Catching up on some older news items from earlier this month. This news from Yokogawa shows how process automation companies have had to expand their offerings and problem sets to solve in this era of process automation and control market maturity. This new product is said to deliver holistic lifecycle management and operational excellence.
Yokogawa Electric Corporation announced the launch of OpreX Plant Stewardship, the most comprehensive lifecycle service program in the company’s OpreX Sustainable Maintenance family, to support customers in achieving and sustaining operational excellence.
OpreX Plant Stewardship offers a tailored, performance-based approach that strategically addresses the ever-evolving challenges faced by customers, enabling them to mitigate risks, effectively manage operational challenges, and achieve key performance indicators across all levels of their organization. OpreX Plant Stewardship is available in all regions outside of Japan.
With the acceleration of plant complexity, IT/OT integration, cybersecurity threats, and a shortage of skilled resources, traditional product-centric maintenance methods are no longer sufficient. In response to these issues, Yokogawa has expanded its lifecycle services portfolio with a program that ensures service performance across systems, field instruments, analyzers, software, and applications.
Main Features
1. A customer-centric lifecycle approach
OpreX Plant Stewardship is a service program designed through a strategic framework to drive long-term operational excellence. By proactively and systematically addressing risks and challenges, organizations can align their operational strategies with business objectives. Through this approach, Yokogawa works closely with various stakeholders across different levels of the customer’s organization, helping customers navigate complex demands and ultimately find the economic optimum that balances performance, cost, and sustainability.
2. Comprehensive coverage of five dimensions
Leveraging decades of domain expertise, Yokogawa’s service approach is built to provide coverage on five essential dimensions that drive a well-operated, efficient, and resilient business throughout the plant lifecycle:
Safety & security: Ensuring robust operational safety and cybersecurity measures are in place
Reliability & availability: Eliminating plant disruptions and improving equipment reliability
Regulatory compliance: Ensuring compliance with evolving industry regulations while supporting relevant Sustainable Development Goals
Operational efficiency: Enhancing process efficiency and reducing waste
Investment efficiency: Optimizing asset investments to maximize long-term value
3. Four-step process for continuous engagement
The four-step engagement model ensures effective collaboration with customers:
Identify: Understanding customer challenges, priorities, and operational risks through an assessment model
Assess: Evaluating which services and solutions are best tailored to address customer pain points and achieve their operational goals, and crafting a tailor-fitted, long-term collaboration proposal
Control: Ensuring seamless and effective global delivery of the services and commitment to high-quality output
Review: Continuously supporting customers through long-term engagement and improvements, utilizing a structured feedback loop to ensure ongoing performance alignment and adaptation to evolving operational needs
Major Target Markets
Oil and gas, petrochemicals, chemicals, renewable energy, power, pulp and paper, pharmaceuticals, food, mining, iron and steel, water distribution, and wastewater treatment.
A highlight of any trip to a trade fair in Germany was always the Festo stand. They turn engineers loose to build some incredible motion displays. This year at Hannover they constructed an “Incredible Machine.”
The Festo Story
It all began 100 years ago in a workshop in Esslingen am Neckar. Festo founder Gottlieb Stoll asked himself how technology could make work easier. From the initial production of machines for woodworking, the company developed into the production of pneumatic and electrical automation technology for mechanical engineering in a wide range of industries. Today, Festo is one of the world’s leading automation specialists.
To mark the company’s 100th anniversary, Festo has designed an extraordinary application, the Incredible Machine. It is not a specific product, but works on the principle of a Rube Goldberg machine, in which one movement triggers the next. The Incredible Machine demonstrates the history of automation technology from the past to the present and reflects our wide range of competencies and our comprehensive expertise.
The Incredible Machine shows the fascination for motion technologies, be it pneumatic, electric, digital or a combination of these, it presents the most important industries in which Festo operates, it inspires enthusiasm for technology and it provides an outlook on what the future of automation could look like – because inventiveness and a pioneering spirit have been part of our DNA from the very beginning.
Just as a butterfly can trigger a chain of movements by fluttering its wings, sometimes a tiny impulse can bring about significant changes. That is why our eMotionButterfly sets the machine in motion. During this journey, we look back at our history, but above all we are looking forward to the future. A motion impulse runs in 12 modules over a total length of 46 feet, triggering a chain reaction of different motion functions in the machine. More than 1000 Festo products and more than 1.12 miles of tubes and cables are installed in the machine.
Whether pushing, turning, lifting, positioning or relocating workpieces, materials and products during their production process, whether dosing, filling, throttling or pumping liquids and bulk materials in the process industry: motion is involved everywhere in industrial manufacturing processes. As a specialist in automation, Festo has made motion its core business.
