Hannover Messe was the place to learn the latest about all things digital—digital twin, Industry 4.0, Industrial Internet of Things (IIoT). SAP was one of the many stops in my itinerary advancing the trend.
My contact at the SAP booth at Hannover wasn’t around when I arrived for my appointment, so I left—only to get a text a half-hour later that he had arrived. But I was off to another appointment by then. However I did glean this information from the company at and following the show.
SAP enters the digital twin era
SAP SE has introduced SAP S/4HANA Cloud for intelligent product design, a new solution for collaborative research and development.
The solution, which is built on SAP Cloud Platform using SAP’s latest digital twin technology, is one of the building blocks for a network of digital twins to enable new business models.
Powered by SAP Leonardo and integrated with business processes in the digital core, SAP S/4HANA Cloud for intelligent product design enables customers to accelerate product design and development with requirement-driven systems engineering and instant collaboration across an extended network of suppliers and partners.
“The solution provides shared views of digital twin information for customers to gain live insights on new products and to store, share and review engineering documents with internal and external participants,” said Bernd Leukert, Member of the Executive Board of SAP SE, Products & Innovation.
SAP’s network of digital twins synchronizes the virtual, physical, conditional, and commercial definitions of assets and products in real time to accelerate innovation, optimize operating performance, predict service requirements, improve diagnostics and enhance decision-making. It enables new levels of collaboration among manufacturers of products, operators of assets, suppliers and service companies. The approach combines digital twins with manufacturing solutions from SAP, cloud networks and SAP Leonardo capabilities, including machine learning, blockchain and Internet of Things (IoT), to optimize the product lifecycle with:
• Digital representation: SAP synchronizes digital twin business data, product information, asset master data and IoT-connected data from both on-premise and cloud solutions enabling companies to represent the world digitally. Solutions including SAP Predictive Engineering Insights, SAP Predictive Maintenance and Service and the SAP 3D Visual Enterprise applications provide access to rich data processing capabilities and live configuration, state, condition and control information.
• Business process: Rich enterprise-grade data processing capabilities allow customers to create, access and update digital twins to support business processes. SAP solutions provide an integrated data model from design, production and maintenance to service, including packaged integration to existing systems for computer-aided design, ERP, and product lifecycle management. Offerings providing end-to-end process support for manufacturers and operators include SAP S/4HANA, the SAP Engineering Control Center integration tool, SAP Hybris Service Cloud solutions, and the SAP Manufacturing Integration and Intelligence and SAP Manufacturing Execution applications.
• Business networks: With leading network offerings such as SAP Ariba solutions, SAP Asset Intelligence Network, and the SAP Distributed Manufacturing application, SAP is uniquely positioned to provide a virtual platform for collaboration on products and assets. The network of digital twins enables secure data access, sharing and governance on a global scale.
• Networks of digital representation: SAP enables twin-to-twin connections in systems within a specific asset and on an asset-to-asset level. SAP solutions such as SAP Asset Intelligence Network provide semantic and industry-standards support in an asset core modeling environment to enable live enrichment during the product or asset lifecycle.
Digital Manufacturing Cloud
SAP Digital Manufacturing Cloud helps companies optimize performance, elevate production quality and efficiency, and ensure worker safety.
Drawing on SAP’s expertise in the Industrial Internet of Things (IIoT), predictive analytics and supply networks, the solution enables manufacturers to deploy Industry 4.0 technologies in the cloud.
The new cloud solution extends and complements the digital manufacturing portfolio of on-premise solutions from SAP and is available in different bundles to serve manufacturers of varying sizes in both discrete and process industries and roles within their respective organizations.
SAP customers can choose from the SAP Digital Manufacturing Cloud solution for execution, which provides all solutions in the manufacturing cloud portfolio, or the SAP Digital Manufacturing Cloud solution for insights, which focuses on performance management and predictive quality.
“Manufacturers in the era of Industry 4.0 require solutions that are intelligent, networked and predictive,” said Leukert. “Our manufacturing cloud solutions help customers take advantage of the Industrial Internet of Things by connecting equipment, people and operations across the extended digital supply chain and tightly integrating manufacturing with business operations.”
SAP Digital Manufacturing Cloud includes the following:
• SAP Digital Manufacturing Cloud for execution: Industry0-enabled shop floor solution features “lot size one” and paperless production capabilities. It integrates business systems with the shop floor, allowing for complete component and material-level visibility for single and global installations.
• SAP Digital Manufacturing Cloud for insights: Centralized, data-driven performance management enables key stakeholders to achieve best-in-class manufacturing performance and operations.
• Predictive quality: This helps manufacturers gain valuable insights to conform to specifications across processes and streamline quality management. It also allows manufacturers to apply predictive algorithms that can reduce losses from defects, deficiencies or variations, and recommend corrective actions.
• Manufacturing network: The network provides a cloud-based collaborative platform integrated with SAP Ariba solutions connecting customers with manufacturing service providers, such as suppliers of 3D and computer numerical control (CNC) printing services, material providers, original equipment manufacturers (OEM) and technical certification companies.
