by Gary Mintchell | Jun 30, 2016 | Automation, Internet of Things, Operations Management, Software
Software platforms that provide specific “apps” for industrial applications was the theme of the week for me. I received a better look at Siemens’ Mindsphere along with a competitor’s app that I’ll discuss in a later post. Tuesday and Wednesday this week found me in Las Vegas at the 2016 Automation Summit—Siemens US users group. There were many sessions and quite a lot of training for customers.
The keynote was given by Klaus Helmrich, a member of the managing board of Siemens. He continued the theme repeated during Hannover Messe—digitalization. His point was that digitalization enhances competitiveness, time to market, flexibility, quality, efficiency. You design in the virtual world; take it to real world; receive feedback from real world to the virtual world to assure design is current to reality.
Although I’ve been told that Europeans are not fond of the term “ecosystem” in this context, Helmrich uttered the “e-word”. The Digital Enterprise Ecosystem enables customers toe realize their wish to interact with the production process making their product.
Memorable quote—“using software is key to realization of Industry 4.0.”
Maintenance and Reliability
Terry O’Hanlon CEO of ReliabilityWeb.com and Uptime magazine invited me to a panel presentation he was on. From the description in the program, I’d probably have never looked a second time. Plus, I’m not fond of panels. Usually each one talks for 10-15 minutes and then there is 10-15 minutes at the end for questions.
This one went against that grain. Each panelist gave about 2 minutes of their interest in the topic, then moderator Bob Vavra, editor of Plant Engineering magazine, proceeded directly to asking questions of the panel. The panel did not just sit back but each chimed in appropriately.
They did hope to hold questions to the final 15-20 minutes of the 105-minute session, but the audience would have none of that and started waving hands to ask follow up questions soon after the beginning.
The other panelists were Jagannath Rao, President of Siemens Industry Services; Brian Clemons, process automation manager at Dow Chemical; and, Keith Jones, of Prism Systems—an integrator.
It was a wide-ranging discussion. So, here are some quotes that capture some of the flavor of the discussion.
O’Hanlon, “What maintenance delivers is capacity.”
Clemons, “We bring a new process into the plant, but we’re still dealing with the same people.”
Clemons, Reliability usually talks MTBF, but what is really important is MTTR (repair or recover).
Rao, “Technology Suppliers more than component sellers, but look at larger solution.”
Jones, “Big data going to analytics is a difficult proposition—both doing and defining.”
O’Hanlon, “You need sensors that are appropriate to the health of the asset. That’s why you need predictive analytics.”
Jones, “IoT increasing traffic on network is a burden and sometimes affects production.”
O’Hanlon, “Reliability as a function of the business case.”
Data Analytics — Mindsphere
MindSphere is Siemens Cloud for Industry built on SAP HANA. It is a platform, which Siemens, customers, and OEMs can build software apps (App Store) on top of.
Speakers acknowledged that some customers are still uncertain about the cloud, but the cloud is where analytics run.
One app already developed is control loops. Customers can connect selected control loops, send data to cloud, analytics check for status of tuning and other things. The customer gets a dashboard. The analytics can even see stiction in valves.
This solution (like many) moves the software expenditure from CapEx to OpEx (note: look for this as a theme for how technology suppliers are beginning to price software).
This formula:
Domain Knowhow + Context Knowhow + Analytics Knowhow = Customer Value
is the foundation of app development.
Siemens has a product “MindConnect” secure data acquisition box. This is a similar idea to the Dell IoT Gateway or Advantech. These edge computing and communicating engines are the current IoT trend.
Current apps include:
Drivetrains (gearboxes)
Energy
Networks
Machine Tools
Control Loops
Cyber-security
by Gary Mintchell | Jun 28, 2016 | Automation, Networking, Operations Management, Standards, Technology
I’ve decided not to try to publish bunches of news for bunches of posts per day. It’s not quantity I’m looking for–and I get the feeling neither are you. Besides, according to some of my sources of statistics, readership of this blog is about half of the big magazines in the space. Not bad considering that half or more of their views come via search–and they have tons more stuff to search.
Tom Burke, president of the OPC Foundation sent this article describing the latest protocol advancement it is working on. It is a publish/subscribe protocol that lets OPC UA and messaging protocols such as AMQP and MQTT play nicely with OPC. This gives users the benefits of both types of messaging. Certainly a winning proposition. In fact, I had been wondering about the OPC response to MQTT which is popping up more frequently.
