELIABLITY

OEE AND UPTIME

IMPROVE OVERALL EQUIPMENT EFECTIVENESS (OEE)

REACTIVE Fix when broken LEVEL 1

PLANNED Scheduled maintenance activities LEVEL 2

CONDITION MONITORING Continuous sensing to identify defects and optimize performance LEVEL 3

PREDICTIVE Advanced analyses of sensing data to predict machine reliability

LEVEL 4

This new scenario allows users to anticipate problems before they actually occur by means of real-time capture and analysis of critical process signs and equipment conditions (temperature, pressure, vibrations, speeds, power, etc.). Information of this kind allows for the permanent surveillance of equipment and greatly enhances decision-making to manage resources more efficiently.

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Enabling technologies to monitor and predict potential failures In terms of maintenance, enabling technologies have provided the driving force required to make this great leap forward. Thanks to breakthroughs such as Big Data, the Internet of Things (IoT) and Cloud Computing, it is nowadays possible to obtain major computation capacity, signal integration, storage of large data volumes and online access to information from remote locations.

These enabling technologies together with advanced data analytics and modelling techniques (Data Mining, Machine Learning, artificial intelligence, neural networks, etc.), have made an exponential contribution as regards progress reported with regard to maintenance strategies currently in use to predict anything that can help overcome a problem before it actually happens (predictive or prescriptive maintenance, also called “Maintenance 4.0”).

We are dealing with a multidisciplinary process in which we must fully understand all the systems involved from the design stage all the way to in-use behaviour to determine signs indicative of fatigue and degradation.

The need to carry out an internal transformation This new predictive maintenance strategy always requires that companies carry out in-house transformations. New technologies such as digital platforms must be incorporated, new operation and maintenance management procedures have to be implemented for assets and all decision-making processes must be transformed to remain one step ahead.

Status analysis is a crucial element to guarantee the successful implementation of an improved maintenance strategy. Consequently, this diagnosis must be performed both internally on the machines, components and processes involved and externally to establish what technologies must be incorporated.

The next step is to design a plan to achieve predictive maintenance. Optimisation goals must be clearly defined and be as specific, measurable and as realistic as possible to facilitate implementation and commissioning.

The IK4-TEKNIKER view IK4-TEKNIKER offers companies its knowledge, expertise, equipment and know-how in this joint effort aimed at implementing predictive maintenance.

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RELIABILITY, STRATEGY AND PLANNING Reliability analysis Criticality analysis of components Analysis of maintenance plans Analysis of information management systems and procedures DATA MANAGEMENT Capture Analytical (descriptive, predictive, prescriptive) Storage and integration Implementation: dashboards and tools for optimising strategies / plans, planning, spare parts and diagnostic support

CONDITION BASED MONITORING Feasibility studies Fingerprint test Develop and implement condition based monitoring (vibrations, ultrasounds, oil, deformations and currents)

SIMULATION Simulate degradation mode and component and machine failure Digital twins Test benches

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In addition to providing assistance to review the initial situation and define optimisation goals, IK4-TEKNIKER plays an outstanding role in terms of development, implementation and validation. The same applies to deploying the operation and maintenance solutions required to achieve these goals.

Consequently, IK4-TEKNIKER offers two major lines of maintenance solutions that take into account the current status of the asset to be maintained in terms of its life cycle, the type of customer and their optimisation goals.

Asset Management Solutions offer technological alternatives whose aim is to optimise plant performance, operations and, ultimately, business outcomes.

Smart Component Solutions, on the other hand, offer the development of “connected” products that deliver a higher added value to the end customer and allow for the implementation of a new business model for maintenance services (servitization).

Our added value in two dimensions In this process it is important to underscore how complex it is to create suitable environments to predict failures. In most instances, the lack of historic information on processed data makes it necessary to implement a learning process to correctly ascertain how assets behave when in use.

IK4-TEKNIKER addresses this learning phase from a dual perspective: operating experience and simulation.

Operating experience developed throughout the entire life cycle of equipment and machines (design, validation, operation and failure), together with experience in terms of equipment monitoring (vibrations, ultrasounds, deformations, process signals, etc.) has allowed IK4-TEKNIKER to incorporate to data analytics and modelling expert knowledge and any knowledge resulting from monitoring equipment status.

Simulations, executed virtually or by means of test benches that can mimic in-service conditions, have allowed IK4-TEKNIIKER to enrich data models to improve predictive capabilities and obtain all the nece-ssary knowledge.

