Artificial Intelligence, or AI, is quite the buzz word. Mention in general conversation, say if you are Axios or The New York Times, and public response is that it is something evil that will take all our jobs away.
Of course, like all technology from the beginning of human history AI can be good or bad depending upon who uses it for what reason.
Now, let me add a second stream to this brief essay. Advanced Process Control, or APC. There are some excellent APC products on the market that I’ve written about over the years. The problem I’ve heard about over those same years relates to keeping the model updated. Too many people (read managers) seem to think you set it up once and then it lasts forever. That could not be further from reality.
Yesterday I had a conversation with Pervez Choudhry, Vice President for Business at Petuum. This is a company started through AI research at Carnegie Mellon University by Eric Xing. He hired a number of Ph.D.s and post-doctoral researchers in AI along with domain experts in industries he targeted for markets and went to work.
My BS antennae always activate at the sound of AI in a press release. So, I asked Choudhry what Petuum meant by the term. That’s when he told me about the research and researchers. AI relates to machine learning. Getting a data set from a process and self-learning from new data feedback from the process.
I’m more impressed by the business model than the technology. The company hosts the application in the cloud deployed as “AI as a Service”. This system addresses the problem so many have run into about maintaining the model as the process morphs over time. A company worth watching. They could well disrupt (in a good way) this particular market.
The press release that provoked my curiosity promoted a new use case—supervised autonomous cement plant operations for CEMEX—a global building materials company.
The two companies entered into a global agreement where CEMEX can implement Petuum “Industrial AI Autopilot” with “autosteer” in all cement plants worldwide for autonomous cement plant operations. The Petuum Industrial AI Autopilot product for cement plant operations are being deployed at select CEMEX USA and Mexico plants, and will continue to be rolled out globally in 2019.
The Petuum Industrial AI Autopilot suite of products deliver real-time precise forecasts for key process variables, prescriptions for critical control variables and supervised autosteer aligned with business objectives for all cement plant operations including clinker cooler, preheater, rotary kiln, pyro process, ball mill and vertical mill processes to achieve lowered energy consumption, optimized fuel mix and increased throughput while maintaining stable operation and high product quality. Additionally, the fuel mix optimization Autopilot enables alignment of global operational excellence initiatives with local site priorities.
The joint CEMEX and Petuum teams achieved a cruise-control-like supervised “autosteer mode,” where the AI Autopilot could run operations with full engage/disengage control available to the operator.
“Petuum Industrial AI Autopilot helped us achieve something we didn’t think was possible at this time,” said Rodrigo Quintero, operations digital technologies manager at CEMEX. “We expect our yield improvements and energy savings to be up to seven percent, from the connected AI-based autopilots, which is game changing for our industry. Additionally, this is a giant step in digital transformation towards safe, highly standardized operations, that will help us strengthen our high-quality products portfolio while also ensuring we meet our operational and sustainability goals, and to minimize costs.”
The Autopilot products deployed at CEMEX for the rotary kiln and clinker cooler systems are integrated with plant control systems and OSIsoft PI data infrastructure for scalable, standardized and rapid deployments across multiple lines and plants globally.
The Autopilot products, developed and operationalized on the Petuum AI platform, can ingest data from a variety of sources including unstructured, images, structured, time series, CRM, ERP and others. The Petuum platform provides sophisticated data processing, cleansing and machine/deep learning pipelines used to implement advanced AI that is sensitive to linear, temporal, long range and non-linear data patterns in a range of industrial use cases.
“Our collaboration with CEMEX has allowed us to demonstrate that resource and skill-intensive advanced AI technologies, previously used to address complex problems only in limited settings, can now achieve tangible business impact in a wide range of real-world industrial environments,” said Dr. Eric Xing, CEO of Petuum. “We are able to achieve new levels of automation, accelerating the journey to Industry 4.0. Our vision is to bring AI benefits to a wide range of businesses in a highly cost-effective and fast manner, solving challenges that can’t be addressed by traditional techniques.”
