Industry 4.0 and Industrial Internet of Things describe manufacturing strategy as much as technology. But as I occasionally write here and write daily on my spiritual practices blog, there is a people side to all this technology and strategy.
Technologists (most people reading this site) tend to talk technology. Then they get carried away and think that technology will replace all need for people. Hence the science fiction writing and movies on that theme.
Arianna Huffington (the Huffington Post) attended the recent gathering of the world’s elite in Davos, Switzerland at the World Economic Forum. She discovered manufacturing and Industry 4.0. But she wrote a book on the power of getting enough sleep for your essential health. She managed to weave a story from both threads.
The dominant topic of discussion this year — both inside the talks and panels and outside, as well — was transition. Klaus Schwab, the Forum’s founder and executive chairman, captured this sense — the possibilities as well as the challenges — with this year’s theme, the Fourth Industrial Revolution.
Schwab describes this new period as “the fusion of technologies across the physical, digital and biological worlds which is creating entirely new capabilities and dramatic impacts on political, social and economic systems.” It’s an era of automation, constant connectivity, and accelerated change, in which the Internet of Things meets the Smart Factory.
Yes, this new manufacturing strategy, which I must say seems to focus on what we call discrete manufacturing (think autos, airplanes), seeks to go deeper in employing digital technologies. In many ways it is following the lead of process industries (they hate the word manufacturing even though that is a government classification) which always seems to lead in applying math and rigor to its processes.
She continues, quoting Mark Benioff of Salesforce about people and technology:
If the Fourth Industrial Revolution will be defined by speed, connectivity, and change, there’s also a need for a countervailing force. Salesforce CEO Marc Benioff said, “Speed is the new currency of business.” But as he also said, the Fourth Industrial Revolution begins with trust, which has been at the heart of business as long as business has existed — and will only become more important in our more transparent ever-faster-moving world. Benioff’s point exemplified a larger truth of this year’s Forum, that far from being add-ons, a focus on trust, transparency, purpose, and a deeper kind of connection are central to meaningful success in the Fourth Industrial Revolution.
I’ve been writing about trust and transparency on my other blog this week. Sometimes we forget basic human values in our pursuit of either technology or profits.
Oh, yes, and she adds that we all need enough sleep each night to perform at our peak. You can go buy her book–or sleep on it.
We are closing in on February and time to start thinking about the ARC Industry Forum in Orlando. I went to my first one in 1998 and have my airline and hotel reservations for this edition.
Given the demise of general industry trade shows, there are precious few opportunities to see a large cross section of the automation and control industry. This is one.
I have 2 or 3 appointments set. If you are there, ping me. Maybe we can do a “meet up” in the lounge before everyone splits for dinner or something. Or stop me to chat during the week. ARC has once again planned an afternoon of press conferences for its sponsors. I’ll arrive in time to listen if you are presenting.
The 20th Annual ARC Industry Forum has the theme, “Industry in Transition: Navigating the New Age of Innovation”.
The conference is February 8-11, 2016 at the Renaissance Sea World in Orlando, Florida.
ARC says, “New information technologies such as Industrial Internet of Things (IIoT), Smart Manufacturing, Industrie 4.0, Digitization, and Connected Enterprise are ushering in a new age of innovation. These concepts are clearly moving past the hype, where real solutions are emerging backed by strong business cases. Expect to see innovations in smarter products, new service and operating models, new production techniques, and new approaches to design and sourcing. Join us to learn how this industrial transformation will unfold and what other companies are doing today to embrace innovation and improve their business performance.”
Questions they expect to address:
- How will inexpensive, easy-to-install sensors change existing products and plants?
- Will cyber security concerns impede disruptive innovation?
- What kind of intelligence will machines have and what value will this bring?
- What role will Wi-Fi and LTE play?
- How do Big Data and predictive and prescriptive analytics enable operational change?
- What is the opportunity in aftermarket services?
- What software capabilities are needed to achieve transformational change?
- Which industries are already changing?
- What steps can organizations take to foster innovative thinking?
Forum’s Keynote Presentations
Michael Carroll, Vice President, Innovation & Operations Excellence, Georgia-Pacific
Michael joined Georgia-Pacific in 2010 to focus his technological and entrepreneurial talents on innovation and leadership. Prior to that he and a partner formed McTech Group, a company focused on innovative products for the building products and construction industry. In addition to his Executive Vice President responsibilities, Michael formed a Joint Venture designed to sell consumer “DIY” products to big box retailers like Wal-Mart, Home Depot, and Lowe’s. Previous positions include Director of Operations at Riverwood International, CEO of North and South American Operations at Shepherd, and Principal Change Agent at Mead Paper.
