Digitalization requires digital data, which in turn requires a place to robustly store that data. This place is most often the cloud these days. OSIsoft PI System must be the most widely used industrial database. The company has released OSIsoft Cloud Services—a cloud-native, real-time data management system for unifying and augmenting critical operations data from across an organization to accelerate industrial analytics, data science projects, data sharing, and other digital transformation initiatives.
OCS highlights and capabilities:
Data sharing – partner companies can access a shared data stream to remotely monitor technology
Functionality – seamless crossover between the PI System and OCS to compare facilities, perform root cause analysis and run hypotheticals
Scalability – tests proved OCS can simultaneously manage over two billion data streams, and safely share information with partners
Petuum uses OCS to stream historical data and live data on production, temperature and variability to its AI platform to assist Cemex, a global cement manufacturer, improve yield and energy to 7% from 2%.
DERNetSoft uses OCS to aggregate data in one place, allowing users to access useful analytics for ways to reduce power and save money.
Pharma companies will use OCS to give a regulator access to anonymized drug testing or production, without risk of unauthorized users in the manufacturing networks.
With OCS, an engineer at a chemical producer, for example, could combine maintenance and energy data from multiple facilities into a live superset of information to boost production in real-time while planning analysts could merge several years’ worth of output and yield data to create a ‘perfect plant’ model for capital forecasts.
OCS can also be leveraged by software developers and system integrators to build new applications and services or to link remote assets.
“OSIsoft Cloud Services is a fundamental part of our mission to help people get the most out of the data that is at the foundation of their business. We want their cost of curiosity to be as close to zero as possible,” said Gregg Le Blanc, Vice President of Product at OSIsoft. “OCS is designed to complement the PI System by giving customers a way to uncover new operational insights and use their data to solve new problems that would have been impractical or impossible before.”
The Data Dilemma
Critical operations data—i.e. data generated by production lines, safety equipment, grids, and other systems essential to a company’s survival—is part of one of the fastest growing segments in the data universe. IDC and Seagate estimate in “Data Age 2025: The Evolution of Data to Life Critical” that “hypercritical” data for applications such as distributed control systems is growing by 54% a year and will constitute 10% of all data by 2025 while real-time data will nearly double to more than 25% of all data.
Critical operations data, however, can be extremely difficult to manage or use.
Data scientists spend 50 percent or more of their time curating large data sets instead of conducting analytics. IT teams get bogged down in managing VPNs for third parties or writing code for basic administrative tasks. Data becomes inaccessible and locked in silos. Over 1,000 utilities, 80% of the largest oil and gas companies, and 65% of the Fortune 500 industrial companies already use the PI System to harness critical operations data, turning it into an asset for improving productivity, saving money, and developing new services.
Natively compatible with the PI System, OCS extends the range of possible applications and use cases of OSIsoft’s data infrastructure while eliminating the challenges of capturing, managing, enhancing, and delivering operations data across an organization. Within a few hours, thousands of data streams containing years of historical data can be transferred to OCS, allowing customers to explore, experiment, and share large data sets the same day.
Two Billion Data Streams
The core of OCS is a highly scalable sequential data store optimized for time series data, depth measurements, temperature readings, and similar data. OSIsoft has also embedded numerous usability features for connecting devices, managing users, searching, transferring data from the PI System to OCS, and other functions. OCS can also accept data from devices outside of traditional control networks or other sources.
“The scale and scope of data that will be generated over the coming decades is unprecedented, but our mission remains the same,” said Dr. J. Patrick Kennedy, CEO and Founder of OSIsoft. “OSIsoft Cloud Services represent the latest step in a nearly 40 year journey and there’s more to come.”
To test the scalability and stability of OCS, OSIsoft created a deployment that contained the equivalent of the data generated by all of the smart meters in the U.S. over the last two years, or two billion data streams (100 million meters with 20 data streams each). OCS successfully stored up to 1.2 billion data points per hour and was managing all two billion streams simultaneously within 48 hours.
