Integrated Service Delivery Model Assess, Manage and Optimize Automation Assets

Continuing coverage of this week’s Honeywell Process Virtual Technical Experience.

[Note: You can have these posts sent to you via email simply by signing up at the appropriate link. There is normally one post per day, however covering two conferences and a couple of press conferences this week necessitates a little extra coverage.]

Continuing the theme of “remote” and also support and services, Honeywell Process Solutions announced this week Enabled Services program powered by Honeywell Forge. This automation lifecycle services offering focuses on ensuring Industrial Control System (ICS) health, reliability and compliance.

In brief:

  • End-to-end solution enables remote preventive maintenance and support
  • Plant operators can reduce number of incidents per year by 40% and improve total cost of ownership

“Honeywell developed the Enabled Services program as a subscription-based service for ICS users dealing with increasing system complexity, an aging industrial workforce and the constraints imposed on plant operations by global health concerns,” said Mark Dean, director of offering management, Honeywell Process Solutions. “Through this Enabled Services offering, Honeywell’s experts can conduct rapid analysis and make fast recommendations to solve the issues and be onsite only when necessary. Honeywell has created a powerful tool for customers to significantly improve maintenance efficiency and redirect expensive resources to high priority corrective maintenance.”

Honeywell estimates it’s Enabled Services solution can deliver increased value by reducing the number of incidents per year by 40%, with a net decrease in total cost of ownership of 15%. These capabilities not only help improve system health, performance and compliance, but also allow customers to redirect existing high skill resources to use more time to work on systems improvements and to focus on their core business.

Based on Honeywell’s step-change Lifecycle Solutions & Services delivery model, which responds to customer-driven feedback from around the world, the Enabled Services solution is designed around three key pillars:

  • System health and performance – in other words, what is going wrong in the plant
  • System compliance — why it is going wrong
  • Prescriptive maintenance and remediation – how the issues can be resolved.

Honeywell’s program uses intuitive and consistent dashboards powered by Honeywell Forge technology, which provides users with real-time intelligence to enable peak performance. It also employs remote connection and/or local data collection, predictive and diagnostic tools, and global resource centers – all to support improved operational and business performance.

Enabled Services remote support capabilities were specifically developed with security in mind. The services employ protected network connections built on industry recognized standards, such as IEC 62443, to transfer data from the customer’s site to Honeywell’s global resource centers.

Through its proactive approach, Enabled Services offer improved efficiencies compared with ad hoc maintenance regimens, homegrown solutions that compromise migration readiness, and/or delaying service and repairs until assets fail. This comprehensive solution can help company executives, plant managers and control engineers to:

  • Understand and improve operational effectiveness and risk profiles
  • Leverage operational benefits from systems, applications and people
  • Focus efforts on core competencies by deploying suitably skilled resources
  • Improve the health, security and stability of control assets

Honeywell’s Enabled Services offering includes two levels of support to meet diverse customer requirements. Enabled Services Enhanced employs fully connected systems and offers continuous insights on system health, performance and compliance with actionable recommendations. Enabled Services Essential is intended for a non-connected system and offers less frequent updates.

AI Research For Tomorrow’s Production

While at the Hannover Messe Preview last week in Germany, I talked with the representatives of a German consortium with the interesting name of “it’s OWL”. Following are some thoughts from the various organizations that compose the consortium.

Intelligent production and new business models

Artificial Intelligence is of crucial importance for the competitiveness of industry. In the Leading-Edge Cluster it’s OWL six research institutes cooperate with more than 100 companies to develop practical solutions for small and medium-sized businesses. At the OWL joint stand (Hall 7, A12) over 40 exhibitors will demonstrate applications in the areas of machine diagnostics, predictive maintenance, process optimization, and robotics.

