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This digital report will explore several aspects of how IIoT will trans-
form manufacturing in the coming years. Among the topics well
cover here are how to use IIoT to improve operations, how to do
a better job of data analysis by using new technologies and new
software, and how manufacturers are already using IIoT to affect
changes in their operation.
This CFE Media digital report should serve as a way to begin the
discussion in your plant about ways to leverage new technology and
new strategies to increase productivity on the plant floor. We believe
IIoT can help manufacturers understand and act more quickly and
precisely to generate greater operational success. Those manufac-
turers who begin today to take advantage of IIoT will gain a competi-
tive advantage in a global manufacturing environment. This digital
report provides you with the tools to start that initiative today.
CONTENT
Use IIoT to improve operations 4
T
Use IIoT to improve hanks to a new generation of wired and wireless sensors, data can now be
operations economically generated and gathered in quantities never previously available
Case Study: and then sent to process control and monitoring systems via plant networks or
Hirotec America through the Internet. Data can then be used to improve automated real-time
Industrial Internet of control and to help plant engineers and operators make better decisions regarding opera-
Things (IIoT) benefits, tion and maintenance. It is also available to data analysis software, which can be used by
examples plant personnel to increase efficiency, diagnose equipment problems, and improve safety.
Enabling IIoT requires
communication proto- As a result of this opportunity for new insights, terms such as the Internet of Things
col translation
(IoT), the Industrial Internet of Things (IIoT), big data, and Industrie 4.0 are now com-
Data analysis: A key mon. Recent advances in sensors, connectivity, and data analysis software combine to
requirement for IIoT
make it easier and less expensive to acquire, send, store, and analyze information. But
IoT - The marger of IT no matter the terminology, the objective is the same: better insights faster.
and industrial
Brownfield refers to existing plants and operations where new sensors are added to
existing control or plant networks. Common brownfield scenarios include adding a
Cash in on services
Finally, servicization is one of several monikers describing the inclusion of a remote
monitoring capability for an asset. This is the future of your personal vehicle-unless
you already have a Tesla and your vehicle information is piped continuously back to
the dealership-and of many assets in process plants. Vendors of pumps, valves, and
Process gisotrians can Learn more about brownfield IIoT monitoring and the four requirements for data analytics.
be an integral part of
the IIoT
The customer
HIROTEC AMERICA is part of the HIROTEC Group Companies, a $1.6 billion corpora-
Use IIoT to improve
operations tion with over 60 years of mass production experience and engineering discipline. With 26
facilities in nine countries around the world, HIROTEC Group is globally recognized as a
Case Study: premier automation manufacturing equipment and parts supplier.
Hirotec America
Industrial Internet of For over 50 years, top vehicle producers like General Motors and Mazda have used HIRO-
Things (IIoT) benefits,
examples
TECs proven, high-quality industrial manufacturing concepts and systems. The parts and tool-
ing supplier designs and builds roughly 7 million doors and 1.5 million exhaust systems a year,
Enabling IIoT requires making it one of the largest private production companies in todays global automotive market.
communication proto-
col translation
HIROTEC is a leading tier-one component and tooling supplier for the Automotive Indus-
Data analysis: A key try, giving us a very unique perspective on how both sides of the industry operate, said
requirement for IIoT
Justin Hester, Senior Researcher, HIROTEC. Weve used this insight to benefit both our
IoT - The marger of IT business and our customers by designing and building a wide array of state-of-the-art
and industrial solutions that are based on proven concepts. In our dedication to our customers success,
Process gisotrians can we pride ourselves on our ability to supply the highest-quality automotive equipment and
be an integral part of services to customers around the world.