PaaS for OSIsoft Marketplace Partners
Software developers are already creating services based around OCS. DERNetSoft is creating a secure marketplace for sharing utility and electric power data to improve energy forecasts and peak shaving strategies. Meanwhile, others are collaborating with customers on efforts to bolster well integrity at oil drilling sites, pinpoint tank leakage, predict maintenance problems, and reduce energy consumption with OCS. OSIsoft partners developing OCS services include Petuum, Seeq, Toumetis, Transpara, Aperio, and TrendMiner. These services will be available from OSIsoft marketplace as they are released.
“Digital transformation requires the ability to compare data and outcomes across multiple plants and data sources,” says Michael Risse, VP/CMO at Seeq. “OCS is a unified solution for process manufacturing customers to enable this type of analysis, generating predictive insights on thousands of assets across company operations to improve production outcomes.”
Pricing and Availability
OCS is a subscription service currently available to customers and partners for use in facilities in North America. OCS will be extended to Europe and to other regions in the near future.
Pricing is based on the average number of data streams accessed, rather than the unique data streams stored, giving customers the freedom to experiment more freely with their data without incurring added costs..
A mere 2.5-hour drive south on I-75 June 13 brought me to the Schneider Electric plant in Lexington, KY that manufactures load centers and other electrical devices. Schneider Electric marketing people invited me down for tours and festivities marking the unveiling of this brownfield manifestation of Smart Factory using the latest of IIoT, AR, digitalization, and other smart manufacturing principles.
Highlights:
• Schneider Electric Lexington facility is a showcase for sharing IIoT integration strategies with End Users, Machine Builders and Partners
• Lexington plant strategically integrates connected EcoStruxure solutions to enhance efficiency and provide end-to-end operational visibility throughout supply chain operations
• Smart Factory has tracked quantifiable benefits from IIoT implementation, including a 20% reduction in mean time to repair and a 90% paperwork elimination
If this plant is to demonstrate “in real time how its EcoStruxure architecture and related suite of offerings can help increase operational efficiency and reduce costs for its customers”, I asked the natural question—“What is EcoStruxure?”
I’ve heard the term for many years, but being a little slow on the uptake, I’ve never really understood what is meant. So, they set me up with an interview with Vice President Domenic Alcaro. Refreshingly, EcoStruxure is neither a platform or a product. Alcaro told me, “EcoStruxure is a phenomenal way to explain our value structure.” The foundation block consists of connected products (connectivity being a key word). The intermediary block is what they call Edge Control. However, whereas many people look at Edge and think hardware, Schneider Electric considers it basically software. Think the InduSoft HMI product, if you will. Atop the model then are apps and analytics.
Back to the plant:
In operation for more than 60 years and employing nearly 500 people, the Lexington factory is truly a showcase of modern integrated digital experience. Among the benefits realized include empowering operators to gain visibility into operations maintenance, driving a 20% reduction in mean time to repair on critical equipment, and process digitization eliminating paper work by 90%.
“We understand the value of IIoT and the positive business impact that innovation and digitization can have on our operations – particularly in our global supply chain. As a living example of how our EcoStruxure solutions deliver benefits to our customers, we are gaining those same benefits in our operation and sharing that knowledge,” said Mourad Tamoud, Executive Vice President, Global Supply Chain, Schneider Electric. “With our latest Smart Factory showcase, we are able to demonstrate this value in real-time, show the solutions at work and share the tangible benefits that we ourselves are seeing from our own IIoT investment as we accelerate our Tailored Sustainable Connected 4.0 digital transformation.”
As part of the Smart Factory program, Schneider Electric exemplifies brownfield implementation for customers who may be facing the same challenges with their existing production facilities. The team is able to offer strategies and talk through the challenges they faced to help customers exploring IIoT connected technologies overcome those same hurdles toward their modernization goals. By sharing their experience in leveraging EcoStruxure solutions, visiting customers can better understand the value of the brownfield modernization and the resulting operational efficiencies.
In this production environment, these solutions have demonstrated operational and quantifiable value since their implementation:
• EcoStruxure Augmented Operator Advisor – Delivered a 20% reduction in mean time to repair on critical equipment where it has been implemented.