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Thanks to its multidisciplinary team, IK4-TEKNIKER has managed to integrate all disciplines to offer a global approach that is mathematical/ algorithmic and uses machine learning techniques and artificial intelligence; the knowledge approach in IT for data management and security; and, finally, an approach connected to domain knowledge and business rules.

In addition to the value that the organisation is delivering, IK4-TEKNIKER owns an IoT platform (the Smart Asset Management - SAM) to integrate and use any knowledge that is produced.

In short, it is nowadays possible to enhance plant performance, optimise operations and, consequently, improve business outcomes by developing solutions that will eventually allow users to implement Predictive Maintenance.

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INTERVIEW

Manuel Baraza Director for Industry and director for Energy & Utilities at Ibermática

Operation and maintenance: once a support, now the essence of the business

1 2 Operation and maintenance solutions have become one of the basic pillars of the industry and are essential component as regards new trends such as Industry 4.0, but where does their importance lie?

What position does a company such as Ibermática aspire to achieve in terms of of operation and maintenance solutions?

Nowadays, digital transformation associated with Industry 4.0 is the main challenge for the industrial sector. It is a structural change conducive to smart factories, to a new culture that must deal with new challenges such as, for instance, unitary traceability in manufacturing (parts with data) or the deployment of autonomous systems equipped with decision intelligence. This has produced a major disruption in the operational efficiency of assets or in the need servitise products. It is in this context where operation and maintenance solutions have become so important and critical to become not only a support but also the essence of the business itself.

At Ibermática, we have a clear vocation and firmly believe in our leadership, because of, on the one hand, our global vision and integration and, on the other, because the Ibermática Manufacturing Platform is one of the best European proposals for midmarket spanning engineering and the plant itself.

But not only is efficiency essential, so is resilience too. You must be able to adapt to demand and do so very quickly. The speed of adaptation to changes of any kind and “knowing what would happen if ” are nowadays a significant competitive advantage. The entire supply chain must be digital and interconnectivity and collaboration between all stakeholders along the value chain, in-house and between companies must exist.

In short, it is crucial to have a global and integrated view of processes and technologies; moreover, all solutions, and not only those related to operation and maintenance, must be focused on and enabled for the IT/OT convergence.

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The roots of an environment like the Basque Country, with an active focus on leadership in the field of industry 4.0, and with hundreds of our customers that have provided us with an enormous amount of knowledge and experience resulting from their leadership in different sectors in which they have carried out expansion and internationalisation procedures after achieving high levels of excellence in their industrial processes have allowed us to maintain a continuous ambition in terms of innovation and growth.

By bringing together essence and knowledge, we can only aspire to playing a leadership role and will always be open to collaborating with third parties. Our creative spirit and collaborative efforts have brought us to this point and will project us even further in the future.

Ibermática is one of Spain’s leading providers of IT services present in the market since 1973 whose mission has consisted in assisting with the digital transformation of companies, institutions and organisations to improve their competitiveness by applying technology and knowledge based on commitment and closeness. By being close to its customer base, the company has been able to carry out a permanent expansion process and further deploy business transactions. Nowadays, Ibermática is a multinational corporation that is present in more than 10 countries in Europe and America with more than 3,350 professionals working at 20 operational centres. The company is engaged in a number of sectors such as finance, insurance, industry, services, telecommunications, health, energy & utilities and public administrations and offers specific sector solutions. Manuel Baraza, the director for Industry and Energy & Utilities sectors shares his thoughts with newtek on the industrial ecosystem.

345 Without a doubt, digital transformation is not only a great challenge and a splendid opportunity but also a necessity. How does Ibermática apply digital transformation and smart industry in different environments?

In this regard, what role does the new Manufacturing Operations Management (MOM) Expertise Center, jointly established with IK4-TEKNIKER, play and would do you think about its implementation?

This is a fine example of a collaboration between a company and a technology centre, but what does Ibermática expect it will deliver and what will it contribute in terms of its value proposal?

We are ambitious and have enough capacity to deliver a strategy and provide the degree of support our customers need to make the most of the opportunities offered by Industry 4.0. Our vision is a company extensive and comprehensive, and so is our value proposal. But if I were to underscore some fields of application, it would be those listed hereunder:

The digital transformation process associated with Industry 4.0 has given rise to changes in how we relate to each other. This reality, coupled with our own essence as a company, has led to collaborative efforts with regard to development, innovation and growth. And it was in this environment where the reality of the Manufacturing Operations Management (MOM) Expertise Center was born with the assistance of IK4-TEKNIKER, to provide enough leverage for this vision of a future based on uniting the strengths of two organisations that know and complement each other so well.