the IIoT
The challenge
Operational downtime is a significant issue facing Original Equipment Manufacturers
(OEMs). In most cases, the machinery involved runs without condition-based monitoring
essentially operating until a failure occurs. At that time, appropriate personnel are con-
tacted to assess the situation and make the repairs as expeditiously as possible to prevent
HIROTEC sought to eliminate this trend of reactive maintenance and lost opportunities by
Use IIoT to improve
operations
utilizing the information and systems it had on hand to gain deeper insight into its opera-
tions and processes. The automotive supplier had long collected industrial data from sen-
Case Study: sors and machines across customer production facilities and its own systems to support
Hirotec America
its decisions and track business progress. However, volumes of this data were manually
Industrial Internet of separated and stored across multiple sourcesmaking it inaccessible to collective and
Things (IIoT) benefits,
examples systematic analysis. In order to improve quality, reduce downtime, and optimize produc-
tion schedules, HIROTEC needed to implement a modern, automated solution that could
Enabling IIoT requires
communication proto-
gather maintenance and operational information into one source and offer actionable rec-
col translation ommendations to its quality professionals.
Data analysis: A key A lack of data was never an issue for us, said Hester. As one of the largest automotive
requirement for IIoT
manufacturing suppliers in the world, we collect volumes of datasets on a daily basis. The
IoT - The marger of IT problem we were faced with was transitioning from a data-heavy organization to a data-
and industrial
smart organization. We realized that in order to bolster profits from untapped machine-
Process gisotrians can generated information, we needed to look towards modern solutions that automated the
be an integral part of
the IIoT process and enabled timely, data-driven decisions.
The approach
Recognizing the need for connectivity, data access, and scalability, executives at HIROTEC
worked to develop a competitive strategy to capitalize on the potential benefits of the Inter-
net of Things (IoT). The initiative began with identifying the fundamental technologies that
would fuel the IoT effort.
HIROTECs North American shop in Detroit, Michigan was chosen as the test bed for the
first small sprint because of the unique data types generated among its eight Computer
Numerical Control (CNC) machines. Kepwares IoT Gateway for KEPServerEX collects data
CFE Media Digital Report: IIoT: Operations & IT 11
from the CNC machines and streams it in real-time to the Cloud, where the ThingWorx IoT
Platform provides analytics and data visualizations. This solution gives HIROTEC labor-free
access to a customized visualization of both the operations and conditions of its industrial
devices and systems.
Use IIoT to improve
operations When first embarking on our IoT journey, HIROTECs core objective was to remain flex-
Case Study: ible in our ability to connect things, said Hester. The offerings and expertise by Kepware
Hirotec America and PTC have enabled us to stay true to our goal by effortlessly adapting to our business
processes and developing the right IoT strategy for our teams. The IoT Gateways ability to
Industrial Internet of
Things (IIoT) benefits, seamlessly put data into ThingWorx to generate real-time insight into operations fuels our
examples sprint framework and allows us to stay nimble in our decision making.
Enabling IIoT requires
communication proto- The results
col translation Since implementing Kepwares IoT Gateway and the ThingWorx IoT Platform, HIROTEC
Data analysis: A key has gained increased visibility into the processes of its CNC shop and deeper insight into
requirement for IIoT operations. The company realized early on that having access to CNC machine uptime
IoT - The marger of IT data significantly impacted the shops scheduling process, which was previously set on
and industrial conjecture and after-the-fact analysis. Manufacturing leadership can now leverage real-time
Process gisotrians can data from the shop floor and tie it to the scheduling ERP system, optimizing the scheduling
be an integral part of of parts to CNC modules.
the IIoT
This process also provides greater insight into asset and resource allocation by automati-
cally formulating smarter questions about current needs and priorities and determining
the most effective course of action. Because of this, HIROTEC has improved productivity
across the shop and increased its ROI.
Organization
HIROTEC AMERICA is part of the HIROTEC Group Companies that have worldwide sales
in excess of 1.6 billion dollars and 26 facilities across 9 countries. For over 50 years, HI-
ROTEC AMERICA has been providing innovative and highly flexible closure manufacturing
solutions.