CEMEX and Petuum will continue close collaboration to deploy additional Autopilot use-cases such as emissions reduction, fuel-mix (alternative fuel) optimization, kiln refractory, preventive maintenance, etc. for global cement plants and expand Petuum Industrial AI Autpilot to other operations worldwide.
Yesterday I tweeted ABB Chief Digital Officer Guido Jauret’s keynote at ABB Customer World that included the digital roadmap ABB is on including digital twin technology with a partnership with Dassault Systèmes. Then I realized I have not put the news on the blog.
This is an important step on ABB’s digital journey—something that has made impressive strides in two quickly moving years. Here is the news.
ABB and Dassault Systèmes announced a wide spanning global partnership to offer customers in digital industries a unique software solutions portfolio ranging from product life cycle management to asset health solutions. The two companies will provide customers an end-to-end offering of advanced open digital solutions, enhancing competitiveness of industrial companies, while increasing flexibility, speed and productivity of their products’ lifecycles, manufacturing and operations.
The partnership will combine the strengths of ABB Ability digital solutions and Dassault Systèmes’ 3DEXPERIENCE platform, and build on both companies’ strong installed base, deep domain expertise, and global customer access. ABB has already adopted the 3DEXPERIENCE platform to model and simulate its solutions before delivering them to its customers. With this partnership, ABB will develop and provide customers with advanced digital twins, enabling customers to run ABB’s solutions and their operations with improved overall efficiency, flexibility and sustainability.
The companies will, in a staged approach, focus on factory automation and robotics, process industry automation, as well as electrification solutions for smart buildings. The first joint solutions will be showcased at the upcoming industrial Hannover Messe trade fair in Germany, April 1-5, 2019.
“This game-changing partnership will serve our customers to lead in innovation and growth, fundamentally transforming their entire value chain to tap the vast opportunities of industrial digitalization. Together, we are offering an open, end-to-end digital portfolio – from digital twin to asset health – that gives our customers a competitive edge, building on our combined offering, domain expertise and global reach,” said ABB CEO Ulrich Spiesshofer. “ABB is adding Dassault Systèmes to its strong partner network for industrial digitalization, including Microsoft, HPE and IBM. We look very much forward to working with the entire global Dassault Systèmes team to drive innovation and customer value.”
“The Industry of the 21st century is no longer determined simply by the ability to manufacture goods. Today’s leaders will be determined by superior mastery of technical know-how. This is the new competitive differentiator and it’s happening now due to a convergence of digital technologies that are transforming every aspect of industrial business,” said Bernard Charlès, Vice Chairman and CEO, Dassault Systèmes. “In this industry renaissance, a platform approach enables the real and virtual worlds to inform and reinforce one another. Our partnership with ABB will draw from decades of combined expertise to help customers make the most of this powerful and dynamic trend.”
In today’s highly automated industries, digital factory modeling and flexible, robotized manufacturing systems help businesses to generate more design iterations at a quicker rate with more robust designs. This, in turn, helps to accelerate the shift from mass production to mass customization, where goods are manufactured in a greater variety and in smaller batches and in shorter product life cycles. For many manufacturers, the cost of downtime has dramatically increased in recent years as just-in-time delivery has become the norm. An hour of downtime at a modern production site can cost more than $1 million.
ABB has already a strong digital solution offering within the industry through its offering ABB AbilityTM. It was launched in 2017 and offers more than 210 digital solutions to plan, build and operate industrial operations with higher productivity and safety at lower costs.
Dassault Systèmes works with companies of all sizes in 11 industries to help them meet new challenges in today’s Industry Renaissance. The 3DEXPERIENCE platform integrates all the technologies and capabilities that leverage knowledge and know-how into one cohesive digital innovation environment that delivers digital continuity from concept to manufacturing to ownership and back. Industrial companies can integrate the platform’s 3D applications to create a digital twin that captures insights and expertise from across their entire ecosystem, to measure, assess and predict the performance of an industrial asset and help optimize its operation in an intelligent way.