Sandy Vasser, Facilities I&E Manager, ExxonMobil Development
Sandy has been with Exxon or ExxonMobil for over 35 years and has been involved in a number of Upstream projects covering offshore facilities, onshore facilities, and cogeneration facilities. He currently manages a team of about 120 electrical and I&C professionals responsible for the design, installation, and commissioning of electrical generation and distribution systems, process control systems, and safety instrumented systems for all major ExxonMobil Upstream capital projects. This team is also responsible for developing, promoting and implementing strategies, practices, processes, and tools for successfully executing project automation and electrical activities.
Rob High, Vice President and Chief Technology Officer, Watson Solutions, IBM Software Group
Rob has overall responsibility to drive Watson Solutions technical strategy and thought leadership. He works collaboratively with the Watson engineering, research, and development teams across IBM. Prior to joining Watson Solutions, Rob was Chief Architect for the SOA Foundation and member of the IBM Academy of Technology. He championed an open industry architectural definition of the principles of business and IT alignment enabled by SOA and business process optimization, as well as ensuring IBM’s software and services portfolio is architecturally grounded to enable for efficient SOA-based solutions. Rob has 37 years of programming experience and has worked with distributed, object-oriented, component-based transaction monitors for the last 26 years.
Allen-Bradley CompactLogix I/O
I am spending the week with Rockwell Automation at its annual user conference and trade fair. Today was Integrated Control Architecture and Connected Enterprise day. More later on Connected.
The last two posts have been Rockwell and there is enough information for me to post many more times. We’ll see when I’ve run the course.
Someone asked me in the press room what was the most outstanding thing from the day on Wednesday, the first day of Automation Fair. The prompt response, “CompactLogix I/O.” First thing in the morning a trusted contact told me to check it out. I was not disappointed. I don’t have all the specs, but it is blazing fast.
Below are summaries of three announcements from Wednesday–Integrated Architecture which includes the I/O discussion, partnership with Fanuc, and some more detail about the “modern DCS” referred to a couple of posts ago on the Plant PAx product.
The expanded next-generation Integrated Architecture portfolio from Rockwell Automation includes a newly released next-generation Allen-Bradley controller, graphic terminal, servo drive and distributed I/O system, as well as the latest release of the Rockwell Software Studio 5000 and FactoryTalk software offerings.
“We’ve invested significantly in the Integrated Architecture portfolio to help our customers prepare their production environments for future growth, and help machine builders simplify machines and get them to market faster,” said Dan DeYoung, market development director, Integrated Architecture, Rockwell Automation. “With this new portfolio and our ongoing collaboration with our PartnerNetwork members, customers have the tools to more easily design, operate and maintain smart, high-performing systems.”
The new additions to the portfolio include:
- The latest release of the Studio 5000 software includes three new applications: Studio 5000 Architect, Studio 5000 View Designer and Application Code Manager. These applications, along with the Studio 5000 Logix Designer application released in 2012, bring more functionality together into one environment to simplify and speed system development. In addition, the latest releases of FactoryTalk ViewPoint Mobile software and FactoryTalk VantagePoint Mobile software allow users to more easily engage with their production information on mobile devices.
- The Allen-Bradley ControlLogix 5580 controller provides up to 45 percent more application capacity and includes an embedded 1-gigabit Ethernet port to support high-performance communications, I/O and applications with up to 256 axes of motion. The new port and additional capacity cuts the amount of control and communications hardware required, reducing system complexity, costs and required panel space.
- The Allen-Bradley Kinetix 5700 servo drive is a single-platform alternative to using multiple servo drives for large custom machines with high axis-count and power requirements. This can reduce cabinet-space requirements by up to 70 percent and wiring requirements by as much as 60 percent.
- The Allen-Bradley Bulletin 5069 Distributed Compact I/O system with two 1-gigabit Ethernet ports scans 10 times faster than previous versions for greater productivity. The system can connect to as many as 31 modules without the need to expand.
- The Allen-Bradley PanelView 5500 graphic terminal provides a modern design and enhanced integration with Logix controllers using the Studio 5000 View Designer application. This integration improves programming efficiency because engineers can enter configuration information once and use it for the entire automation design.
The expanded portfolio also incorporates a number of security features to help manufacturers and industrial operators protect their facilities, assets and intellectual property.
Rockwell – Fanuc Collaboration
Rockwell Automation and FANUC are collaborating on several new initiatives to help customers realize productivity gains.
