m

INDUS MOMENTUS BUSINESS SOLUTIONS

INDUSTRIAL INTERNET OF THINGS (IIOT 4.0)
EMPOWERING MES
m INTRODUCTION

 Manufacturing Execution Systems manage and monitor the work in progress on the plant
floor. MES provide a strong foundation around which manufacturers can build the Industry
4.0 application. However, Industry 4.0 cannot be implemented overnight; therefore MES
need to be upgraded alongside Industry 4.0.
 MES plays a critical role in Industry 4.0, as it accommodates the Industrial Internet of
Things (IIoT)-enabled production marketplace. However, not all MES are currently
designed to accommodate the integration, decentralization, and new technologies of
Industry 4.0
 The Industrial IOT (Industry 4.0) incorporates machine learning & big data technology,
harnessing the sensor data, M2M communication & automation technologies that have
existed in the industrial setting for years to computational capabilities residing in Cloud
based storage & Analytics.
 IoT is a transformative, disruptive technology. It enables MES to securely connect smart
things, quickly manage processes and easily analyze data. Ultimately transforming the
current manufacturing landscape.
m IIOT FOR EXTENDED MANUFACTURING ENTERPRISE VALUE CHAINS

THE INTERNET OF THINGS (IOT) REFERS TO THE

NETWORK OF NETWORKS ENCOMPASSING THE USE OF
STANDARD INTERNET PROTOCOL (IP) TECHNOLOGIES
TO CONNECT PEOPLE, PROCESSES, AND “THINGS” TO
ENABLE NEW CYBER-PHYSICAL SYSTEMS.
OVER THE PAST SEVERAL YEARS, AND INCREASINGLY
IN THE FUTURE (SOME ESTIMATE 50 BILLION
CONNECTED THINGS BY 2020), PHYSICAL THINGS
CONNECTED TO THE INTERNET WILL BE THE
DOMINATING FORCE, INCLUDING BUT NOT LIMITED TO,
NEW IP ENABLED:

 Devices
 Sensors
 Instrumentation
 Materials
 Mobile and Fixed Assets
 Products
m IIOT ARCHITECTURE
m SCADA, ERP, MES VS INDUSTRIAL IOT – WHAT’S THE DIFFERENCE
m IIOT ADDING VALUES TO MES

WITH THE ADVENT OF IOT AND THE SHEER VOLUME OF THE DATA IT PULLS IN THE ECOSYSTEM, MES HAS
HAD EVOLVED FROM A RIGID, HARD-CODED, LIMITED FUNCTIONALITY TO MORE FLEXIBLE, MODULAR
DESIGNS THAT CAN BE TAILORED TO FIT VARYING NEEDS AND CONFIGURATIONS FOR THE ENTERPRISE.

 Cloud Support  Scalability

 Heterogenous Device
connectivity  Predictive analytics

 Agility
 Real time alerts &
 Anywhere access Reports

 Vertical & Horizontal

Integration  Flexibility
m SHORT COMES OF MES

 The siloed, non-‘cloud’ nature of MES makes it extremely difficult for

manufacturers to benchmark the efficiency and productivity across the
machines in the same plant, versus different plants of the same group versus
plants of competitors.
 limitation in processing real-time data analytics
 large deployment times, costs.
 On premise access only.
 Scalability
 Limited Holistic approach
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INDUS MOMENTUS BUSINESS SOLUTIONS

SOME USE CASES IIOT
m SMART CONNECTED ASSETS USING IIOT

CONVERGED SENSORS, INSTRUMENTATION, CONTROLS, AND ASSETS

AWARE OF AND CAN REACT TO:

 Design and Configuration
 Internal and External Operating Conditions
 Past Performance
 Predicted Future Failure
 MRO Inventory (Internal and External)
 Energy Use
 Raw Material
 Supplier Performance
 Customer Requirements
 Environmental Impact
m SMART CONNECTED OPERATIONS USING IIOT

INTEGRATED ASSETS, OPERATIONS, AND BUSINESS SYSTEMS

AWARE OF AND CAN REACT TO:
 Plant, Asset and Product Design or
Configuration
 Inventory levels and flow | Quality
performance
 Asset performance | Internal and
External Operating Conditions Supplier
Performance
 Customer Demands and Requirements

 Environmental Impact Mobile enabled

employees with collaboration and
optimal decision making
 Closed loop business process
m STREAMLINED FACTORIES

Sensors are attached to

components, forklifts,
employees and other assets

By geolocating the sensors, one can

see how people and products are
moving
Processes can be streamlined and
production time reduced.
m SMART INVENTORY MANAGEMENT

 Sensors on containers can determine when a product is

running low
 Employees will be alerted to proactively re-order the
parts when a certain level is reached or orders can be
automatically placed with suppliers
 Components will not run out or run low Reduced costs
of production More uptime for factories which leads
to higher productive levels
 Sensors can also be used to determine if a container is
reaching its capacity. This could trigger an alert for a
forklift to remove the container and replace it with an
empty one.
 Components will not overflow from a container More
uptime for factories which leads to higher productive
levels
m SMART QUALITY CONTROL

 RFIDs attached to products can be used to tag

defective products
 If over a certain number, an employee can be alerted to
see if there is a bad batch of components or if an
adjustment needs to be made to the machinery
 Employees can be alerted if the problem is the result of
a defective part
 If an adjustment is needed, it can be automatically
made in real-time
 Product quality is controlled and course corrections are
made while product is still moving through the
production line
m SMART SUPPLY CHAIN MONITORING

 Supply Chain efficiency relies heavily on the timeliness

of the interconnected pieces all the way from production
to the consumer’s hands. This journey becomes even
more critical for perishable goods like food and more
importantly pharmaceuticals. Lack of proper and reliable
temperature control is one of the most important reasons
for wastage in supply chain. This makes end-to-end
visibility in cold chain even more crucial that needs to go
beyond barcode, RFID scanning and supply chain
management software.