The ABB – Dassault Systèmes partnership will initially focus on:
Factory Automation and Robotics
Digital twin experiences for end-to-end optimization of processes and systems, combined with the flexibility of robotics automation, will give factories the agility to adapt to increasingly dynamic markets. This includes ready-to-operate manufacturing solutions and services, along with joint consulting for industrial business transformation, to optimize and speed the launch of new products. Electronics makers can increase the production of new but short-lived products quickly, while food processors can alternate between locally tailored seasonal offerings while producing at high speed. In highly automated industries such as automotive, the digital twin experience of factories allows an integrated design and manufacturing environment to support new assembly processes with flexible and reconfigurable cells. It also makes it possible to link separate systems, such as connecting logistics automation systems to robots at work on manufacturing lines that rely on precise parts delivery for optimal production performance.
The digital partnership between Dassault Systèmes and ABB around digital twin systems will enable a seamless workflow during design, engineering and operation of buildings, as well as connected sustainable transportation solutions. The available information, in combination with Dassault Systèmes’ virtual universe 3DEXPERIENCE, will also allow greater customer interaction during the design specification phases and operation.
Process industries: Mining example
Competitive pressure in process industries, such as mining, requires companies to continuously look for new ways to increase safety, productivity and energy efficiency of sites, while reducing costs and risk of daily operations. A digital model of the underground environment, in connection with mine planning and control systems, would allow to optimize energy consumption and mine automation, as well as enable mine operators to monitor and optimize production in real-time, while running virtual simulations of future scenarios.
Our schedules finally aligned and I was able to catch up with Ed Harrington, director of the Open Process Automation Forum for The Open Group. A few months ago I talked with Gary Freburger and Peter Martin of Schneider Electric’s process automation unit. We discussed the OPAF and what had been going on since the ARC Forum in Orlando last February.
OPAF has laid out an ambitious agenda moving automation toward an era of open connectivity and interoperability.
The original plan broached a couple of years ago at ARC Forum by representatives of ExxonMobil and Lockheed Martin was to prod suppliers into reducing the problem of upgrading systems in the field without the huge expense of rip-and-replace. Considerable industry jockeying ensued. Schneider Electric (Foxboro) eventually taking a leadership position in the effort with assistance from Yokogawa and to a degree Siemens. Other suppliers are watching and evaluating.
Smaller suppliers such as Inductive Automation have become involved along with some of the major automation systems suppliers.
The OPAF specification is really a standard of standards. The group wishes to build upon existing standards, assembling them in such a way as to advance the cause of open automation.
Harrington told me that so far this year, the group has published three items (that are open to the public). One is a business guide, The Open Process Automation Business Guide: Value Proposition and Business Case for the Open Process Automation Standard.
The industrial control systems that manufacturers use to automate their processes are critical to the company’s productivity and product quality. To increase the business contribution from control systems, manufacturers need:
1. Increases in operational benefits from improved capabilities
2. Improvements in cybersecurity compared to currently available systems
3. Reductions in the system’s capital and lifecycle costs
The organization has also published The Open Group Snapshot—Open Process Automation Technical Reference Model: Technical Architecture and a white paper Requirements for an Open Process Automation Standard.
Harrington also told me to expect an announcement of further work at next week’s Open Group Quarterly Meeting in Singapore.
I have seen a number of these initiatives in my career. Few succeed in entirety. However, the thinking that goes into this work always moves industry forward. I don’t know if we’ll ever see a truly OPAF control system. Anything that brings more rationality to the market keeping in minds the goals of OPAF will do much for helping manufacturers and producers improve performance. And that’s what it’s all about.
This week is another week on the road—five out of the last six—and now I’m in Chicago at Pack Expo. Much like IMTS, Pack Expo fills three halls of McCormick Place with machines. And machine components such as controls, drives, software, instrumentation, and the like.
Two weeks ago was Emerson Global Users Exchange. I wandered into the Emerson Automation Solutions booth not expecting much that was new. OK, got that one wrong.
If you want an indicator that Emerson has seriously expanded beyond oil & gas, keep on reading. It is now a serious player in this space, as well.
I once was an executive with a company that designed and built automated assembly machines. One interesting niche we had was an expert in helium mass spectrometry leak testing. I can give the sales pitch on the value of in-line, 100% testing of products.