Also at Hannover Messe 2018, SAP announced SAP Connected Worker Safety, a solution designed to reduce risks, costs and protect employees. Information from wearables and other sensor-enabled equipment can help companies react immediately to a hazardous situation or incident while proactively managing worker fatigue and other hazard inducers. Real-time information allows monitoring of compliance at all times against regulatory and other parameters.
My latest email from The Information highlighted the woes and tribulations of Tesla. There are headlines in all the major media outlets—manufacturing problems at Tesla impacting stock price, profitability, and cash flow.
How would you like to be the engineers who “over automated” the factory according to the boss (Elon Musk)? Want to be the Director of Manufacturing hung out to dry in the Wall Street Journal or The New York Times?
Just consider all this and see how you matter to the company—the employees, stockholders, customers.
From The Information quoting Reveal:
Tesla’s 2018 is starting to look like Uber’s 2017: Every week there is a new allegation or setback about workplace culture or business performance or the quality of its products. In this case, an investigative report by Reveal says that Tesla consistently under-reported ailments suffered by workers at its main production plant. “Everything took a back seat to production,” said a former safety manager, Justine White, who left at the start of 2017. “It’s just a matter of time before somebody gets killed.” Tesla, as is its custom, fired back by calling the report by Reveal, which is part of the nonprofit Center for Investigative Reporting, a tool of an “extremist organization” that is trying to unionize Tesla’s workers and that reporters misunderstood how injuries are reviewed. We suggest reading the Reveal report and Tesla’s response, and coming to your own conclusion. (the Reveal)
And another quote from The Information about a class action lawsuit where the former director of manufacturing is giving information to the plaintiffs.
It’s not common for a shareholder class-action lawsuit, typically filed after a stock’s value has fallen precipitously, to get buzz among reporters. But this one against Tesla and its CEO Elon Musk seems unique: No fewer than 11 former workers at Tesla, including an ex-director of manufacturing at the company’s main car-production plant, provided information to the plaintiffs’ lawyers who filed the suit, according to an amended filing from March 23. It alleges Musk knowingly made false statements to investors that Tesla would be able to make 5,000 Model 3 sedans per week by the end of 2017, despite being told by his subordinates that that would never happen and continued to do so in the face of mounting evidence. Tesla’s stock dropped in price by 20% between May 2017 and November of that year, after it became clear that production target would not be met—not by a long shot. Five months later, the production pace is about 2,000 per week, Tesla has said. A spokesman for the company didn’t immediately respond to a request for comment about the suit, which is worth reading.
We have an important role within our companies. We must always consider that. Sometimes even being required to tell overoptimistic executives the reality of manufacturing.
From in-store shopper research to evaluating the gaze of an expert pianist, thousands are using wearable eye trackers to accurately measure what people see as they move freely in a range of real-world settings.
However, the design of the eye trackers has excluded certain sports and sectors from using the technology to its full potential due to the restrictions caused by protective headwear.
That is, until now. Two new versions of Tobii Pro Glasses 2 have been developed to fit easily under helmets and safety accessories, allowing athletes, industrial workers and other professionals to participate in eye tracking research. By moving the processor box below the temple the Helmet edition facilitates the use of most safety equipment while the Integration edition can be purpose fitted to most headwear thanks to it’s reduced frame and movable processor box.
Expanding the benefits of eye tracking for sports research
As sports become increasingly more competitive, athletes need to stay ahead of the game. To do so, many coaches are opting to make cutting edge technologies like eye tracking an integral part of their evaluation and training programs.
The beauty of eye tracking is that it reveals methods and techniques which occur instinctively or too quickly to be observed. Basketball, golf, and tennis are just a few of the sports utilizing wearable eye trackers to compare the visual strategies of experts and novices in a bid to identify the best techniques and fine-tune strategies.
William Rahm, a goalie coach with the Swedish Hockey League, is using eye tracking glasses to train his goalies. According to him, one of the greatest challenges as a coach is being able to understand what a player sees on the ice. Being able to watch in real-time how a goalie tracks the puck with their eyes and scans the ice during a game will help him expedite training and translate subconscious actions into, teachable strategies.
The new editions of these wearable eye trackers open up increased possibilities for this growing area of eye tracking research in sports.
Design improvements are delivering increased research opportunities across a range of sports like cricket, American football, and baseball as headgear limitations are greatly reduced or removed.
Improving safety in the workplace with eye tracking
Changes to the physical specifications of wearable eye trackers is also increasing the applications of their use to improve workplace safety. By seeing operations through the eyes of workers, management can gain greater insight into inefficient processes, distractions and unsafe conditions.
This is an important area for all. The University of Nebraska used wearable eye trackers to investigate the nature of human error on construction sites and their underlying causes. Their findings, about the importance of situational awareness, yielded a reliable model for predicting human error and preventing subsequent injuries on construction sites. This model can be used by safety managers to identify at-risk workers and prevent potentially fatal situations, which is of particular relevance to those in the sectors like mining and manufacturing.
There’s an increased scope for eye tracking research which is accompanied by other measures of human behavior. Through its recent integration with Qualisys, a provider of motion capture technology, it’s possible to access combined real-time output of both eye tracking and motion data. This provides essential information needed to further improve sports performance, diagnose visual-motor disorders, and much more.