“Industrial IoT technologies are delivering on the promise of enabling operators to have access to the timely, contextualized information they need in order to prevent downtime,” said Sujeet Chand, senior vice president and chief technology officer, Rockwell Automation. “Working with FANUC, we can help customers gain access to the data that previously was either unavailable or trapped in their operations. This data is drawn from smart industrial assets, and then contextualized and delivered with actionable information related to asset health, performance and energy usage.”
Major strides have been made in monitoring and managing remote assets to further extend The Connected Enterprise.
“Companies are continuously searching out the latest manufacturing technologies that will help them drive future growth, innovation and profitability,” said Rick Schneider, president and CEO, FANUC America. “In the future, products such as Zero Downtime (ZDT), a cloud-based application, could virtually eliminate unexpected production downtime.”
ZDT from FANUC demonstrates how cloud-based data analysis can predict and prevent unexpected downtime from automation equipment in a connected infrastructure built upon Cisco and Rockwell Automation products.
New system capabilities include a more productive design environment to enhance automation productivity; easier adoption of new enabling technologies to improve user experience; and enhanced control capabilities to help meet operational goals.
“The latest release of our modern DCS platform focuses heavily on improving automation productivity,” said Jason Wright, PlantPAx system marketing manager, Rockwell Automation. “The system now includes pre-built process control strategies to help users greatly reduce the effort and risk to deploy new applications, which helps improve their time-to-market.”
Increased Automation Productivity: The system now includes expanded estimation, design and development guides. New pre-built control strategies developed within the Rockwell Automation library of process objects provide a consistent user and maintenance experience.
Improved User Experience: Leveraging network improvements and built-in mobility, the PlantPAx system delivers an improved, reliable user experience. Expanded industrial Ethernet switches support Layer 3 topologies, enhancing scalability for a variety of applications. Smaller control systems can now be integrated into larger enterprise networks with a common, fully supported network infrastructure. The network switches include embedded Cisco technology to integrate and translate operations technology (OT) and information technology (IT). This makes it easier for process operators to configure and manage system networks.
The PlantPAx system also now includes a mobile component that enables users to create displays and interact with process data across any HTML5-compliant mobile platform. The software is responsive to the user’s specific device, allowing operators and plant managers to access and view performance metrics and data analytics in their preferred format.
Enhanced Control: New built-in control features – such as integrated PlantPAx model predictive control (MPC), alarm management and batch management – now operate in a common environment, helping to improve plant efficiencies and operational performance. Control-based PlantPAx MPC provides the ability to predictably manage external and complex process disturbances, and maximize process performance up to process constraints. This allows continuous improvements within the process while reducing waste and variability.
The updated system also leverages the recently introduced batch application toolkit to help reduce the risk, time and cost of implementing batch control systems. Containing documentation, application examples and sample code, the toolkit gives engineers a starting point to build and maintain a consistent batch control system. It also provides flexibility to customize system elements for increased functionality.
I’m wrapping up my coverage of the EHS Today Safety Leadership Conference held last week in Greenville, SC. I covered the Technology Track sponsored by Rockwell Automation.
Steve Ludwig, safety program manager at Rockwell Automation, presented on the impact of the evolving workforce on safety.
“We are facing a shortage of skilled workforce, and it is a global issue,” began Ludwig. “The average age of skilled worker is 56, and this demographic is prone not to delay retirement. Add to this the fact that birth rates have declined for the last 35 years, so we do not have the usual situation of increasing population to fuel economic growth.
There are now more inexperienced workers who are more at risk. This is not just a situation for your plant, but also for the plants of all your suppliers. Businesses face supply chain interruption, reputational / brand risk. Businesses face not only an aging workforce that may be prone to injury, but also a younger, less experience workforce that tend to have more frequent acute injuries.
When Ludwig asked attendees, “How do we improve with a changing workforce?” most responded that they were proactively going out to schools to recruit and evangelize manufacturing. They were also assuming much responsibility for helping train young people.
Connected enterprise for safety
Jeff Winter of system integrator Grantek discussed connecting the enterprise for safety. He noted a problem that continues to exist is that dashboards rely on manual data collection and input.
There are three “Eras” of safety technology–initially just preventing access; then detecting access (something that increased both safety and productivity); today controlling access (integrated safety into machine, about as productive as you can get).
“EHS must get a chair at the table when data collection and analysis are being discussed in the plant or company,” he concluded. Winter continued with this advice, “Ask for data on actions such as emergency stops, intrusions, shut downs.”