 With Online Remote Monitoring solutions with real-time

monitoring, cold chain operators can maintain the
integrity of the goods and avoid wastage. This also helps
them meet industry regulations for ensuring consumer
safety
m HOW DO I GET MY MACHINES CONNECTED?

 Studying your manufacturing facility. Identifying critical machines

and assembly lines that would benefit from IoT.

 Identifying the right hardware to be installed. Often machines need

additional hardware components so that they can be monitored. In
some cases machines would require the right sensor to be installed.

 Identifying the right IOT connectivity kits if you have existing

SCADA, DCS, Historians or any combination of these.

 Providing a recommendation for connectivity, which could be

wired, wireless or a combination of both.

 Working with your factory maintenance team to commission the

system and to ensure that data is being captured in an accurate,
robust and failsafe manner.
m START SMALL WITH WHAT YOU HAVE

 Beginning with small IIoT projects that use the equipment and data you already have allows you to
prove ROI and establish best practices before full-scale implementation. With data growing
exponentially, it is tempting to want to analyse it all. Don’t. Everything is more manageable when
you begin small, pilot a concise program with well-defined KPIs, establish a new flow of data,
develop policy, and expand it once it’s refined. That said, prepare a solution that can scale.

 Realize new value from legacy assets: Even if your assets and systems weren’t originally designed to
connect to the Internet and share data, they still can. By attaching intelligent gateways to existing
assets, you can collect data from these previously untapped resources. So getting the benefits of an
IIoT solution doesn’t mean starting from scratch.
 m

INDUS MOMENTUS BUSINESS SOLUTIONS

SMART PLANT - DATASAVI
m CLOSED LOOP SYSTEMS New

WE ARE ACTIVELY DEVELOPING SOLUTIONS THAT WOULD AID IN COLLECTING DATA FROM
BUSINESS EXECUTION (AS OPPOSED TO TRANSACTION DATA IN ERP SYSTEM)
 While Planning and Transaction systems have been
two legs from previous systems, we strongly believe
in the third leg which will bring in the stability and
sustainability of such solutions.
 The third leg is Execution solutions, systems that would
allow data from various operating sources (factory
floor, supply chain partners, equipment, field
salespeople etc.) to be automatically collected,
collated, analysed and acted upon.
 While previously Planning and Transaction systems
were handicapped by data sufficiency and accuracy
due to dependence on human interventions, execution
system will automate data collection, which in turn
would lead to better planning and transaction
Portal
systems Senso
MES BLE NFC RFID GPS Apps RPM HMI
s r
 m DATASAVI – CONFIGURABLE WEB PORTAL WITH HYBRID EXCEL

DATASAVI – MULTI PURPOSE PLATFORM LEVERAGED FOR DEALER-VENDOR PORTALS,

QUALITY MANAGEMENT, PRODUCTION AND MAINTENANCE LOGGING, IOT & BUDGETING
Data from various Sensors as
The Cloud is integrated to
the Web Data Portal as well as PLCs from intelligent
User Access would be through Machines are collected on real
well as a Mobile Data
Web Services allowing for time / batch basis
Portal / Mobile App which
Security, Authentication and
can be used both for Data
Access Authorisation
Acquisition as well as Data
Visualisation

dataSAVI Cloud
Platform
The data from Excel will
however be synched with the
The Templates and the local
The Cloud / Internal Server is there to
Database
copies will remain in Excel facilitate the exchange of data from /
The data will also populate the
Spreadsheets to Excels to Database
Excel Spreadsheet
The Spreadsheets will also allow If Version Control needs to be
analysis / trace of formula etc. done same can be
accommodated here

dataSAVI – data Sensing, Acquisition, Visualisation, Interpretation is our platform on which Execution systems are being built
m ILLUSTRATIVE USE CASE FOR DATASAVI EXECUTION SOLUTIONS IN MANUFACTURING

CURRENT SCENARIO ALL THESE THREE CRUCIAL FUNCTIONS OPERATE IN SILOS WITH LIMITED AND
MANUAL EXCHANGE OF DATA
IT Systems Connected to: IT Systems Connected to:
ERP, PM, Engineering Data Acquisition, Analysis and Visualisation ERP, Excel
Cross Function Impact: Allows Common Platform for Data Cross Function Impact:
A better Maintained plant and a Better preventive maintenance
better Quality assured process / prevents losses in Production and

Maintenance
product improves Production improves Quality through

Production

Quality
Levels reduced breakdowns

IT Systems Connected to:

ERP, Excel
Cross Function Impact:
Better Quality Assurance and
Quality Control systems would
Planning assist in ensuring that higher
Creates the Crucial Baseline required to Compare Production is achieved

There is a need for a common platform for data from the plant floor which is
seamlessly interfaced with the Enterprise Applications.
 m

Gurugram
Saqib Hussain
Saqib.hussain@indusmomentus.com
+91 7889387491

INDUS MOMENTUS BUSINESS SOLUTIONS

THANK YOU