T
Use IIoT to improve he Industrial IoT (IIoT) is much more advanced than the commercial IoT, primarily
operations
due to the prevalence of connected sensors in the industrial world, which are
Case Study: the things in the IoT. Hundreds of millions of connected wired and wireless
Hirotec America
pressure, level, flow, temperature, vibration, acoustic, position, analytical, and
Industrial Internet of other sensors are installed and operating in the industrial sector, and millions more are
Things (IIoT) benefits, added annually, increasing value with additional monitoring, analysis, and optimization.
examples
This is part of the June Control Engineering cover story on Industrie 4.0 and Industrial
Enabling IIoT requires Internet of Things to help make smarter factories.
communication proto-
col translation
These sensors connect to a variety of higher level software platforms, both on- and off-
Data analysis: A key site. On-site connections are often via a local intranet, creating an Industrial Intranet of
requirement for IIoT Things. Offsite connections are usually made through the Internet, often via a cloud-
IoT - The marger of IT based storage system.
and industrial
Process gisotrians can When traps fail to close, they dont remove water droplets from the steam. These wa-
be an integral part of ter droplets, moving through piping and equipment at a high rate of speed, can rup-
the IIoT ture steam lines and cause turbines to throw blades. Repairs are very expensive, and
downtime is often significant.
Most plants monitor their steam traps manually via annual checks. This is very costly
in terms of labor, misses many problems, and in the worst case can allow failed traps
to operate for years.
Case Study:
These wireless sensors are battery-powered and can operate for up to 10 years be-
Hirotec America tween battery changes. Compared to wired sensors, installation takes place much
more quickly at significantly lower costs, and required plant downtime for installation
Industrial Internet of is greatly reduced or eliminated.
Things (IIoT) benefits,
examples
The IIoT is here today, and plants are using it to realize value from the hundreds of
millions of connected sensors currently installed and the millions more coming on-
I
Use IIoT to improve mplementations of Industrial Internet of Things (IIoT) and Industrie 4.0 frameworks are
operations progressing, and translations of major industrial network communication protocols
Case Study: enable the flow of data that becomes actionable information with analysis. Hilscher
Hirotec America is among many companies providing network gateways and other communications
Industrial Internet of from the plant floor to the enterprise and cloud for manufacturing data analysis. Company
Things (IIoT) benefits, executives explained the necessity of efficient data translations to Control Engineering,
examples
Plant Engineering, and Oil & Gas Engineering publications on Feb. 2.
Enabling IIoT requires
communication pro- Hilscher representatives at the Hilscher North America facility in Lisle, Ill., said the com-
tocol translation
pany devices aim to make it easier for end users, device manufacturers, and machine
Data analysis: A key builders to access the benefits of Industrial Internet-connected manufacturing. Enabling
requirement for IIoT
technologies include Hilschers recently introduced netIOT solutions for Industrial Cloud
IoT - The marger of IT Communication, which extract data parallel with current control networks and deliver it
and industrial to cloud-based analytical services without compromising existing systems or services.
Process gisotrians can
be an integral part of Cloud reality today
the IIoT
Armin Phringer, Hilscher business development manager, said these products are
designed to help make industrial cloud benefits a reality today. Hilscher North America
CEO, Phil Marshall, also addressed the benefits of such connectivity, explaining how
Hilscher, which began as a system integration firm in 1988, quickly moved into produc-
ing network communication devices. Now with 250 employees, Hilscher provides com-
Enabling IIoT requires The new Hilscher netIOT line includes netIOT In-
communication pro- terface Modules, netIOT Edge-Gateways, and
tocol translation netIOT Service. See additional product informa-
Data analysis: A key tion linked at the bottom of the article.
requirement for IIoT
Case Study:
The models can be put on existing wire in the plant without disturbing the PLC, using
Hirotec America presently available protocols such as OPC UA (Unified Architecture), DDS, and MQTT,
as well as TSN (Time Sensitive Network), an emerging Ethernet standard designed to
Industrial Internet of
Things (IIoT) benefits, bring one real-time Ethernet structure to the many-flavored protocol soup of today.
examples
Enabling IIoT requires We see OPC UA gaining momentum. MQTT is expanding quickly beyond its IBM ori-
communication pro- gins, Phringer said, as IIoT is bringing new standards for engineering and to cloud-
tocol translation based architectures, with vertical integration from sensor into the cloud.