Well, not as good as when Emerson explained its new food and beverage leak detection system.
Emerson’s RosemountTM CT4215 uses laser technology to detect leaks, reject defective packages with no production slowdown.
The Rosemount CT4215 is the first quantum cascade laser/tunable diode laser (QCL/TDL) continuous, inline detection system designed to help assure quality and safety, maximize production volume and decrease product waste for food and beverage products. The Rosemount CT4215 tests the seal and integrity of every bottle or package on a production line, detecting leaks at a sensitivity as low as 0.3 mm and automatically rejecting any defective bottle or package without slowing down production. This is in contrast to the traditional practice of testing occasional grab samples, which can leave a manufacturer vulnerable to low quality, unsafe food or beverages, reduced profitability and damaged reputation.
“In an industry being driven by an increasing consumer awareness of freshness and safety, manufacturers need solutions that allow them to assure these qualities while maintaining, or even increasing, efficiency,” said Peter Watmough, global leak detection product manager, Emerson Automation Solutions. “The Rosemount CT4215 provides packagers with an easy-to-install, easy-to-use assurance of freshness and safety. For the first time, food and beverage packagers can measure every package and bottle for leaks without having to compromise their production speed.”
Emerson further unveiled a new line of transmitters designed specifically for hygienic applications in the food and beverage industry with a compact form factor that will enable manufacturers to minimize downtime and lower production costs.
The new line of transmitters—Rosemount 326P Pressure, Rosemount 326T Temperature, Rosemount 327T Temperature and Rosemount 326L Level instruments—are designed to operate in the hygienic environments required by food and beverage manufacturers:
All comply with 3-A and FDA specifications, and are available with nine common industry process connections to ensure the right fit for new tanks and pipe fittings, as well as capability to be retrofitted on legacy systems. The new, small transmitters also can be mounted in tighter locations common on packaging machinery. Conventional 4-20 mA outputs and IO-Link connectivity make the transmitters easy to integrate with automation systems.
To give a sense of the breadth of Emerson Automation Solutions commitment to the space, following are some summaries of products.
Emerson’s ASCO G3 Fieldbus Electronics completely modular system plugs together via mechanical clips that allow easy assembly and field changes without dismantling the entire manifold, and its modules can be used in centralized or distributed applications.
One particular demonstration that will feature G3 Fieldbus Electronics is Emerson’s ASCO Bread Packing Machine. This state-of-the-art system provides full pneumatic automation control to ensure high-speed, repeatable packaging of food products. Its G3 Fieldbus integrates pneumatic control and provides real-time diagnostic data via an integrated webserver. It demonstrates flexible and energy-efficient design through proper sizing of pneumatic systems to fit any food packaging operation.
Emerson’s SolaHD Power Quality solutions remove limitations in the power architecture, allowing machine designers and operators to safely put power where they need it. These power supplies can be mounted directly on a machine, freeing packaging lines from design constraints; eliminating the complexity and cost of unnecessary enclosures and excess wiring; and providing the power for current and future automation capabilities.
Emerson’s Branson Ultrasonic Automated Cutting System provides precise food portioning with an almost frictionless cutting surface resulting in cleaner cuts, faster processing, minimal waste, longer blade life, higher productivity for greater throughput, and reduced downtime for cleaning.
Emerson helps packaging operations reduce process variation and decrease costly losses through technologies that deliver real-time insight into machine and process performance. With the accurate, relevant data in hand, packaging operations can achieve better reliability, reduce losses and contamination as well as ensure long-term performance.
With Emerson’s Micro Motion Filling Mass Transmitter (FMT), high-value packaging lines can accurately fill a wide range of container sizes and products with a single meter, eliminating the cumulative error associated with multiple-device measurement solutions. The Micro Motion FMT reliably measures fluids with entrained solids or gases or with changing viscosities, making it ideal for high-speed filling and dosing applications. Its Coriolis mass-based measurement is immune to variations in process fluid, temperature or pressure, and Automatic Overshoot Compensation (AOC) ensures repeatable fills even under valve performance changes. In addition, the Micro Motion FMT enables operators to track quality control and filling valve-performance data in real time to reduce filler maintenance and cost.