Beyond lockout, tagout
Turning to electrical safety specifically, Jimi Michalscheck business development manager for safety looked at going beyond Lockout Tagout (LOTO). His point was how to balance safety with production. He posited a system of engineered safety control, which he called a new way of addressing LOTO.
“If you haven’t designed an alternative, then you must use LOTO (OSHA). To prevent unexpected restart of the equipment during service from causing harm to employees.”
Engineering safe alternatives. Think of your machine as simple components. For example, a case packer. Notorious for frequent need for getting into it, so also for citations. Using Alternative Protective Measure (APM), design the machine in components. Task specific, area specific, documented (know that the service area is protected for the reach of the worker). APM developed must provide the same or greater level of protection as LOTO in order to comply with CFR1910.147.
Here is the official wrap of the recent Honeywell Users Group (HUG) Americas symposium. It was the 40th anniversary celebrated with the theme “40 Years of Innovation.” Officially “more than 1,200 people” attended the event.
I have written a couple of times during the week here and here. This information comes from a press release issued last week. Along with some executive quotes is a note that Honeywell Process Solutions has been developing and implementing technologies for the Industrial Internet of Things (IoT) for many years.
During the event, Honeywell announced a collaboration with Intel Security McAfee which will expand its industrial cyber security capabilities to help defend customers from the increasing threat of cyber attacks.
“The process manufacturing industries are facing a critical time in history due to a convergence of factors such as security threats, a shrinking workforce and lower oil prices, among others,” said Vimal Kapur, president of Honeywell Process Solutions (HPS). “These factors are driving a greater need for our technologies and services because they’re designed to help companies conduct operations more efficiently, and with less risk.”
The conference revolved around three core technology themes directly impacting companies’ abilities to successfully adapt to changing market conditions: digital transformation and smart operations, system evolution and risk reduction, and smart instrumentation with smart integration. Throughout the week, Honeywell executives, technology experts and customers explained how these core areas can turn technology buzzwords like Big Data and Industrial Internet of Things (IoT) into practical applications.
“HPS has been leveraging the concepts and technologies behind the Industrial IoT as part of the vision that we have been evolving towards for several years,” Bruce Calder, HPS chief technology officer told general session attendees. “In order to run a reliable operation that continues to improve performance and business results, you will need to install smarter field devices, achieve more connectivity, collect more data and find ways to use that data to run a smarter operation.”
Calder also gave attendees a first look at HPS’ first native app for mobile devices and tablets that connects to different sources and applications across the company’s portfolio to create a more-intuitive mobile experience for plant workers. Mobility is part of the initiative to introduce a suite of apps that, along with new cloud functionalities, will enhance existing solutions to deliver better business efficiencies.
The conference agenda included a wide range of presentations from Honeywell customers ExxonMobil, Chevron, Reliance, DuPont, Great River Energy, Syngenta, Genentech, Valero and others. These presentations – covering everything from wireless applications and cost-effective control system migrations, to alarm management and energy conservation – highlighted how real-world manufacturers have used Honeywell technology to streamline their businesses by generating and analyzing the most-meaningful data from their operations.
In addition to these presentations, attendees received a first-hand look at some of Honeywell’s newest technologies designed to change the way their enterprises work, generate the right data to inform decisions, and reduce overall risks. Highlighted technologies included:
- UniSim Competency Suite – the newest addition to the UniSim family of training technology, which now includes 3D virtual environment capabilities to provide realistic experiences.
- DynAMo Alarm and Operations Suite – software that leverages more than 20 years of alarm management experience in the process industries to help users reduce overall alarm count by as much as 80 percent, identify maintenance issues and increase visibility of critical alarms that require urgent attention.
- Honeywell Industrial Cyber Security Risk Manager – the first digital dashboard designed to proactively monitor, measure and manage cyber security risk for process control systems.
- SmartLine Level Transmitter – the newest addition to Honeywell’s line of modular, smart field instrumentation designed to integrate with control systems to provide benefits such as extended diagnostics, maintenance status displays, transmitter messaging and more.
- The EC 350 PTZ Gas Volume Corrector – the first member of a new line of high-performance electronic volume correctors (EVCs) that more accurately measure natural gas delivered to industrial customers, helping them meet government and industrial standards.
Since I have to follow the Honeywell User Group (number 40, by the way) from afar, I’m relying on tweets and any Web updates or articles I can find.
So far, Walt Boyes (@waltboyes, and Industrial Automation Insider) has posted a few things to Twitter, mostly slides from presentations that are barely legible; Aaron Hand (Automation World) has posted a few tweets; Mehul Shah (LNS Research) has a couple of tweets—interestingly saying he things as an analyst that Honeywell has all the elements of a complete IIoT solution—hmmm; and Larry O’Brien, analyst at ARC Advisory Group has published a few tweets. If they would post links to articles in the tweets, that would be interesting.