Data analysis: A key
requirement for IIoT Phringer said hes observed a change in recent months where companies are mov-
IoT - The marger of IT ing beyond prior concerns about safety, security, and privacy risks. IBM is working on
and industrial a major pilot installation, expected to be announced at Hannover Messe, and Hilscher
Process gisotrians can is supplying network protocol translators. A bottle-filling application was shown at SPS
be an integral part of Drives in Nurnberg, Germany, fall 2015.
the IIoT
Faster, smarter
The IoT seems likely to move along more quickly, with clear and well-thought-through
roadmaps, improving overall equipment efficiency (OEE), as all companies seem eager
to understand what they can do with data in the cloud, Phringer suggested. IoT is a
game changer in our industrial business.
Interconnected
Energy
Everything from oil platforms
and pipelines to wind turbines
and solar panels provide instant
analysis of performance and
uptime from the edge to the
cloud to centralized operations.
Edge Computing
Mission-critical data is close
to the gateway. High density
computing with a small Smart Manufacturing
footprint. Data analysis from Sensors and scanners provide real-time
the floor in near-real time. intelligence and analytics of machinery
and inventory to guarantee optimal
performance of equipment and facilities.
www.RittalEnclosures.com
(800) 477-4000
T
Use IIoT to improve he dramatic change in fortunes of the oil and gas sector in the past few years
operations has had a wide-ranging impact across many industry sectors, resulting in an
Case Study: increasing requirement for engineers to show a good return on any technol-
Hirotec America ogy investment. This has led many to consider doing things differently, with
Industrial Internet of automated solutions becoming more relevant and much easier to justify.
Things (IIoT) benefits,
examples
At the annual Honeywell User Group (HUG), which was held in Madrid in November
Enabling IIoT requires 2015, Honeywell placed a heavy emphasis on data analysis solutions. Knowledge is
communication proto- the theme of this HUG event because our customers run some of the most complex
col translation
industrial operations in the world, and they require better knowledge to improve pro-
Data analysis: A key cess safety, reliability, security, and sustainability, said Vimal Kapur, president of Hon-
requirement for IIoT
eywell Process Solutions (HPS). He said the influx of new engineers replacing those
IoT - The marger of IT now reaching retirement age do not have the same wealth of experience relating to
and industrial
the often aging control technology still in use at many process plants; more intuitive
Process gisotrians can control solutions are required to help inform decisions about process efficiency im-
be an integral part of
the IIoT
provements.
Technology change
The pace of technology change is much faster today, continued Kapur. Systems
traditionally would have become obsolete every 5 to 10 years. However, the underly-
ing operating system technology used today is changing much more rapidly so there
is a need to update systems more regularly.
In the cloud
According to Kapur, Honey-
well is enabling customers to
One-third of process and manufacturing industry executives from around the world
surveyed by Honeywell said that they already are using data analytics to improve busi-
Another new offering was an alarm and operations management software family, said
to offer advanced capabilities for alarm system compliance, monitoring, and rational-
ization. Expanded process performance analysis software was also on display, dem-
onstrating how it can provide real-time digital intelligence by collecting process and
Commenting on this subject Kapur said: Today we communicate between the plant
and the control system through different communication mechanisms. There is no one
standard. There is a need for a common language that allows devices and equipment
to talk to the control system. OPC UA is a key standard enabling this communication.
Honeywell is a key provider of OPC UA and is working with different organizations to
Expanding on this subject, Calder said: OPC UA is the leading contender to be the
Use IIoT to improve
device interface protocol for the language of the IIoT. To enable this connected world
operations Honeywell also has invested heavily in the instrumentation business-from field devices
Case Study:
to gas measurement control, we are developing products with leading accuracy that
Hirotec America can openly and securely communicate.
Industrial Internet of
Things (IIoT) benefits, Suzanne Gill is editor-in-chief of Control Engineering Europe.
examples
I
T and Industrial are not exactly merging, but the borders between the two have
become fluid. They arent oil and water, but creating a miscible solution between IT
and their industrial counterparts takes cooperation, understanding and ownership.