As mentioned before, collaboration is an essential characteristic of the environment and our character. It is nowadays an intrinsic element of the industrial economic ecosystem. But the ties with IK4-TEKNIKER are much stronger. Our long-standing collaborative relationship is solid in terms of knowledge, reliability and performance and allows us to share their mindset with regard to continuous creation and innovation.

We also fully coincide with their creative drive.

• Knowledge and experience in the area of Big Data and advanced analytics applied to processes adapted to the new dynamic required by industrial organisations.

• Solutions in all three industrial domains: fully integrated plant engineering and management.

• Design, development and implementation of integral IT/OT for smart factories.

• Global geographic support capacity.

• Etc. In short, a flexible solvency, as demonstrated by the five consecutive years of our leadership with regard to private reports on service quality in which customers have evaluated their key providers of technological services.

The MOM is a wonderful opportunity for industrial firms as it allows them to reduce implementation risks by designing and developing specific solutions for each customer (as per company standards) followed by implementation/testing in pilot settings. This is possible because MOM offers teams with a high level of expertise in terms of production processes and technologies and a close relationship with R&D teams focused on developing products.

We hope that this shared project, the MOM Expertise Center, will allow us to generate greater value for our customers and the industrial market as a whole to assist in setting up smart factories based on the possibilities that will be offered by the Industry 4.0 digital revolution that has only just begun.

The value proposal we deliver to our customers is exceptional because, when dealing with development, innovation, international challenges or new launches, it can reduce the duration of what is known as the death valley in the life cycle of an investment and it is frequently vital to do so.

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MOM: an industry 4.0 ecosystem The ‘Manufacturing Operational Management (MOM) Expertise Center’ has brought together experts dealing with different technologies and tools to design and develop innovative projects that are to be subsequently commissioned and deployed in the form of a final on-site solution.

Continuous technological advances reported in the industrial sector have made it increasingly necessary to produce open innovation ecosystems to develop and test integrated projects before being deployed at plants on an international scale.

In order to meet this demand, IK4-TEKNIKER and Ibermática have established the ‘Manufacturing Operational Management (MOM) Expertise Center’, a unique space for development, simulation and testing that has brought together experts in automation, robotics, Big Data and Manufacturing Execution Systems (MES) to implement integrated solutions.

The MOM Expertise Center is an initiative that stands in line

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with customer needs in terms of progressing towards Industry 4.0 with regard to initial design stages, project testing, commissioning and deploying final solutions.

The Expertise Center is based on two pillars: on the one hand, a focus on new production concepts based on Industry 4.0 accelerators such as additive manufacturing, predictive maintenance, in-process inspection, automation and industrial robotics.

And, on the other, it provides support to consolidate more connected integrated, resilient, smart and automated industrial firms by delivering specialised services and solutions allowing for a more efficient implementation.

NEWS

Production control Production plant monitoring KPI Quality Traceability Maintenance: preventive, corrective Machine energy comsuption sensorics Logistics

4.0 INDUSTRY ACCELERATORS

IMPLEMENTATION

ADDED VALUE

This also lessens any risks involved, shortens implementation, delivers a customised solution and offers specialised support.

Additive manufacturing Predictive maintenance “In Process” Inspection Automation and robotics

CUSTOMER STANDARD

APPLICATIONS

The MOM Expertise Center allows solutions to be delivered via a single proposal that contains a number of technologically advanced tools to carry out pilot projects to be rolledout and supported on-site in terms of quality, production, automation and maintenance.

Implementation methodology Deployment Operation support

MOM Manufacturing Operational Management

Risk reduction Time reduction 4.0 Industry customisation Specialized support Exclusive access

In short, the Expertise Center’s proposal delivers value based on open collaboration models between manufacturers of digital solutions, manufacturers of production resources and technology centres for the purpose of implementing solutions at industrial plants. The ultimate goal is to adapt their operations to all the elements that form part of an interconnected industrial ecosystem in which they operate to according to certain processes and systems.

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NEWS

Sustainable and adaptable workplaces for the industry of the future

The he A4BLUE European p project led by IK4-TEKNIKER -TEKNIKER incorp incorporates automation mechanisms tto manufacturing environments to adapt production systems to workers and enhance their capabilities.

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Due to the presence of intense competition in the aeronautical business and continuous implementation of technological developments, manufacturers are currently under pressure to increase their productivity figures and develop highly resilient production systems.