Putman Publishing (Control magazine) once again is doing a digital “show daily” and therefore is posting several articles a day and blasting out an email daily.
Walt sent a tweet about obsolescence of open systems to which software geek Andy Robinson (@Archestranaut) replied. I didn’t understand until I saw Paul Studebaker’s article online (see below). The open systems in use today are getting long in the tooth. They feature Microsoft Windows XP—evidently never getting upgrades. Now there is no Microsoft support, the world has moved on, and all these DCS interfaces based on PCs are getting ancient.
Paul Studebaker, Control magazine’s editor-in-chief, reported on the keynote presented by Vimal Kapur, Honeywell Process Solutions president.
“ ‘Since Q4 of last year, since oil prices have changed, capital investments have been reduced’, said Kapur. Investments were up about 20% in 2010 and 2011, and remained flat through 2014, but so far, 2015 is down about 12%. Operational expense spending is also off.”
Kapur described how Honeywell is helping operators meet those challenges with strategies, technologies and services.
1. Honeywell will expand the role of the distributed control system (DCS). Now, the DCS has become a focal point of all control functions, taking on the functionality of PLC, alarm, safety, power management, historian, turbine control and more. Having a single system and user leverages scarce resources, and a single platform leveraging standards does more with less.
2. Cloud computing is becoming a standard part of HPS automation projects, with a logarithmic increase in the number of virtual machines in the HPS cloud over the past two years.
3. While process safety management has always depended on detecting unsafe situations, preventing them from causing an incident or accident and protecting people from any consequences.
4. For cybersecurity, Honeywell has created a team of specialists who can do audits, identify vulnerabilities and recommend solutions. But cybersecurity requires constant monitoring, so consider using a cybersecurity dashboard, “a step toward enabling a much higher level of proactivity by identifying cyber threats before it’s too late,” Kapur said.
5. Standardization holds great promise for reducing cost and time to production by allowing pre-engineering of control systems.
6. Honeywell continues to expand and refine its field device products to offer a complete line of smart instrumentation that can be preconfigured and use the cloud for fast auto-commissioning, and that have full auto-alerts and diagnostics to enable predictive maintenance.
7. OPC UA is becoming the key to leveraging the Industrial Internet of Things (IIoT).
8. Kapur told attendees their existing investments are not fully leveraged.
9. Expansion of mobility is changing workflows and the responsibilities of individuals.
10. Honeywell is driving more outcome-based solutions in services.
Jim Montague, Control executive editor, reported on the technology keynote.
(Jim, you need to update your bio on the Control Global page)
“This is a transformative time in process controls, rivaling the open process systems introduced in the early 1990s,” said Bruce Calder, new CTO and vice president of HPS, in the “Honeywell Technology Overview and New Innovations” session on the opening day of Honeywell User Group (HUG) Americas 2015, June 22 in San Antonio, Texas. “Today, the words are cloud, big data, predictive analytics and IoT, but this situation is similar to when Honeywell pioneered and invented the DCS in the early 1970s. For instance, our Experion PKS integrates input from many sources, which is what big data and the cloud aim to do, and our Matrikon OPC solution gives us the world’s leading contender for enabling IoT in the process industries. And all these devices are producing lots more data, so the question for everyone is how to manage it.
“This is all part of the digital transformation that Honeywell has been leading for years. So Experion and our Orion interfaces enable IoT because they collect and coordinate vast amounts of data, turn it into actionable information and turn process operators into profit operators. At the same time, Honeywell enables customers to retain their intellectual property assets as they modernize and do it safely, reliably and efficiently.”
1. The downturn in the price of a barrel of oil whose impact we first noticed with the decline in attendance at the ARC Forum in February has really impacted Honeywell’s business.
2. Honeywell, much like all technology suppliers, addresses the buzz around Internet of Things by saying we do it—and we’ve always done it. (mostly true, by the way)
3. Otherwise, I didn’t see much new from the technology keynote—at least as it was reported so far.
4. I got some good reporting, but It’s a shame that all the media has retrenched into traditional B2B—reporting what marketing people say. You can read that for yourself on their Websites. Context, analysis, expertise are all lost right now. Maybe someone will spring up with the new way of Web reporting.
At any rate, it sounds like a good conference. About 1,200 total attendance. Even with oil in the doldrums, the vibes should be strong.