In addition, Emerson’s Micro Motion Multiphase Flow Meter technology can help complex process operations reliably log Gas Void Fraction and liquid density and concentration measurements. Utilizing Micro Motion Advanced Phase Measurement software, these meters also tolerate “real life” conditions of foaming, end-of-batch cavitation or slug flows to enable consistent measurements in challenging multiphase conditions. In addition, Smart Meter Verification delivers detection of coating or fouling within the meter for added clean-in-place efficiency and insight.
An interactive display illustrating pneumatics and IIoT features Emerson’s AVENTICS Smart Pneumatics Monitor, an IIoT hub allowing local data collection and analysis independent of the controller. The pick-and-place display illustrates “predictive maintenance” by showing the health and performance of valves, cylinders and shocks, which can minimize the risk of unplanned machine downtime to increase ROI.
To demonstrate how operators can protect personnel and reduce risk without impacting productivity. the Emerson booth will feature the Emerson ASCO 503 Series Zoned Safety Manifold (with G3 fieldbus electronics). It simplifies the design of a redundant pneumatic safety circuit with a manifold system that can be configured to shut down air and power only to the group of valves that controls the machine’s motion in the operator’s vicinity while the rest of the machine remains in operation. Multiple independent safety circuits can easily and cost-effectively be designed into a single pneumatic valve manifold, reducing the number of safety system components by up to 35 percent, requiring less plumbing, and shrinking the size of a safety system so that valuable real estate within the machine and manifold can be used for other purposes while still providing enhanced operator safety.
Last week was where industrial automation and information technology met along with my vice–soccer.
Emerson Automation Solutions–Digital Transformation, IT/OT collaboration, corporate acquisitions (GE Intelligent Platforms, once known as GE Fanuc, joins the fold), WirelessHART applications expand, flow control data becomes an integral part of digital transformation.
Hewlett Packard Enterprise (HPE)–Refinery of the Future tour of the Texmark refinery that I’ve written about before and CenterPoint Energy where digital boosts the electrical utility industry.
Marketers may still talk of IT/OT convergence as something coming. In many forward thinking plants it is here. Texmark CEO Doug Smith talks freely about the kick in the pants delivered by his insurance carrier that propelled him and his team toward finding innovative solutions to operations challenges.
I sometimes joke that “I’m the point of convergence of IT and OT”, or at least my blog and writing are.
Don’t believe hype or nay-sayers. The collaboration is real–among suppliers, partner ecosystems, managers, engineers. And real benefits are accruing.
Have you joined the 21st Century?
Foxboro and Triconex looks to be on the path to health under Schneider Electric. Its annual user conference is this week in San Antonio. I‘d love to be there, but personally more important is “grandparent duty” that I’m on this week. So, I had the opportunity to talk with Gary Freburger, leader of the group, and Peter Martin, VP of marketing, to get an update and view of what I’ll be missing.
Gary Freburger began with the market rebounding due to current oil pricing. Business is starting to get strong. IA product line has done well and the process business also did well going up 6% in the first half of the year. He’s expecting majority of growth over the next two years. Schneider Electric is still investing around EcoStruxure system. Foxboro is continuing on the path they discussed with us at the last user conference—how to get more value from control systems going from “necessary evil” to value add in the eyes of customer executives. The strategy is to turn data and connectivity into a business driver. The goal is enabling better decisions and improving profitability.
Freburger discussed cooperating with OPAF for a comprehensive strategy. Then he dropped in an interesting tidbit—cooperation with AVEVA. I’ve wondered about how AVEVA with the inclusion of previous Schneider Electric software would work with the Foxboro side of things. He told me they now have and end-to-end relationship to improve time to market. He noted as oil prices dropped customers thought “what can I afford to do?” Now, all have reset expectations. As oil prices rebound, they have not changed expectations. Some interesting applications and strategies include AVEVA auto populate control system, digital twin of facility, operations feedback our systems to AVEVA’s, then customer asset management upgrade works easier.