Prof. Dr. Roman Dumitrescu (Managing Director it’s OWL Clustermanagement GmbH and Director Fraunhofer IEM) explains: “Our research institutes are international leaders in the fields of machine learning, cognitive assistance systems and systems engineering. At our four universities and two Fraunhofer Institutes, 350 researchers are working on over 100 projects to make Artificial Intelligence usable for applications in industrial value creation. With it’s OWL, we bring this expert knowledge into practice. In 2020, we will launch three new strategic initiatives worth 50 million € to unlock the potential for AI in production, product development and the working world for small and medium-sized enterprises.”

In the initiative ‘AI Marketplace’ 20, research institutes and companies are developing a digital platform for Artificial Intelligence in product development. Providers, users, and experts can network and develop solutions on this platform. In the competence centre ‘AI in the working world of industrial SMEs’, 25 partners from industry and science make their knowledge of work structuring in the context of AI available to companies.

Learning machine diagnostics and ‘SmartBox’ for process optimization

The Institute for Industrial Information Technology at the OWL University of Applied Sciences and Arts will present new results for intelligent machine diagnostics at the trade fair. Using a three-phase motor, it will be illustrated how learning algorithms and information fusion can be used to reliably identify, predict, and visualize states of technical systems. Patterns and information hidden in time series signals are learned and presented to the user in an understandable way. Inaccuracies and uncertainties in individual sensors are solved by conflict-reducing information fusion. For example, motors can be used as sensors. Within a network of sensors and other data sources in production plants, motors can measure the “state of health” and analyze the causes of malfunctions via AI. This reduces scrap and saves up to 20 percent in materials.

The ‘SmartBox’ of the Fraunhofer Institute IOSB-INA is a universally applicable solution that identifies anomalies in processes in various production environments on the basis of PROFI-NET data. The solution requires no configuration and learns the process behavior.

With retrofitting solutions of the Fraunhofer Institute, companies can prepare machines and systems in their inventory for Industrie 4.0 applications without major investment expenditure. The spectrum ranges from mobile production data acquisition systems in suitcase format for studies of potential to permanently installable retrofit solutions. Intelligent sensor systems, cloud connections and machine learning methods build the basis for data analysis. This way, processes can be optimised and more transparency, control, planning, safety, and flexibility in production can be achieved.

Cognitive robotics and self-healing in autonomous systems

The Institute of Cognition and Robotics (CoR-Lab) presents a cognitive robotics system for highly flexible industrial production. The potential of model-driven software and system development for cognitive robotics is demonstrated by using the example of automated terminal assembly in switch cabinet construction. For this purpose, machine learning methods for environ- mental perception and object recognition, automated planning algorithms and model-based motion control are integrated into a robotic system. The cell operator is thereby enabled to perform different assembly tasks using reusable and combinable task blocks.

The research project “AI for Autonomous Systems” of the Software Innovation Campus Paderborn aims at achieving self-healing properties of autonomous technical systems based on the principles of natural immune systems. For this purpose, anomalies must be detected at runtime and the underlying causes must be independently diagnosed. Based on the localization it is necessary to plan and implement behavioral adjustments to restore the function. In addition, the security of the systems must be guaranteed at all times and system reliability must be increased. This requires a combination of methods of artificial intelligence, machine learning and biologically inspired algorithms.

Predictive maintenance and digital twin

Within the framework of the ‘BOOST 4.0’ project, the largest European initiative for Big Data in industry, it’s OWL is working with 50 partners from 16 countries on various application scenarios for Big Data in production. it’s OWL focuses on predictive maintenance: thanks to the systematic collection and evaluation of machine data from a hydraulic press and a material conveyor system, it is possible to identify patterns in the production process in a pilot company. The Fraunhofer IEM has provided the technological and methodological basis. And successfully so: over the past two years the prediction of machine failures has been significantly improved in this specific application by means of machine learning methods. The Mean Time To Repair (MTTR) has already been reduced by more than 30 percent. The Mean Time Between Failures (MTBF) is now six times longer than before. A model of the predictive production line can be seen at the stand.