OPC UA PubSub: Bringing the Power of the Cloud to Industrial Automation
Many OPC systems today have a small number of HMIs or SCADA applications which manage a larger number of devices. In some cases, MES systems and ERP systems are part of the picture and use OPC interfaces to collect data from the factory and send it on to enterprise applications. This model works well for many applications and will continue to be a mainstay of many industrial automation users which have a lot of equipment installed in a single location that needs to be managed. However, the widespread deployment of cloud based solutions has many factory operators wondering how they can take advantage of it to streamline their operations. The needs of these users have been the driving force behind the new OPC UA PubSub Specification. This specification layers OPC UA on top of message based middleware such as AMQP or MQTT in a way that allows users to take advantage of OPC UA features such the robust information modelling framework while adapting to the message centered communication paradigm of the middleware.
Use OPC UA PubSub to Broadcast Data and Events to the Cloud
OPC UA PubSub defines a loosely coupled message protocol that can be used with multiple encodings (e.g. JSON, UA Binary or XML) and multiple transports (e.g. AMQP, MQTT, XMPP et. al.). Applications which publish information create data or event subscriptions as they would for normal OPC UA communications and forward the notifications produced to the Message Oriented Middleware. Applications which consume information create subscriptions with the Message Oriented Middleware which will forward the messages to them as they arrive. The OPC UA PubSub Specification defines a format for these messages that allow them to be consumed by subscribers who have no knowledge of OPC UA and no ability to connect to the publisher (Figure 1).
The middleware in these cases may support durable queuing, multicast and/or filtering which allows OPC UA data or events to reach a much larger variety of applications including big data applications which depend on a supply of real time data from the factory.
Data is not Enough: OPC UA Extends its Information Model to the Cloud
The raw data in messages produced by publishers can have a structure which can be understood by subscribers which have no access to information other than the message. However, the metadata associated with the message can provide important additional context which allows the subscribers to properly interpret the message. To facilitate this OPC UA PubSub defines a metadata message that can be delivered using the same middleware broker infrastructure. These messages also allow the publishers to instantly report changes to their configuration which affects the content of the messages. Each message published includes an identifier for the metadata version that applies to the message which ensures that subscribers can easily detect and manage changes to the metadata.
End to End Security: Cloud Services run by Third Parties may not be Secure Enough
The Cloud relies on infrastructure provided by vendors that specialize in providing large scalable systems. However, the nature of the Cloud means these third parties will have access to the data even if the communication between the application and the broker is secure. OPC UA PubSub provides for end-to-end security which ensures that only applications authorized by the operators will be able to view or modify the data no matter how many intermediaries are required to deliver the data. OPC UA PubSub includes a key distribution model that allows loosely coupled applications to share keys as needed (Figure 2). Access to the Security Key Servers is controlled using web based standards for federated identity management such as OAuth2. For example, a factory owner can use the OAuth2 support built into Active Directory to provide authorization services for their Security Key Servers. This access will be independent of the middleware used to deliver the messages to their intended recipients and allows for access to be granted or revoked as needs evolve.
Figure 2 – OPC UA PubSub End-to-End Security Model
OPC UA PubSub: A Flexible solution that can Evolve
Different middleware vendors want operators to commit to using their protocol for their operations. OPC UA PubSub provides a framework for simultaneously supporting multiple protocols as the needs of factory owners evolve while providing a standard architecture for describing complex information. Figure 3 illustrates how this works in practice where a Machine Vendor uses MQTT to communicate with its machines deployed in a customer’s factory while the Factory Operator uses AMQP to capture analytics. In both cases, the data being sent to the Cloud is based on OPC UA PubSub and conforms to an OPC UA Information Model. The bottom line for factory operators is OPC UA reduces costs and provides greater flexibility by allowing factory operators to focus on information their enterprise needs instead of the protocol needed to move the information between systems.
Figure 3 – OPC UA PubSub a Flexible Framework that Evolves as Needs Change
by Gary Mintchell | Jun 24, 2016 | Podcast, Productivity
Here is my 150th podcast. I’m back on the theme of personal development–how people affect you. The source is Dr. Henry Cloud’s latest book The Power of the Other.