To review the benefits and challenges of this cooperative, and the considerations
Use IIoT to improve
operations
to put it into place, well start with the why.
Case Study:
Hirotec America The barriers to moving the controls closer to the actual equipment have fallen away.
Edge computing can provide the proper environment for IT in any environment: from
Industrial Internet of
Things (IIoT) benefits, polar to tropical, remote land-based to cruise ships at sea. In IoT, enclosures house
examples the components controlling hundreds of thousands of data points. The durability and
Enabling IIoT requires
gasket sealability of enclosures allow IT equipment safe harbor in contaminant filled
communication proto- production. The equipment formerly housed in a 100,000 square foot data center can
col translation now contained in a couple of enclosures. Given the shift in data management, and the
Data analysis: A key logistical strategy required to accomplish this, why is data moving towards the site and
requirement for IIoT away from the data center?
IoT - The marger of
IT and industrial Latency and flexibility
Process gisotrians can
Data, in its most effective platform, must be accessible to the people who need it, in
be an integral part of real time. One hundred percent of the time. Accessibility with reduced latency brings
the IIoT responsiveness to a higher level. The data is not 20, 200 or 2000 miles away, or even
in the cloud, awaiting analysis before it is transmitted back to the area where it is
needed. It is on site, with the controls as close as practical to the actual equipment.
Changes can be made, if needed, in minutes, rather than hours. The deployment of
sensitive IT allows a level of remote monitoring which was previously impossible. This
Modularity
Use IIoT to improve
You start with two edge enclosures. If the parameters of the process change, unless
operations your enclosures are adaptable and expandable, you may find yourself in the market for
Case Study:
a third or fourth enclosure. With modularity within the structure, if a power load needs
Hirotec America to be increased and the corresponding cooling system must be upgraded, a properly
designed modular enclosure can be refitted to meet different demands. This modularity
Industrial Internet of
Things (IIoT) benefits, allows for variants within the enclosure, but it also moves us to the next point of scal-
examples ability.
Enabling IIoT requires
communication proto- Scalability
col translation Scalability flows from the modularity of the enclosure. Additional enclosures and equip-
Data analysis: A key ment added can be bayed at the site. Simple plug and play connections between
requirement for IIoT bayed enclosures create and expand on demand capability.
IoT - The marger of
IT and industrial Redundancy & resiliency
Process gisotrians can These work hand in hand. Any IoT/IT installation must have complete redundancy and
be an integral part of resiliency. Redundancy, referred to as N+X, defines the duplication of critical compo-
the IIoT nents and having a spare or standby unit available. Resiliency, expressed as a percent-
age (i.e. 99.9%, 99.999%, etc.) defines a systems capability to provide an acceptable
level of service in the face of system faults or interruptions. Maintaining the highest lev-
els of redundancy and resiliency are critical as IoT systems are deployed further away
from the safety and stability of the data center.
Case Study:
Adoption rates and speeds vary by industry. While spending on IoT is projected to
Hirotec America reach $500 million by some trend watchers, manufacturing has been broadly charac-
terized as slow to adopt.
Industrial Internet of
Things (IIoT) benefits,
examples Reasons cited for slow adoption have included questions over up-front costs, ROI and
Enabling IIoT requires
plant machinery retrofitting or replacement. Despite these questions, U.S. manufactur-
communication proto- ers are warming up the idea.
col translation
Data analysis: A key According to a Price Waterhouse Cooper study among U.S. manufacturers:
requirement for IIoT
IoT - The marger of 35% are currently collecting and using data generated by smart sensors to enhance
IT and industrial manufacturing and operating processes.
Process gisotrians can
be an integral part of 34% believe it is extremely critical that U.S. manufacturers adopt an IoT strategy in
the IIoT their operations.
38% currently embed sensors in products that enable end-users and customers to
collect sensor-generated data.