• EcoStruxure Resource Advisor and Power Monitoring Expert – Delivered 3.5% YOY energy savings in the Lexington facility in addition to $6.6 Million in regional savings since 2012; sophisticated reporting capabilities and increased transparency also drive operational performance.
• AVEVA Indusoft Web Studio – Delivered powerful Edge digitization of paper processes to eliminate paper work by 90% and cloud connectivity has enabled digital dashboarding of a critical process.
• RFID OsiSense – Eliminated 128 daily fork truck miles and eliminated $500,000 in Work in Progress (WIP) inventory with a 33% first year ROI.
• AVEVA Insight Data – Unlocked and shared silos of data in a mobile manner reducing downtime in critical processes by 5% with ROI of less than 6 months.
• Magelis GTU/GTUX HMI – Provided agile operator management of the process and vivid visual of the process onsite and via mobile devices.
Among the tidbits of information I picked up on the tour include:
Extensive use of Ethernet and IP networking. Interesting in that the very first conversations I had with a Modicon VP 20 years ago concerned how Ethernet was the network of the future. In 1999 that was revolutionary thinking. Today—it’s the backbone. Hat tip to Mark Fondl.
Great use of data tracking involving RFID tags, MES software, Ethernet connectivity, and visualization that coordinates all the products and containers throughout the company-wide power-and-free conveyor system.
Oh, and a Megelis computer/HMI collecting data from sensors and passing it on uses Node-RED for programming. It’s only the second instance of Node Red I’ve seen in automation.
Finally, Schneider Electric plant management correctly combines digitalization with Lean principles enhancing their daily stand ups and feeding continuous improvement.
Impressive facility. When our politicians and east coast journalists go ripping on American manufacturing, they should be forced to take deep dives into plants like this one.
ABB has appointed Maryrose Sylvester as Country Managing Director (CMD) and Head of Electrification for the United States, effective August 1, 2019. In the CMD role, she will succeed Greg Scheu, who will support a smooth transition until his retirement at the end of October 31, 2019.
Sylvester was most recently President & CEO of “Current, powered by GE”, a GE startup business that was acquired in April by New York-based private equity firm American Industrial Partners. Having spent her career at GE, she held several executive-level positions, including President & CEO of GE Lighting, of GE Intelligent Platforms/GE FANUC, which was GE’s longest-running joint venture with a Japanese company, and of GE Quartz.
I remember interviewing Sylvester during her tenure as president of GE Fanuc/GE Intelligent Platforms. She did well at a relatively small unit and obviously progressed within the organization.
These corporate changes at the top are not always relevant to most working engineers and managers. The thing I find most surprising is that ABB reached out to GE for new management talent. First, it shows just how similar the GE and ABB businesses are. In fact, throw in Honeywell, Schneider Electric, and Siemens as part of an industrial big five. Emerson is lurking just behind, but it is refocusing. Rockwell Automation has eschewed following a similar path and seems to be in a group with companies such as Beckhoff Automation.
A second thought occurred which is that I’m surprised by a selection from GE given the less than satisfactory fit of Joe Hogan who came from GE to ABB as CEO.
“Maryrose Sylvester brings extensive experience of managing and transforming industrial businesses and of applying digital technologies in industry,” said ABB Chairman and CEO, Peter Voser. “Her proven track record at GE makes her an ideal candidate to run our Electrification business in the US and to be our CMD for the US.”
Sylvester is a board member of Harley-Davidson and a member of the board of governors of the National Electrical Manufacturers Association. She also sat on GE’s Corporate Executive Council and its Commercial Council, and was a member and co-founder of GE’s Women’s Network.
“On behalf of the Board of Directors and the Executive Committee, I would like to thank Greg Scheu for his many years of committed service to ABB in numerous leadership roles, and especially for his strong contributions as Region President Americas, US Country Managing Director, and head of Group service and business integration,” Voser said. “Under his direction, ABB has significantly strengthened its market presence in North America and positioned itself as a digital technology leader among key customer groups. We wish him every success in his future endeavors.”