Research reveals that the types of connections we have with others affects our performance. Cloud intersperses research with examples from his practice to drive the point home.
Cloud discusses what makes for a “Corner Four” connection. This type of connection with people fleshes out just what we’d like to be and to experience in our relationships.
- Connection that fuels.
- Connection that gives freedom.
- Connection that requires responsibility.
- Connection that defangs failure and learning.
- Connection that challenges and pushes.
- Connection that builds structure.
- Connection that unites instead of divides.
- Connection that is trustworthy.
This is like a check list. But we can’t just follow a list. We make the list part of us reflected in the quality of relationships. Then by referring back from time to time during quiet time, we can remind ourselves where we’ve fallen short and need to improve.
by Gary Mintchell | Jun 23, 2016 | Automation, Internet of Things, News, Process Control
This week Honeywell Process Solutions held its 41st annual Honeywell Users Group (HUG) for the Americas in San Antonio. Speakers were all over the Industrial Internet of Things (IIoT) trend.
I did not make it. There are too many places to go, and I no longer work for a larger company with a financial base for lots of travel. So, I stayed in Sidney. News came via HPS’s PR agency and Control Global. Walt Boyes posted some cryptic notes on his blog one or two days.
Vimal Kapur, president of HPS, told attendees, “The Industrial Internet of Things will allow manufacturers to more efficiently gather and analyze a broader range of data across multiple operations and plants to use data to transform entire enterprises.”
Showing how IIoT is working in real-world scenarios is especially critical this year. A recent survey of North American manufacturing executives suggests that investments in data analytics are rising. However, companies are still grappling to better understand its benefits.
The Honeywell-commissioned survey, conducted by KRC Research, found the majority of respondents (between 60 and 70 percent) believe data analytics can help reduce equipment breakdowns and unplanned downtime. It can also help reduce supply chain management issues. This is noteworthy because around 40 percent of the executives see unscheduled downtime and supply chain management issues as the top two threats to maximizing revenue.
At the same time, though, nearly half of the respondents said they don’t fully understand the benefits of data analytics. More than a quarter say more proof is needed to show that data analytics work.
IIoT to Analytics
I find it fascinating how quickly the news from HUG transitioned from IIoT to data analytics. Some people look at the IIoT phenomenon as connected edge devices often through a network using the IP protocol. Increasingly analysts are broadening the scope to include the entire system of connected sensors, data collection, analytics, visualization.
That automation companies, such as HPS, are now emphasizing data science over control and instrumentation is an intriguing proposition to ponder over the future.
Digital Transformation
Just as I witnessed in Hannover, the real technology and term people are concerned with is digitalization.
“We are seeing a lot of interest from our customers attending this conference on how best to manage this digital transformation within their companies. They are looking to get more production out of existing assets and determine the best areas for investment for the long-term success of their operations – to improve process safety, reliability, security and sustainability,” said Kapur.
“HPS has been providing solutions and technologies to help manufacturers leverage critical operational data on a site by site basis for years,” said Andrew Hird, vice president and general manager of HPS’ Digital Transformation business. “Today, with the increased connectivity and the IIoT by Honeywell, they are able to gather and analyze data across multiple sites to find and implement best practices. The results of the IIoT survey of manufacturers reflect very closely the areas where Honeywell has been investing in solutions.”
Product Introductions
Honeywell’s newest industrial automation technologies unveiled at HUG included:
- Data acquisition and analytics: The expanded Uniformance Suite software provides real-time digital intelligence through advanced process and event data collection, asset-centric analytics and powerful visualization technology, turning plant data into actionable information to enable smart operations. This solution is a backbone for the IIoT by Honeywell. New this year is Uniformance Insight, which allows customers to visualize process conditions and investigate events from any web browser.
- Control: ControlEdge PLC, one of Honeywell’s first IIoT-ready controller, is part of Honeywell’s next generation of controllers providing unprecedented connectivity through all levels of process and business operations. When combined with Experion, ControlEdge PLC provides secure connectivity and tight integration to devices from multiple vendors and works with any SCADA system. Also showcased is the newest version of Experion Orion that will help industrial plants further optimize automation project execution, reduce loop commissioning time, minimize operational risk and protect intellectual investments while keeping current with today’s technology.
