by Gary Mintchell | Nov 21, 2018 | Internet of Things, Podcast, Technology
Last week I gave a short presentation at a breakout session of the Industry of Things East World event in Orlando. This podcast is a recap of the talk done in a slightly different style. As the fourth speaker in the afternoon surveying the audience, I switched styles to one I hope kept everyone awake.
I wanted to talk about data. Why we collect it. How we can use it. And good management practices. All in fewer than 20 minutes. Allowing time for a decent discussion at the end.
by Gary Mintchell | Oct 26, 2018 | Operations Management, Software
It’s not the technology; it’s what you do with it. Here are companies (and their engineers) who have done some cool projects with HMI/SCADA software. Inductive Automation has selected the recipients of its Ignition Firebrand Awards for 2018. The announcements were made at the Ignition Community Conference (ICC) in September.
The Ignition Firebrand Awards recognize system integrators and industrial organizations that use the Ignition software platform to create innovative new projects. Ignition by Inductive Automation is an industrial application platform with tools for the rapid development of solutions in human-machine interface (HMI), supervisory control and data acquisition (SCADA), manufacturing execution systems (MES), and the Industrial Internet of Things (IIoT). Ignition is used in virtually every industry, in more than 100 countries.
The Ignition Firebrand Awards are presented every year at ICC. The award-winning projects are selected from the ICC Discover Gallery, which features the best 15 Ignition projects submitted by integrators and industrial organizations.
“Once again, we had a lot of variety with the Firebrand Award winners this year,” said Don Pearson, chief strategy officer for Inductive Automation. “Many industries were represented — automotive, oil & gas, food & beverage, water/wastewater, and more. It was great to see quality projects in all kinds of settings.”
“It’s inspiring to see the creative applications people are building on top of the Ignition platform,” said Travis Cox, co-director of sales engineering for Inductive Automation. “Every year, people create some really interesting projects, and this year was no exception.”
These Ignition Firebrand Award winners demonstrated the versatility and power of Ignition:
- Brown Engineers (Little Rock, Ark.) took a unique approach to improving the filter backwash process for a water treatment plant at the City of Hot Springs. Brown used the Ignition SCADA platform to dramatically improve the automatic backwash, conserve water, improve water quality, and initiate collection of filter data needed to extend regulatory run-time limits. See the video here.
- ECS Solutions (Evansville, Ind.) and Blentech Corporation (Santa Rosa, Calif.) partnered on a project that brought a unified platform to JTM Food Group’s new state-of-the-art plant in Harrison, Ohio. The result was a SCADA system that included the full spectrum of process automation. The Ignition application includes material management, formulation control, batch processing, and process control. See the video here.
- Open Automation SRL (Santa Fe, Argentina) improved operations for a Cargill-owned animal nutrition plant. The project used Ignition to increase efficiency, productivity, and traceability without increasing labor. Greater access to data, less paper, and improved product quality were just a few of the benefits. See the video here.
- Roeslein & Associates (St. Louis, Mo.) helped global automotive supplier Dana Incorporated increase productivity by 30 percent at some of its sites. The project provided real-time statistical analysis and visualization of machine data to enable better and faster decision-making. The flexible solution can be leveraged by Dana in numerous additional plants. See the video here.
- Tamaki Control (Auckland, New Zealand) created a comprehensive clean-in-place scheduling system for the largest yogurt-manufacturing facility in the world: the Chobani plant in Twin Falls, Idaho. The solution increased visualization and made it much easier for operators to share information. It can also be leveraged for other uses at Chobani plants. See the video here.
- Weisz Bolivia SRL (Buenos Aires, Argentina) solved weather-related data-communication problems for the largest offshore oil operation in Argentina. Results included better access to data, easier reporting to a government agency, and streamlined processes. See the video here.
Information on all 15 Discover Gallery projects can be found here.
by Gary Mintchell | Oct 2, 2018 | Asset Performance Management, Manufacturing IT, Operations Management
This week is Emerson Global Users Exchange week in San Antonio—with a quick side trip to Houston and a tour of some refineries implementing IoT applications with Hewlett Packard Enterprise. The theme of the week is Digital Transformation just where I reside—at the convergence of OT and IT.
Emerson Automation Solutions (new-ish name for Emerson Process) continues to flesh out its drive to help customers achieve “Top Quartile” performance through Digital Transformation.
It doesn’t just talk digital transformation. The company builds out its offering through product development, services / engineering, and acquisitions. Similar to other major suppliers, it has been making strategic acquisitions rather than taking minor stakes in companies.