My wife’s family took me off for a week-long vacation to the beach last week. Eight days of much needed rest after a bunch of travel and a hectic (meaning wet) spring soccer season.
Last week was also Rockwell Automation TechED. That conference was once open only to distributer and integrator tech people. Several years ago it opened to media and became quite a thing for a few years. Last year I received an invitation to attend but they said that there was no media program. The timing was bad for me, so I passed. This year, there was no word at all. And I saw no news.
There are several industrial automation user conferences this week. PTC invited me to its conference in Boston. Then I was invited to Honeywell User Group (HUG). Then there were other invitations. Busy week. I initially told PTC I would attend, then putting it in my calendar, I realized that the week included my wedding anniversary. It’s big number (as in large). My better sense prevailed and I’m watching both of those conferences from afar.
So far this week, Honeywell Process Solutions has made a big announcement with some innovative product releases. Rockwell Automation, which owns about 8% of PTC and is banking on the partnership to bring its software into the new age, also issued a release. I’m still figuring that one out.
Honeywell Proclaims New Approach to Engineering
• Experion PKS Highly Integrated Virtual Environment (HIVE) significantly simplifies control system design, implementation and lifecycle management while reducing cost
• Market-first solution uniquely decouples the assignment of input/output (IO) modules and control strategies from specific controllers, and leverages IT capabilities in customers’ own data centers
My take on this announcement considers the HIVE product suite part of the growing trend under the umbrella of “digital twin.” Other companies have some somewhat similar products, but what I’ve found is that each company moves the ball forward a little more in a seemingly endless cycle of innovation. Honeywell labels it an evolution of the company’s flagship Experion Process Knowledge System (PKS).
Experion PKS HIVE uses Honeywell’s LEAP project execution principles, software, and networking to unchain control applications from physical equipment, and controllers from physical IO. This enables control systems to be engineered and implemented in less time, at lower cost and risk, and with simpler, modular builds. The solution also transforms the way control systems are maintained over their lifecycle, shifting day-to-day management of servers to a centralized data center, where experts and established protocols mitigate cybersecurity risk, allowing plant engineers to focus more proactively on optimization of their control systems.
Experion PKS HIVE incorporates three elements – IT HIVE, IO HIVE and Control HIVE – which can be used individually or collectively, in tandem with customers’ existing systems and infrastructure:
• Experion PKS IT HIVE centralizes up to 80% of the IT infrastructure traditionally used in project engineering to lower project delivery and lifecycle costs, better leverage skills, and drive consistent physical and cybersecurity management across an enterprise.
• Experion PKS IO HIVE provides flexible IO and control distribution enabling the control system to become a natural extension of process equipment and to facilitate modular and parallel project execution.
• Experion PKS Control HIVE uniquely applies control containers to provide flexibility and standardization of control hardware platform, control location, and control engineering. With multiple physically controllers operating as part of a Experion PKS Control HIVE, control engineering is dramatically simplified through automated load balancing.
“In developing Experion PKS HIVE, Honeywell worked closely with customers across the chemical, refining and oil and gas industries,” said Jason Urso, chief technology officer, Honeywell Process Solutions. “Many of these organizations want a more efficient approach to control system engineering, yet one that can be adopted incrementally and used interchangeably with their existing systems and infrastructure. Experion PKS HIVE provides these benefits and is truly a distributed control as it applies and geographically distributes technology to where it is needed.”
Experion PKS HIVE shifts IO to the field and makes it fully accessible to any controller, taking individual physical controllers and distributing the load so that they appear as a single controller to eliminate complexity. The solution distributes IT compute from onsite to offsite providing a seamless operations experience.
The Experion PKS IT HIVE and IO HIVE can be ordered now, with deliveries beginning Q1 2020. Experion PKS Control HIVE will be available in the second half of 2020.
Rockwell Automation Emphasizes PTC Partnership
Rockwell Automation announces its “unique combination of IT and OT software accelerates customers’ Digital Transformation Initiatives.” It says its solutions-oriented approach simplifies how manufacturers achieve business outcomes that transform operational processes, workforce productivity and efficiency.