Martin discussed how Schneider is trying to change the question—from how to do control to how do we help customers solve problems that impact business? He pointed out that they’ve been doing digitization for years. What’s new is how to drive this new approach. 40 years ago controls was a solution-driven business; then with digitization the industry went from solutions to technology-driven. The times now require a need to flip flop. Solutions oriented but with today’s portfolios taking it to a much higher level. The speed of industrial business has increased—what was stable, e.g. cost of electricity—is stable no longer. The speed means IT world can’t keep up. Built-in real-time accounting control helps plants go beyond control to profitability. Foxboro is still dedicated to taking the use of technology to the next level.
During the conference (while I am writing from the forests in southern Ohio while the grandkids are in bed), Schneider Electric announced the release of EcoStruxure Foxboro DCS Control Software 7.1.With expanded capabilities and an enhanced HMI, the updated software simplifies engineering and enhances the user experience, while expanding the ability of EcoStruxure Foxboro DCS to drive measurable operational profitability improvements, safely.
The EcoStruxure Foxboro DCS is an open, interoperable and future-proof process automation system that provides highly accurate and effective control over a manufacturing plant’s operational profitability. It is the only process control system that provides measurable operational profitability improvements and a future-proof architecture, enabling a measurable 100 percent ROI in less than one year.
EcoStruxure is Schneider Electric’s open, interoperable, IoT-enabled system architecture and platform. This includes Connected Products, Edge Control, and Apps, Analytics and Services. EcoStruxure has been deployed in 480,000+ sites, with the support of 20,000+ system integrators and developers, connecting over 1.6 million assets under management through 40+ digital services.
EcoStruxure Foxboro DCS Control Software 7.1 runs on Windows 10 and Windows Server 2016, to provide maximum flexibility while ensuring robust cybersecurity. When planning upgrades, Schneider Electric customers can mix Windows XP, Windows 7 and Windows 10 on the same system, allowing flexibility in scheduling and timing for upgrades. Customers can upgrade individual sections of the plant in any order, at any pace, to best accommodate plant production schedules. With Microsoft support for Windows 7 due to end in 2020, transitioning to Windows 10 allows EcoStruxure Foxboro DCS customers to benefit from the strongest operating system with the most up-to-date cybersecurity features.
Among other new and updated features, the continuously current EcoStruxure Foxboro DCS Control Software 7.1 now includes:
• EcoStruxure Field Device Expert that improves efficiency, safety and profitability, while considerably reducing time for startup and restarts. It includes:
◦ Intelligent Commissioning Wizard, to reduce commissioning time up to 75 percent by automating HART device commissioning and documentation processes.
◦ Device Replacement Wizard to significantly reduce time and expertise to replace or commission HART devices, either individually or in bulk.
◦ Bundled HART DD library for increased security, faster device deployment, eradication of version mismatch and elimination of cybersecurity risks previously created by moving documents from the HART consortium web page into the system.
• New HMI Bulk Graphics Editor for increased operational efficiency and reliability by greatly reducing engineering hours and improving quality during testing. Use in major projects shows that replicating hundreds of displays with the new Bulk Graphics Editor saves months of man hours and improves quality by delivering highly predictable results. The Bulk Graphics Editor makes migrating from the classic FoxView HMI to the new Foxboro DCS Control HMI easier, requiring far fewer engineering hours, which reduces the time and cost to transition between technologies.
• Control Editors Activity Monitor for increased efficiency by improving communication, workflow and collaboration.
• Real-time asset health condition monitoring for increased reliability.
• Future-proof technology supporting the latest FTD 2.0 standard, which improves compatibility with digitized field devices from Schneider Electric and third-party vendors.
• New migration path, along with the new HMI Bulk Graphics Editor, simplifies the transition from existing FoxView HMI displays to the EcoStruxure Foxboro DCS Control Software 7.1 HMI platform for a continuously current and future-proof system. An upgrade migration path is available from previous Control Software Versions 5.x, 6.x and 7.0. After upgrading, users can tap into newer technologies that improve productivity, cybersecurity, efficiency and profitability.