Mike Train, Executive President, set the themes and talked about his optimism in the business and industry. Train was recently promoted to COO of Emerson Corporation and introduced Lal Karsanbhai as the new Executive President of Emerson Automation Solutions.
My friends at Putnam Publishing are doing the show daily this year. Flash back to 8 years ago when I was still at Automation World nursing a torn quadraceps muscle doing the show daily in San Antonio. You can see the news from the team here.
Peter Zornio laid out the logic of an “Actionable Roadmap” at a subsequent press conference. The company’s PlantWeb ecosystem continues to grow and develop becoming the key element of Emerson’s Digital Transformation strategy. Below is from the press release.
The Digital Transformation Roadmap includes consulting and implementation services to help companies develop and execute a tailored digital transformation plan to reach Top Quartile performance.
“Our customers have different starting points and levels of maturity when it comes to evaluating and implementing digital transformation strategies,” said Lal Karsanbhai, executive president of Emerson Automation Solutions. “Emerson’s proven digital transformation approach provides the ultimate flexibility while pinpointing the optimum path for each customer, based on their objectives, readiness and overall digital maturity.”
In an Emerson study of industry leaders responsible for digital transformation initiatives, merely 20 percent of respondents said they had a vision, plus a clear and actionable roadmap for digital transformation. Additionally, 90 percent stated that having a clear roadmap was important, very important or extremely important. Absence of a practical roadmap was also cited as the No. 1 barrier for digital transformation projects; cultural adoption and business value round out the top three barriers to progress. While all respondents were actively conducting pilot projects, only 21 percent had moved beyond that stage into new operating standards.
Leveraging customer engagements with successful digital transformation programs, Emerson defined a structured, yet flexible approach to help customers focus on priority areas with a practical roadmap tailored to their business needs and readiness. The goal is to help companies use technology to reach Top Quartile performance, measured by optimized production, improved reliability, enhanced safety and minimized energy usage.
“There is a clear global urgency among executives to harness innovation to improve performance, but many companies feel stalled for lack of a clear path,” Karsanbhai said. “Customers who engage with our operational certainty consultants quickly gain clarity on their best bets for digital transformation and a realistic implementation plan to accelerate time to results.”
Digital Roadmap Combines Technology with Industry Expertise
Emerson’s Digital Transformation Roadmap has two focus areas: business drivers and business enablers. Business drivers look at capabilities and performance relative to industry benchmarks in key areas: production management, reliability and maintenance, safety and security, and/or energy and emissions. The business enabler focus looks at capabilities in organizational effectiveness and systems and data integration. For each, Emerson has identified detailed criteria to measure customer performance along the digital journey – from conventional to best-in-class to the highest level: digitally autonomous operations.
Companies can start the digital transformation journey wherever they are, from starting small in one facility to address key issues, such as pump health or personnel safety mustering; to exploring companywide programs across an entire business driver, such as reliability of critical assets; to driving enterprise-wide adoption of cloud-based technologies and analytics for overall business transformation.
Emerson’s Operational Certainty Consulting Group provides a host of services, from Digital Transformation Jumpstart workshops to deep-dive change management to deployment and adoption of new digitally enabled toolsets. Customers partner with Emerson not only for its consulting expertise, but also to implement its Plantweb™ digital ecosystem, which offers a robust software, data analytics, and product technology and services portfolio to solve real-world problems while improving plant performance.
Emerson’s proven capability is bolstered by a global implementation team that includes more than 80 solutions architects and analytics integration engineers, backed by a project and service engineering workforce that exceeds 8,400. Important foundations for digital transformation have been established with producers around the world. For example, Emerson has collaborated with customers to deploy more than 37,000 wireless network installations and over 175 integrated reliability platforms and applications, to name a few.
by Gary Mintchell | Sep 26, 2018 | Internet of Things, Leadership
Browsing LinkedIn, something I seldom do, I saw this image from a company called Seebo. “Where IoT Projects Fail.” Interesting, but can’t these be summed up in a word or two?
Try “management” or “leadership”.
The recurring theme I’ve found in my consulting and qualification process for a client concerns not really understanding what Internet of Things (IoT) means. Nor do they always understand realistically what benefits could accrue. Or what technologies fit.
A client one time hired me to justify a decision already made—in their minds at least—about acquisitions that would enter them into the IoT market. Another looked for use cases and settled on one not understanding the complexity of that use case.
On the other hand, a wise CTO once explained to me about themes for the company’s annual conference. One year might be IoT and another digitalization. He said they looked at the current themes in the market and then figured how their products fit, and presto—a theme.
If you are in an IoT project or contemplating one as a user or looking at a product and service plan as a supplier, step back and try using good basic management first. Organizing, defining, staffing.