The digital twin is an important prerequisite for increasing the potential for efficiency and productivity in all phases of the machine life cycle. Companies and research institutes are working on the technical infrastructure for digital twins in an it’s OWL project. Digital descriptions and sub-models of machines, products and equipment as well as their interaction over the entire life cycle are now accessible thanks to interoperability. Requirements from the fields of energy and production technology as well as existing Industrie 4.0 standards and IT systems are taken into account. This is expected to result in potential savings of over 50 percent. At the joint stand, Lenze and Phoenix Contact will use typical machine modules to demonstrate how digital twins can be used to exchange information between components, machines, visualisations and digital services across manufacturers. Interoperability proves for the first time how the combination of data can be used to create useful information with added value for different user groups. For example, machine operators and maintenance staff can detect anomalies and receive instructions for troubleshooting.

Connect and get started – production optimization made easy

The cooperation in the Leading-Edge Cluster gives rise to new business ideas that are developed into successful start-ups. For example, Prodaso—a spin-off from Bielefeld University of Applied Sciences—has developed a simple and quickly implementable solution for the acquisition and visualization of machine and production data. The hardware can be connected to a machine in a few minutes via plug-and-play. The machine data is displayed directly in the cloud.

Prodaso has succeeded in solving a central challenge: Until now, networking machines from different manufacturers have been complex and costly. The Prodaso system can be retrofitted to all existing systems, independent of manufacturer and interface. In addition, the start- up also provides automated analysis and optimization tools. This enables companies to detect irregularities and deviations in the process flow at an early stage and to initiate appropriate measures. The company, founded in 2019, has already connected approximately 100 machines at companies in the manufacturing industry.

ABB Updated MOM

ABB Updated MOM

Suppliers of manufacturing software, some from surprising places, are putting sizable investments into products that will help customers reap the rewards of digitalization. Today, I’m looking at both ABB and Emerson Automation Solutions. Previously I checked out GE Digital and Rockwell Automation. Each has taken a slightly different course toward the goal, but notice the common thread of enhancing software products to help customers prosper.

ABB enhances manufacturing management technology

The new version of ABB Ability Manufacturing Operations Management will offer new features including:

  • Enhanced user experience based on new HTML 5 web client;
  • A new smart interactive dashboard application that provides greater visibility and collaboration;
  • A new statistical process control (SPC) application, to determine if each process is in a state of control;
  • A new Batch Compare application – for advanced batch analysis.

“ABB Ability Manufacturing Operations Management is a comprehensive, scalable and modular software suite that optimizes visibility, knowledge and control throughout the operations domain,” said Narasimham Parimi, Head of Digital Products – Product Management, Process Control Platform. “This release provides a range of rich new functionality and a new enhanced user experience that enables operations to become more productive and responsive.”

ABB Ability Manufacturing Operations Management is designed to simplify production management by enabling performance monitoring, downtime management, and maintenance support, as well as providing statistical production analysis tools. It provides solutions and tools to facilitate the collection, consolidation and distribution of production, quality and energy information via the plant’s web-based reports, trends, and graphs.

A new, self-service dashboard application promotes increased collaboration, providing visibility from shop floor to top floor and spanning IT and OT environments. It increases data connectivity to all apps and modules within the MOM suite, combining historic and manufacturing data and providing the user with improved customization capabilities. Dashboards can be shared amongst users, further promoting collaboration between teams. Trends and events are displayed together, which enables customers to identify issues and opportunities enabling informed and timely decisions.

The new common services platform features an HTML 5 web platform that runs across all suites ensuring customers have a seamless user experience, so that applications can be viewed on different devices right down to a 10-inch tablet.

Statistical data process control (SPC) is used in manufacturing to determine if each process is in a state of control. The new SPC application works across all the different apps and modules and helps the user to improve quality and production related performance.

In addition to the existing Batch View and Batch Investigate features, a comparison option has been added to the platform’s batch analysis applications, allowing different types of comparison.