- Natural gas measurement: Honeywell’s new IIoT-ready gas measurement and data management solutions for North American gas transmission and distribution from the wellhead to the burner tip. The portfolio includes the EC 350 PTZ Gas Volume Corrector, Honeywell Elster Rotary Gas Meter, the Cloud Link 4G Modem, MasterLink and PowerSpring.
- Connectivity: MatrikonOPC Unified Architecture (OPC UA) extends the highly successful OPC communication protocol, enabling data acquisition and information modeling and communication between the plant floor and the enterprise reliably and securely, accelerating the IIoT.
- Mobility: Honeywell Pulse is a new mobile app used to remotely connect plant managers, supervisors and engineering staff to customized real-time plant performance notifications sent from HPS’ industrial automation software. It brings relevant metrics and the tools to resolve issues directly to their mobile device.
by Gary Mintchell | Jun 22, 2016 | Technology, Workforce
Writers have been busy wringing their hands over a “coming workforce crisis” in industry and manufacturing for years. Hand wringing is a professional hazard for magazine editors and other writers. You know, like the old fable about Chicken Little and “the sky is falling.”
I’ve long maintained that we will tackle these problems in due time as the opportunities and actual needs arise.
Klein Tools catalyzed my thoughts in this direction once more by sending a not on the results of its second-annual ‘State of the Industry’ survey. Over the course of two years, the survey asked more than 400 union and non-union electricians about their project preferences on job sites. This year it found higher percentages of electricians who prefer to work on high-tech installations, and home technology remains the most widely viewed residential trend by electricians.
High-tech Installations
The Klein Tools’ State of the Industry survey found preferences towards working on industrial projects, office buildings and commercial properties have stayed relatively the same since last year. There was a noticeable increase, however, in the number of union electricians, and electricians with 10 to 19 years’ experience, indicating they prefer to work on high-tech installations.
- This year, 42 percent of union electricians say they prefer working on high-tech installations, up from 31 percent in 2015.·
- The survey also found 51 percent of electricians with 10 to 19 years of industry experience said they prefer working on high-tech installations, a significant increase from 24 percent in 2015.
- In comparison, 29 percent of electricians with less than 10 years’ experience said they prefer working on high-tech installations, and only 24 percent of electricians with more than 20 years’ experience said they prefer working on high-tech installations.
“We’re seeing increased interest from younger electricians and apprentices in high-tech systems. They see opportunities to work on the latest technology as a way to gain experience in an area of future growth and like the challenge associated with learning a complicated skill,” said Mark Klein, president of Klein Tools. “It’s great to also learn many experienced electricians are taking a fondness to more advanced systems and want to keep up-to-date on their craft. This allows electricians with varying levels of expertise to learn from each other on the jobsite and advance the entire industry as technology continues changing the way we operate.”
Multi-Family and Smart Homes
The Klein Tools’ State of the Industry survey also found electricians are seeing more smart or “connected” homes in residential areas. Technology in homes is the most popular trend viewed amongst electricians—over open living spaces, home additions and multi-family homes. However, multi-family homes have significantly increased since 2015.
· Nearly one-half of electricians, 48 percent, are seeing more smart or connected homes in the residential area—just slightly down from 56 percent in 2015.
o One-third of electricians, or 31 percent, are seeing more multi-family homes in the residential area, up significantly from 25 percent in 2015.
“This tech-focused residential data aligns with what we’re seeing in the industry,” added Klein. “Contractors are calling for more technicians who are skilled in newer, more digital-tech focused systems, and technicians are doing their best to keep up with this developing trend. Klein Tools is working with its partners to ensure younger electricians are trained in the old and news models so they are prepared for all types of scenarios on the job site.”
Solving Not Hand Wringing Over Workforce
In the same vein of thinking, these writers have also been wringing hands over millennials. Will they work? Will they just be like when they were kids? How about the following generation? Coddled and part of the entitlement society where everyone won a trophy, will they be able to hold a job?
Well, “they” said that about my generation. And the GenX generation. Overall, despite some problems with kids learning to make their way, there are plenty of good workers. They also bring along some better values than the later part of the Boomers who thought mostly about partying and drugs.
Educators and business executives rise to meet challenges. Check out Paul Galeski’s column in ISA InTech on mentoring. This is an important initiative that companies can promote. Or, just you. If you are not mentoring someone now, find someone.