The purpose of the A4BLUE project that kicked off in 2016 and will end in September 2019 consists in ensuring that all of these systems will meet workers’ needs in full. Its aim is to develop and validate a new generation of sustainable and adaptive workplaces to cope with continuous changes in process requirements that can adapt to workers’ characteristics.

A4BLUE introduces adaptive automation mechanisms allowing tasks to be performed efficiently and flexibly together with secure person-machine interaction and customised training and assistance for workers during assembly operations featuring augmented and virtual reality.

The adaptation process itself does not only cover automation but also the entire workplace so it can adapt to worker needs and profiles. It is based on an IoT (Internet of Things) architecture that allows knowledge related to the the production context to be obtained by compiling information via different elements located in the environment such as, for instance, automation equipment, safety sensors, devices for interactions to take place between operators and the automation itself via voice/gestures and systems for production management.

This project has received funding from the European Union’s Horizon 2020 resear and innovation programme under grant agreement n° 723828.

A number of technologies have also been developed to esta-blish the optimum level of automation for production facilities and evaluate the degree of worker satisfaction and the extent to which it can be used in new production environments.

The consortium currently involved in the A4BLUE project is testing four new workplaces in real environments in which aeronautical companies such as Airbus and CESA, Compañía Española de Sistemas Aeronáuticos (a division of the Héroux-Devtek group), the renowned RWTH University of Aachen and IK4-TEKNIKER itself are monitoring pilot validation implementations.

As regards Airbus, the scenario chosen is based on the assembly of a complex hydraulic system installed on wings.

In this particular instance, the aim was to provide flexibility and productivity by introducing “smart” tools that can be automatically adapted to different process parameters during assembly as a function of the production context.

During this assembly process, operators are guided, step by step, by glasses equipped with augmented reality features.

Additionally, CESA, the European leader in terms of fluid-mechanical equipment, and nowadays known as Héroux-Devtek Spain, has set itself the goal of optimising the assembly of a hydraulic actuator on landing gear.

Consequently, work is mainly focusing on reducing the duration of deburring processes and improving workers’ ergonomic and safety conditions throughout the process.

Smart tools are currently being introduced to allow workers to access and share information in different stages of an actuator’s assembly process by using augmented reality devices that enhance their skills and guide them whilst they work.

IK4-TEKNIKER provides the third leg of this pilot research action by means an existing person-robot collaborative environment for the assembly of a latch valve used in the aeronautical sector. Mechanisms have been introduced to adapt the robot to the worker’s characteristics, together with multi-modal interaction capabilities (voice and gestures) and customised assistance to perform assemblies.

The robot also features active safety mechanisms in this collaborative environment to differentiate between inanimate objects and operators. It has been designed, moreover, to identify certain body parts to adapt its behaviour accordingly.

Finally, RWTH Aachen University has focused on improving the final assembly of electric vehicles. A4BLUE has built a mobile standalone platform that supplies tools to improve worker efficiency and ergonomy and interactions with the platform. It also provides workers with customised instructions based on their level of expertise and skills to conduct assemblies more efficiently with step-bystep guidance featuring augmented reality.

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PROJECT

Data exploitation and management for wind turbine predictive maintenance IK4-TEKNIKER commissions its performance-enhancing SAM platform

The project carried out for ATTEN2 allows data to be collected with regard to wind turbines and their oil sensors to predict component behaviour when in use and reduce failure risks.

Maintenance actions involving wind power infrastructures, especially those associated with offshore facilities, are critical to learn more about wind turbine operating behaviour, anticipate potential problems or breakdowns and, consequently, optimise costs and achieve maximum efficiency.

IK4-TEKNIKER has developed, together with its spin off ATTEN2, a monitoring solution for several wind turbines in operation at the P.E. Los Monteros to gather information at different operating regimes, predict gearbox behaviour and diminish risks associated with unexpected failures and unscheduled shutdowns. Thanks to this solution it has been possible to implement a condition-based maintenance strategy for wind turbine generators at the P.E. Los Monteros.

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RELIABILITY, STRATEGY AND PLANNING Reliability analysis Criticality analysis of components Analysis of maintenance plans Analysis of information management systems and procedures DATA MANAGEMENT Capture Analytical (descriptive, predictive, prescriptive) Storage and integration Implementation: dashboards and tools for optimising strategies / plans, planning, spare parts and diagnostic support

CONDITION BASED MONITORING Feasibility studies Fingerprint test Develop and implement condition based monitoring (vibrations, ultrasounds, oil, deformations and currents)

SIMULATION Simulate degradation mode and component and machine failure Digital twins Test benches

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In orrder to carry outt the prroject and diagnose equipment properly, attention has been paid to the different regimes at which win nd turbines operate.