Cyber security remains one of the key issues in the advancement of Industry 4.0, and the new features in MOM include enhanced security.

Emerson Expands Analytics Platform

Plantweb Insight platform adds two new Pervasive Sensing applications that manage wireless networks more efficiently with a singular interface to the enterprise.

Emerson has added two new IIoT solutions to its Plantweb Insight data analytics platform that will enable industrial facilities to transform the way they manage their enterprise-level wireless network infrastructure.

As digitalization and wireless technology adoption continue to rapidly expand in industrial facilities throughout the world, the need for greater visibility of network infrastructure performance is key. These new Plantweb Insight applications provide a quick-to-implement, scalable IIoT solution that helps customers advance their digital transformation strategies and achieve greater operational efficiencies.

The new Plantweb Insight Network Management application provides continuous, centralized monitoring of WirelessHART networks. This first-of-its-kind application provides a singular, consolidated view of the status of all wireless networks in a facility, with embedded expertise and guidance for advanced network management.

A key feature of the Plantweb Insight Network Management application is a configurable mesh network diagram, providing visualization of network design and connections along with device-specific information. It also provides an exportable record of syslog alerts, network details outlining conformance to network best practices and more.

While the new network management application provides a holistic look at wireless networks, the Plantweb Insight Power Module Management application drills down to the device level, allowing facilities to keep their wireless devices appropriately powered so they can continuously transmit key monitoring data. By aggregating power module statuses, users can evolve traditional maintenance planning and implement more efficient and cost-effective practices.

“We were able to infuse a decade of experience with wireless technology into these new offerings,” said Brian Joe, wireless product manager with Emerson’s Automation Solutions business. “Our customers will now be able to manage and improve hundreds of networks through a singular interface, realizing significant efficiencies in individual network and wireless device management and maintenance.”

These new applications further enhance the Plantweb Insight platform, a set of pre-built analytics primarily focusing on monitoring key asset health. Other applications in the platform include pressure relief valve monitoring, heat exchanger monitoring and steam trap monitoring.

The IIoT market is booming—so why are half of all IIoT deployments failing?

The IIoT market is booming—so why are half of all IIoT deployments failing?

Management!

OK, the headline came from IHS Markit | Technology, an Informa Tech market analyst company. The answer from me.

One of the value adds of analyst firms is to provide market research studies. Where once I received industrial market information from just one analyst firm, now several send me updates. Helps round out information. But these are always estimates, and prone to some error. It’s a good guide though.

This research looks at Industrial Internet of Things (IIoT) nodes. It also does the analyst thing of providing some guidance on implementation. The research is interesting. The guidance requires another post on management practices, I think. However, what I’m hearing is that some executive reads about IIoT and picks an unlucky person to head up the project. A pilot project is authorized, mostly completed, and mostly forgotten.

Notes from the Report

The global IIoT business is arriving at a tipping point, with the industry reaching a connectivity milestone next year that will pave the way for market-changing events like the proliferation of cloud-based technologies. These developments will help propel annual IIOT node shipments to 224 million units in 2023, a 100 million unit increase from 124 million in 2018.

However, despite the industry’s progress, about half of all IIoT deployments are failing. All too often, these deployments are being hamstrung by planning breakdowns, including the failure to set reasonable objectives and to gather support and cooperation from critical personnel within organizations. Without addressing these issues, the global IIoT market could face major challenges in reaching its growth potential.

The connection inflection

Industrial assets have traditionally employed fieldbus for connecting to the industrial network, and while Ethernet solutions have been in place for a couple of decades, their adoption has been slow. However, after years of making progress in the market, Ethernet is set to displace Fieldbus as the primary network medium for the first time in 2020. Ethernet will account for 43 percent of IIOT node shipments next year, compared to 41 percent for Fieldbus.