Showcasing solutions during LiveWorx this week the company highlights:
Enterprise Operational Intelligence – cuts manufacturing costs and increases flexibility and agility of manufacturing networks by providing real-time manufacturing performance management across the industrial enterprise.
Digital Workforce Productivity – heightens productivity, improves quality, and avoids safety and compliance risk by equipping workers with actionable, augmented intelligence.
Intelligent Asset Optimization – reduces downtime and maximizes asset utilization through real-time monitoring, diagnostics, and predictive and prescriptive analytics into asset capacity, performance, and health status.
Scalable Production Management – lowers cost of inventory, improves quality, and compliance and accelerates time to market with effective planning and control of production processes.
The Manufacturing Connection conceived in 2013 when I decided to go it alone in the world from the ideas of a new industrial infrastructure and enhanced connectivity. I even had worked out a cool mind map to figure it out.
Last week I was on vacation spending some time at the beach and reading and thinking catching up on some long neglected things. Next week I am off to Las Vegas for the Hewlett Packard Enterprise “Discover” conference where I’ll be inundated with learning about new ideas in infrastructure.
Meanwhile, I’ll share something I picked up from the Sloan Management Review (from MIT). This article was developed from a blog post by Jason Killmeyer, enterprise operations manager in the Government and Public Sector practice of Deloitte Consulting LLP, and Brenna Sniderman, senior manager in Deloitte Services LP.
They approach things from a much higher level in the organization than I usually do. They recognize what I’ve often stated about business executives reading about all these new technologies, such as, cloud computing, internet of things, AI, blockchain, and others. “The potential resulting haste to adopt new technology and harness transformative change can lead organizations to treat these emerging technologies in the same manner as other, more traditional IT investments — as something explored in isolation and disconnected from the broader technological needs of the organization. In the end, those projects can eventually stall or be written off, leaving in their wake skepticism about the usefulness of emerging technologies.”
This analysis correctly identifies the organizational challenges when leaders read things or hear other executives at the Club talk about them.
The good news, according to the authors: “These new technologies are beginning to converge, and this convergence enables them to yield a much greater value. Moreover, once converged, these technologies form a new industrial infrastructure, transforming how and where organizations can operate and the ways in which they compete. Augmenting these trends is a third factor: the blending of the cyber and the physical into a connected ecosystem, which marks a major shift that could enable organizations to generate more information about their processes and drive more informed decisions.”
They identify three capabilities and three important technologies that make them possible:
Connect: Wi-Fi and other connectivity enablers. Wi-Fi and related technologies, such as low-power wide-area networks (LPWAN), allow for cable-free connection to the internet almost anywhere. Wi-Fi and other connectivity and communications technologies (such as 5G) and standards connect a wide range of devices, from laptops to IoT sensors, across locations and pave the way for the extension of a digital-physical layer across a broader range of physical locations. This proliferation of connectivity allows organizations to expand their connectivity to new markets and geographies more easily.
Store, analyze, and manage: cloud computing. The cloud has revolutionized how many organizations distribute critical storage and computing functions. Just as Wi-Fi can free users’ access to the internet across geographies, the cloud can free individuals and organizations from relying on nearby physical servers. The virtualization inherent in cloud, supplemented by closer-to-the-source edge computing, can serve as a key element of the next wave of technologies blending the digital and physical.
Exchange and transact: blockchain. If cloud allows for nonlocal storage and computing of data — and thus the addition or extraction of value via the leveraging of that data — blockchain supports the exchange of that value (typically via relevant metadata markers). As a mechanism for value or asset exchange that executes in both a virtualized and distributed environment, blockchain allows for the secure transacting of valuable data anywhere in the world a node or other transactor is located. Blockchain appears poised to become an industrial and commercial transaction fabric, uniting sensor data, stakeholders, and systems.
My final thought about infrastructure—they made it a nice round number, namely three. However, I’d add another piece especially to the IT hardware part. That would be the Edge. Right now it is all happening at the edge. I bet I will have a lot to say and tweet next week about that.