Here is the list from the image:
- Failure to capture business opportunities
- Unclear and incomplete use cases
- Systems are too complex to communicate
- Missing critical data
- Unable to extract actionable insights
- Unable to identify root cause of product malfunctions
- Ensuring market-fit and early buy-in
- High cost of mistakes
- Prototyping products not technically or financially feasible
- Skills or capacity gap
- Aligning and syncing teams
- Detailed and complete spec docs and keeping them up-to-date
by Gary Mintchell | Jun 21, 2018 | Internet of Things, Manufacturing IT
Antonio Neri, CEO and President of Hewlett Packard Enterprise (HPE), used the phrase “Data is the new currency, memory the new gold” in his keynote to the company’s annual US customer conference Discover in Las Vegas in June. Just one of the many places I’ve been lately.
If you haven’t planned for data in your machine and process control designs, you had best begin.The race for improved operations performance is on now.
We talk often of “edge” in the world of Internet of Things or Industrial Internet of Things. The edge has many definitions, but it can be defined as any place outside a data center. PLCs, for example, not only perform logic control, but they also aggregate data from perhaps thousands of sensors. SCADA devices and industrial computers also collect and channel data from a few to many sensors and data sources.
Business operations managers are hungry for this data to feed their information systems that in turn fuel their business decisions. Data in context is information. Information correctly presented to decision makers leads to better, faster decisions—and a competitive edge.
This search for competitive edge has moved me from an emphasis on control and automation (something we still need to do well) to Industrial Internet of Things. The IIot is taken by many as a similar strategy to Industrie 4.0 or Smart Manufacturing or whatever different countries call their strategies. This means I’m looking at a new generation of edge computing, enhance networking standards, human-centered design for mobile visualization of data, and even Augmented Reality (AR) and Artificial Intelligence (AI). These are not far-out technologies any longer. They are here and applications are growing.
Neri talked about the future as edge-centric, cloud-enabled, data-driven. He said the edge is where the action is, where the data is created. HPE is going to invest $4 billion in the intelligent edge over the next 4 years.
The company announced a new edge computing device with enterprise grade computing power (far beyond a PC) plus up to 48TB (yes that’s Tera not Giga) of memory. Oh, and it also comes in an environmentally hardened package. The CTO of Murphy Oil talked of using these on off-shore oil rigs.
Texmark Chemicals is a Houston, Texas based petrochemical refiner. I had several opportunities to talk with them about their IoT projects. They orchestrated an ecosystem of 12 suppliers initially to instrument critical pumps in their process in order to achieve predictive maintenance. This potentially saves the company millions of dollars by avoiding catastrophic failure. (Note: I previously wrote about the Texmark use case here–and expect more to come.)
Back to the announcement from HPE about the new edge product—a family of edge-to-cloud solutions enabled by HPE Edgeline Converged Edge Systems to help organizations simplify their hybrid IT environment. By running the same enterprise applications at the edge, in data centers and in the cloud, the solutions allow organizations to more efficiently capitalize on the vast amounts of data created in remote and distributed locations like factories, oil rigs or energy grids.
(Dr. Tom Bradicich wrote a blog post you can find here.)
HPE’s new edge-to-cloud solutions operate unmodified enterprise software from partners Citrix, GE Digital, Microsoft, PTC, SAP and SparkCognition, both on HPE Edgeline Converged Edge Systems – rugged, compact systems delivering immediate insight from data at the edge – and on data center and cloud platforms. This capability enables customers to harness the value of the data generated at the edge to increase operational efficiency, create new customer experiences and introduce new revenue streams. At the same time, edge-to-cloud solutions enabled by HPE Edgeline simplify the management of the hybrid IT environment, as the same application and management software can be used from edge to cloud.
“The edge is increasingly becoming a centerpiece of the digital enterprise where things and people generate and act on massive amounts of data,” said Dr. Tom Bradicich, Vice President and General Manager, IoT and Converged Edge Systems, HPE. “Our edge-to-cloud solutions help bring enterprise-class IT capabilities from the data center to the edge. This reduces software and IT administration costs, while accelerating insight and control across the organization and supply chain.”
HPE also announced the HPE Edgeline Extended Storage Adapter option kit, adding up to 48 terabytes of software-defined storage to HPE Edgeline Converged Edge Systems. This enhancement enables storage-intensive use cases like artificial intelligence (AI), video analytics or databases at the edge, while leveraging industry-standard storage management tools such as Microsoft Storage Spaces, HPE StoreVirtual VSA, and VMware vSAN.