In order to carry out the project and diagnose equipment properly, attention has been paid to the different regimes at which wind turbines operate. This is a basic task as equipment operations differ significantly in each operating mode and this could hinder data analysis.

This is why, in order to pick up operating signals, data from the SCADA system (Supervisory Control And Data Acquisition) has been selected, i.e., wind speed, turbine speed, active power, pitch angle (blade angle relative to the wind), gearbox oil temperature and operating status. Moreover, sensors have been installed to monitor oil degradation in gearboxes.

In order to monitor everything properly, IK4-TEKNIKER has used its own Fingerprint methodology. Real-time information is used to learn about wind turbine operating conditions and decide when conclusions can be drawn based on signals picked up in a controlled manner.

Thanks to this methodology, to the analysis of turbine opera-

tions and to the data delivered by sensors, information is generated to diagnose gearbox conditions, anticipate potential failures and reduce unscheduled shutdowns affecting wind turbine availability.

This information is then fed into IK4-TENIKER’s SAM (Smart Asset Management) platform to be processed and monitored with a view to optimising equipment performance and extending service life. The SAM platform combines technologies and expertise to detect, diagnose and anticipate failures and breakdowns involving mechatronic equipment and maximise maintenance returns by increasing asset availability and life cycles and reducing operating costs.

In the case of the P.E. Los Monteros, IK4-TEKNIKER is using the SAM platform to analyse the information provided by the SCADA system and the network of sensors, by incorporating intelligence by means of algorithms to process data and provide ATTEN2 with management capabilities for alarm monitoring and servitisation.

SEPTEMBER 2019

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PROJECT

A pioneering solution for agricultural spraying Developing a sensor device to monitor how plant-protection products are applied

IK4-TEKNIKER is collaborating with Goizper S. Coop. in a project aimed at developing a sensor to individually monitor spray nozzles used to apply pesticides or plant-protection products to crops. In addition to digitising manual equipment, it will also allow information to be gathered on a number of parameters to implement better strategies to apply plant-protection products.

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As agricultural and protection techniques applied to crops are changing at a fast pace, only the very best methods and equipment must be selected to optimise soil yield.

Pesticides or plant-protection products have to be used in farming to maximise agricultural output and fully guarantee quality in accordance with current food requirements.

This sector requires, however, that specific doses of pesticides or plant-protection products be applied at plantations to prevent uncontrolled spraying that only produces product waste or evaporation and soil pollution as well as potential exposures of workers to chemicals.

Consequently, agriculture requires a Farming 4.0 solution to accurately spray plant-protection products rapidly and safely. Activity data must also be compiled to develop better strategies for the application of plant-protection products.

It is in this context that Goizper S. Coop., a company specialised in manufacturing spraying systems, and IK4-TEKNIKER are jointly involved the DigitalR project to develop new remote equipment and ensure that nozzles used to spray plantprotection products operate correctly.

More specifically, the aim of this project is to digitise manual equipment so that a pioneering solution can be offered in the field of agricultural spraying. In fact, the new remote equipment currently being developed by Goizper S. Coop. and IK4-TEKNIKER will make it possible to compile and manage information fed into spraying procedures and provide users with data on to efficiently manage manual application processes for which no electric cables or additional facilities will be required.

But the project is also looking into a real-time and cable-free information gathering system that is connected to the grid, as well as a cloud storage solution, i.e., a set of analytical tools used to improve spraying strategies and data viewing tools for smart systems such as tablets, smartphones or PCs that use web applications.

A number of technologies are nowadays mainly based on monitoring pump outlets or spraying bars. The added value of this project consists in developing a custom-made proprietary sensor that is sensitive to the entire range of fluid typologies used whenever plant-protection products are applied. It opera-tes reliably in aggressive environments and meets very restrictive cost and compacting requirements.

IK4-TEKNIKER is developing a measuring transducer (sensor element) designed to meet condition analysis needs of the fluid to be sprayed and a digital transducer signal analysis system with a wireless communication system to configure the system and transfer results.

The organisation is also designing and developing a mechanicalfluidic casing to structurally position internal components and maintain watertightness.

Finally, IK4-TEKNIKER will integrate the different elements and perform sensor laboratory tests to validate them with Goizper S. Coop. in a real environment application.

The end result of this project will be total control for how plantprotection products are applied as farmers will receive, among other things, information on whether the system is operating correctly before spraying as well as data related to dosing volumes, spraying conditions, humidity, wind and speed of the vehicle where the nozzles are installed.

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