The machine is not a purchasable product, but rather an innovation carrier that demonstrates the range of technical solutions in automation technology. Festo also wants to show how important freedom for creativity and inventiveness are to maintain a leading position in global competition. Festo wants to be the best partner for its customers, always at the highest technological level and as a holistic provider of electrical, pneumatic and digital solutions and – as a special USP – the matching training courses from Festo Didactic.
Innovations can solve specific problems and have the potential to change entire sectors and create new industries. The driving forces behind these innovations are the ecosystems of customers and partners who are looking for solutions to their challenges. The journey in the machine leads through specific industries, such as battery production for electric cars, laboratory automation in the life sciences, intralogistics and the semiconductor industry. It delves into the company’s history and ends with insights into the actuator technology of the future. But the momentum continues.
Motion is changing our world and will continue to do so in the future. How this change will unfold over the next 100 years remains to be seen. But one thing is certain: it will be characterized by motion and bold ideas. Through small impulses that can trigger chain reactions and ultimately lead to something big.
While I am on a standards reporting kick, this news reflects the growing collaboration among formerly competitive standards development organizations. I wrote recently about how OPAF is actively taking an end user view into standards collaboration and rationalization. Working together usually brings benefits to users.
From the statement of purpose: Accurate energy consumption data is essential for companies aiming to achieve climate-neutral production. To support this goal, a consortium of organizations has recently published a groundbreaking specification for interoperable and efficient energy management in industrial and process automation.
\A key goal of the mechanical and plant engineering industry is to achieve climate-neutral production in the future. This effort is supported by the European Union’s European Green Deal, which aims to make Europe climate-neutral by 2050. In order to achieve this goal and implement many other use cases, accurate data on energy consumption in production is crucial. The consortium, consisting of the organizations ODVA, OPC Foundation, PI and VDMA, has now jointly published version 1.0.0 of their groundbreaking specification for interoperable and efficient energy management in industrial automation and process automation. This group is chaired by the VDMA.
Dietmar Bohn, Managing Director of PNO, explains: “The measurement and analysis of energy consumption in machines and systems is an extremely important topic for the future. We are pleased to make an active contribution to this important initiative to optimize energy consumption and thereby reduce the harmful effects on the environment caused by waste and surplus.”
This specification defines a standardized information model based on OPC UA that enables comprehensive energy management in industrial automation. “This Power Consumption Management collaboration ensures that end users have a highly standardized and interoperable means of achieving their environmental, social and governance (ESG) goals,” explains Dr. Al Beydoun, President and CEO of ODVA.
The introduction of this standard will make energy management in industry considerably easier: companies can now record, analyze and use precise and consistent energy data even more efficiently in order to further increase their energy efficiency. This not only helps to reduce operating costs, but also to reduce the ecological footprint. Standardization makes it possible to implement innovative technologies and best practices faster and more effectively, which contributes to more sustainable and environmentally friendly production in the long term.
The specification essentially comprises two main content fields: Firstly, monitoring, i.e. the display of all types of energy consumption, including electrical energy as well as energy from air, water or coal. Secondly, standby management, which is understood to mean the control and display of various energy-saving modes on machines and components. It is based on the results of the research project “Development of energy management interfaces for IoT technologies (IoTEnRG)”. “The aim of the IoTEnRG research project was to make the results available to industry. We were able to contribute our results directly to the Joint Working Group and thus significantly accelerate the development of the OPC UA Companion Specification,” says Prof. Dr. Niemann from the Institute for Sensor Technology and Automation at the University of Applied Sciences and Arts in Hannover.
“For digitalization, we need an agreement on a common understanding and description of data, including in the energy sector. OPC UA provides exactly that. I am proud that with this joint group, we can also contribute to the energy transition and thus promote optimized energy savings through standardized and efficient monitoring,” says Stefan Hoppe, President of the OPC Foundation.
The VDMA has defined a fundamental standard for the entire mechanical and plant engineering industry, known as “OPC UA for Machinery”. Various functional building blocks are specified in this standard. A new building block for energy management is being developed based on the publication. “The four organizations have been working hard to harmonize and standardize information on energy consumption in manufacturing. This is an excellent first step towards defining an upcoming OPC UA Building Block for mechanical engineering that will bring the machine and plant manufacturing industry a big step closer to the goal of climate-neutral production,” says Andreas Faath, director of the VDMA Machine Information Interoperability department.
I have mixed feelings toward standards organizations and consortia. Some engineers use their work to build systems. I’m never sure what the final benefit is. Some have built technology in everyday use—OPC, ODVA, FieldComm (HART, FDT), Profinet. Some publish papers that I have hear practical outcomes emanating from.