“There are now more than 1 billion connected devices on factory floors around the world,” said Alex West, senior principal analyst, industrial technology, at IHS Markit | Technology. “This massive installed base is about to reach a tipping point, with Ethernet overtaking Fieldbus in 2020. The proliferation of Ethernet is enabling the transmission of larger volumes of data. This will ultimately bring in technologies like the cloud that are going to supercharge the IIOT business.”

Connecting to reduce downtime

The arrival of a faster connectivity solution will allow manufacturers to utilize cloud-based solutions to reduce downtime.

“One of the really significant challenges faced by industrial companies is unplanned downtime,” West said. “Just to quantity that challenge, it’s estimated in the automotive industry that $20,000 to $30,000 per minute is lost through unplanned downtime. New applications enabled through IIoT, maintenance and asset-health monitoring, are really helping overcome these challenges. We’ve estimated around a 30 percent average saving or reduction in unplanned downtime can be achieved through industrial IoT solutions.”

Monitoring assets

The benefits of IIoT solutions facilitated by enabled devices can be realized across the entire lifecycle of production, from product design, to monitoring inventory levels in the supply chain.

For example, Harley Davidson, a few years ago was facing business challenges in terms of fulfilling customer requirements. By improving the connectivity of its plant, the company was able to reduce the time to meet new orders filled from 21 days down to six hours.

Addressing IIoT deployment fails

While faster connectivity holds great promise for expanding the IIoT market, the reality is that current deployments are failing as often as they succeed.

“At the proof-of-concept phase, about half of IIoT projects are failing—which is acceptable for companies attempting to be agile and trial new applications,” West said. “However, there is a similar failure rate when companies move to the deployment stage. This means companies are investing enormous sums in these projects but aren’t getting the payback they expected.”

The failure of a project is defined as not meeting the customer’s expected payback. Many times, the high failure rate can be attributed to inflated expectations. A total of 50 percent of companies expect to see payback within one year, although many of these projects can take much longer to generate returns.

IHS Markit | Technology recommends manufacturers take the following steps to increase their chances of IIoT success:

  • Specify the project by determining in advance which exact challenges you want IIoT to address.
  • Start small, with some pilot projects of concepts to see how the technology can be utilized.
  • Go right to the top, with senior-level management support for projects.
  • Get the urge to converge, by ensuring support from all relevant functional groups.
  • Leverage your people power, by getting staff involved with deploying the technology and encouraging them to view IIoT not as a threat, but as an augmentation to their job capabilities.
Taking a Digital Journey

Taking a Digital Journey

Keynoters have a tough time with originality these Digital Days with everyone emphasizing Digital Transformation. Steve Lomholt-Thomson, chief revenue officer of AVEVA, took us on a Digital Journey this morning. Setting the tone of the three days of AVEVA World Congress (North America edition).

Three technology trends to watch: an IoT boom; cloud/empowered edge; and, AI / ML. The theme is digital. The Digital Organization discovers its Digital DNA, figures out how to build that Digital DNA through people who challenge the status quo; and then figures out how to track talent flow.

Which all starts us on our Digital Journey. On this journey, we unify end-to-end data, connect data silos taking an wholistic view of the business, and then visualize our assets and supply chain. I believe implied in all this is the company’s product AVEVA System Platform. The company touted six customer stories with at least five of them (and probably the sixth) all leveraging System Platform.

Oh, and the only time the “W” word was used referred to past tense.

Other areas of the company were highlighted:

Focus on assets–asset performance management including how to use machine learning (ML) and artificial intelligence (AI) for predictive analytics (predictive maintenance.

How to combine it all into a Digital Twin–bringing the design lifecycle and physical lifecycle into congruence.

Recently hired head of North America business, Christine Harding, interviewed customers from Campbell’s (soup/snacks), Quantum Solutions (integration project at St. Louis/Lambert airport), and Suncor (Canadian oil sands).

I have the rest of today and then tomorrow to take deeper dives into many of these topics. If there is anything you want me to ask, send a note.