Those manufacturers who do adopt IoT will be in good company. At 27%, manufactur-
monitoring and information sharing between global management systems and factory
control systems
Data analysis: A key However, a manufacturer decides to integrate IoT into its operation, experts at SAE
requirement for IIoT International say that a vital foundation in creating robust IoT standards is schemathe
IoT - The marger of process for tagging information for digital consumption, but which is retrievable and
IT and industrial readable both by humans and machines.
Process gisotrians can
be an integral part of Tech Beacon has also eliminated the guesswork in building an IoT architecture with a
the IIoT checklist of four recommended stages and their essential components.
2. Internet gateways and data acquisition systems to aggregate sensor data and for
analog-to-digital data conversion
4. The data center or cloud, where data is analyzed, managed, and stored on tradi-
Use IIoT to improve
tional back-end data center systems
operations
Case Study:
In its report published last month titled, The Industrial Internet of Things Volume G1:
Hirotec America Reference Architecture, the Industrial Internet Consortium condensed a typical IoT sys-
tem into five functional domains:
Industrial Internet of
Things (IIoT) benefits,
examples 1. Control domain the collection of functions that are performed by industrial con-
Enabling IIoT requires
trol systems, such as a control room in an electricity utility plant.
communication proto-
col translation 2. Operations domain the collection of functions responsible for the provisioning,
Data analysis: A key management, monitoring and optimization of the systems in the control domain.
requirement for IIoT
IoT - The marger of 3. Information domain the collection of functions for gathering data from various
IT and industrial domains, most significantly from the control domain, and transforming, persisting
Process gisotrians can and modeling or analyzing those data to acquire high-level intelligence about the
be an integral part of overall system. An example of an application of this domain would be changing the
the IIoT route of a fleet of freight trucks based on weather, traffic and the condition of the
goods in the trucks.
Data analysis: A key SAE International even cautions against competing on old measures like speed, price
requirement for IIoT and product quality. IoT has introduced a new standard in manufacturing that makes
IoT - The marger of it critical for companies to incorporate new technologies that offer greater intelligence
IT and industrial and the ability to monitor, learn, and fix problems.
Process gisotrians can
be an integral part of Who is in charge?
the IIoT
The last sentence illuminates the greatest challenge of all. You have your operations
manager. You have your IT manager. In this consolidation of resources and blurring of
processes, who claims ownership of the process? Where does the buck stop?
A standard operating procedure which combines the expertise of both operations and
IT must be developed, agreed upon and consistently implemented. This convergence
P
Use IIoT to improve rocess historians are the first step up the automation pyramid beyond process
operations
controls and are the foundation for turning data into information. Process
Case Study: historians provide the data necessary for powerful data analysis tools to do
Hirotec America
their job. Following the current technological trends, they can even be moved
Industrial Internet of out of datacenters and into the cloud.
Things (IIoT) benefits,
examples
Process historian essentials
Enabling IIoT requires At its most basic level a process historian is a database used to store time-series
communication proto-
col translation
data from an industrial process. Data is collected either on a cyclical basis of usually
1 to 10 sec, or as data points change. Actual values, the associated timestamp and
Data analysis: A key other information such as data integrity are written to the historian each time data is
requirement for IIoT
collected.
IoT - The marger of IT
and industrial
Once the data is in the historian, it can be accessed in a handful of ways. Many ven-
Process gisotrians dors offer data analysis packages that can be used in con-
can be an integral
part of the IIoT junction with the historical data for trending, reporting, and
various database query capabilities. Most historians also
can be queried directly using existing database systems,
such as structured query language (SQL) or stored proce-
dures. Other tools (big data analysis or machine learning
algorithms) can be applied to the data to find interesting
insights not easily obtainable through other methods.
Leveraging information
A historian by itself is not a tremendously useful tool. As described in Oil & Gas Engi-
One example of this type of integration using the API interface approach is in use by a
company that manufactures golf course irrigation pump stations. Each system in the
field has a local PC running a historian and a webserver. The webserver is configured
with a reporting and trending interface accessible via browsers and mobile devices. It
also has an API exposing historical data to third-party SaaS system.
www.kepware.com
www.rittal.com