Yet, I still report on some of these. You never know how some engineers may benefit from the work while building their systems.
This news (I’m catching up on news that came my way while traveling and thinking about what I learned there) comes from The Digital Twin Consortium (DTC), a unit of the Object Management Group. My last two trips and several subsequent interviews and press events all worked in the term Digital Twin somewhere in the discussion. So, it’s relevant.
The Digital Twin Consortium (DTC) published a whitepaper titled Spatially Intelligent Digital Twin Capabilities and Characteristics to help business executives, enterprise, business, and solution architects, system designers, and developers understand the base concept of spatial information relative to the capabilities and characteristics used to describe locational intelligence in the context of digital twin capabilities. The concepts described in the whitepaper apply to a broad spectrum of digital twin use cases, industries, and disciplines.
The whitepaper provides organizations guidance to:
Document the capabilities and resulting value streams provided through the ability to visualize, understand, and analyze the geospatial locational characteristics of real-world entities and conditions.
Understand the distinction between different forms of locational representations, including geometric (3D models), spatial, and geospatial models.
Document the key characteristics of locational representations in a digital twin so organizations can consistently capture locational attributes, enabling digital twin system-to-system integration.
Capture the Spatially Intelligent Digital Twin’s locational characteristics in the context of capabilities using the DTC’s Capabilities Periodic Table (CPT).
By completing the steps outlined in the white paper, organizations can define locational capabilities and data requirements for their digital twins. They can design, develop, and operate digital twins that meet organizational needs and provide business value.
The Digital Twin Consortium Architecture, Engineering, Construction, and Operations (AECO) Working Group prepared the whitepaper. Download the DTC website’s Spatially Intelligent Digital Twin Capabilities and Characteristics whitepaper. Become a DTC member and join the global leaders in driving digital twin evolution and enabling technology.DTC is a program of Object Management Group.
People used to (actually, still do) respond to my answer about what I cover as automation, “Oh, robots.” And I’d say, “Yes, that, too.” The robot market was pretty stagnant for quite a time until the cobot flurry from Denmark. Then, quiet again for the most part. Something interesting does come my way at times. The current topic seems to be expansion of software control to make robotics easier to use and with expanded repertoire.
Flexxbotics announced the latest release of FlexxCORE, the patent-pending technology at the center of the Flexxbotics solution. The new release delivers more powerful capabilities for advanced robotic machine tending, robotic quality control, and robotic production lines by enabling robots—both industrial and collaborative—to run multiple machines with multiple operations for multiple part SKUs. These new FlexxCORE capabilities equip manufacturers to scale robotic production across the smart factory in a standardized way for greater plant capacity, quality, and EBITDA margins.
FlexxCORE now includes enhanced robot awareness, parallelized data pipelines, and greater data granularity which further extends the interoperable communication and coordination between robots, factory machines, inspection equipment, and other plant machinery.
Enhanced Robot Awareness – Empowers robots in advanced tending scenarios to interpret each machines’ jobs, processing routines, operational status, and more
Parallelized Data Pipelines – Leverages asynchronous, parallel pipelines for hyperperformant real time robot+multi-machine orchestration
Greater Data Granularity – Expanded data model and event data capture for robotic operational context, pattern recognition, and machine learning
FlexxCORE is a low-code environment for composing and running Transformers – powerful translation driver connectors – which includes a secure, high performance run-time framework with data pipelines, protocols, class structures, method sets, and data models for development. Transformers enable bi-directional read/write between robots and all types of factory equipment for many-to-many interoperability.
FlexxCORE delivers compatibility with over 1000 different makes and models of robots, machines, other factory machinery and inspection equipment options, and enables 22x faster connector creation than conventional automation integration methods.
Now, global companies can roll out production robotics across the smart factory in a standardized way for advanced robotic machine tending to enable:
Robot+Multi-Machine Orchestration—Robots control multiple machines simultaneously to achieve longer unattended robotic production for “lights out” manufacturing.
Robotic Processing of Multiple Parts—Coordinated robotic production of numerous different part types or SKUs within a part family while managing multi-step processes.
Robot Multi-Job Work Order Staging—Work order changeovers detect order completion – including FDA regulated Line Clear – and update part properties for the next order in-feed.
Autonomous Process Control—Offset parameters adjusted in real time directly in the machine controller’s G-code for process control autonomy, improving quality and digital thread traceability.
Future-Ready Agility—Enables the flexible adoption of new breakthroughs – such as AI-driven processes – to quickly adapt to new market realities and rapidly changing conditions.