Honeywell released three announcements while I am still recapping the ARC Forum. There are one or two more to go. Thèse regarded maintenance management, simulation, and safety under the umbrella of Connected Plant.
The first is a new offering as part of Honeywell Connected Plant that allows customers to more effectively manage the maintenance and operations of their industrial equipment. The new Honeywell Connected Plant Asset Performance Insight connects the customers’ assets and equipment to the cloud, and applies analytical models from Honeywell and its partners, so that customers can avoid unplanned downtime and unnecessary maintenance.
“In today’s competitive business climate, in which asset capacity is often sold out, equipment performance is key to increased profitability,” said Richard Shaw, general manager, Honeywell Connected Plant. “With operational and maintenance-induced equipment failures accounting for most of the unplanned downtime, industrial companies are looking to digital transformation and IIoT to make sense out of huge amounts of data. Honeywell Connected Plant and our new Asset Performance Insight will help our customers operate more strategically and effectively.”
Honeywell designed the Asset Performance Insight solution to be rapidly deployed to customers through pre-configured templates. These templates are based on the company’s deep industry experience and real-world customer challenges enhanced with advanced analytics. The offering can also be configured and tailored to customers’ specific needs, making it extremely flexible.
The second is a cloud-based simulation tool that uses a combination of augmented reality (AR) and virtual reality (VR) to train plant personnel on critical industrial work activities. With as much as 50 percent of industrial plant personnel due to retire within the next five years, the Honeywell Connected Plant Skills Insight Immersive Competency is designed to bring new industrial workers up to speed quickly by enhancing training and delivering it in new and contemporary ways.
Honeywell’s advanced training solution combines mixed reality with data analytics and Honeywell’s 25 years of experience in worker competency management to create an interactive environment for on-the-job training. It uses Microsoft’s HoloLens, the world’s first and only self-contained holographic computer, and Windows Mixed Reality headsets to simulate various scenarios for Honeywell’s C300 controller – such as primary failure and switchovers, cable and power supply failure – that train and test personnel on their skills.
“Megatrends such as the aging workforce are putting increased pressure on industrial companies and their training programs,” said Youssef Mestari, program director, Honeywell Connected Plant. “There is a need for more creative and effective training delivered through contemporary methods such as Immersive Competency, ultimately empowering industrial workers to directly improve plant performance, uptime, reliability and safety.”
Simulating specific job activities through virtual environments, which are accessed through the cloud, Honeywell’s solution offers a natural way to interact and communicate with peers or a trainer. Similar to a flight simulator, trainees can safely experience the impacts of their decisions. This approach improves skill retention versus traditional training methods by up to 100 percent and reduces the length of technical training by up to 66 percent. Additionally, the employees’ training progress is tracked as part of a formal competency management system.
And wrapping up is a new solution for real-time safety monitoring of workers in plant and remote operations. Honeywell Connected Plant Skills Insight Personal Gas Safety helps to protect lives and enable faster response in case of hazardous leaks or worker injury.
The solution’s wearable gas detectors monitor gas, radiation and dust, and are tightly integrated with Honeywell’s distributed control system, Experion® Process Knowledge System (PKS). In case of harmful exposures, man-down or panic alarms of workers in the field, accurate, automated alarms now alert control room operators in real time. In addition, safety teams can take advantage of powerful tools embedded in Experion PKS to provide detailed trending, reporting and data analysis of the gas detectors to further ensure safe operations.
“Monitoring worker safety and ensuring proper response to emergencies are top priorities for industrial producers,” said Adrian Fielding, marketing director, Integrated Protective Solutions for Honeywell Process Solutions (HPS). “Personal Gas Safety gives plant operators eyes and ears in the field to improve their situational awareness, helping avoid potentially life-threatening conditions while also providing workers with the assurance that help will be on the way quickly if they need it.”
Acquisitions are a big reason explaining growth and innovation in big companies. Not that long ago Emerson acquired partner Mynah Technologies. Today I see that it acquired ProSys. These are both good acquisitions. Emerson has a better than average success with acquisitions. ProSys is a good fit. Congratulations.
Emerson announced it has acquired ProSys Inc., a global supplier of software and services that increase production and safety for the chemical, oil and gas, pulp and paper, and refining industries. By building intuitive processes for plant operators, these solutions make everything from everyday operations to responding during abnormal situations easier.
“Adding ProSys’ differentiated technologies and expertise allows us to help our customers improve plant performance, safety and profitability by optimizing their human and automation resources,” said Mike Train, executive president, Emerson Automation Solutions. “With ProSys, we can provide innovative control and operator performance capabilities to make control room operators far more effective.”
ProSys’ portfolio includes solutions that help operators manage alarms critical to plant production and safety, and efficiently handle changing plant states. In addition, ProSys provides modern, high performance and intuitive graphics for better operator communications.
ProSys complements Emerson’s May 2017 acquisition of MYNAH Technologies, which provides dynamic simulation and operator training software. Together, these technologies embed expertise to help operators navigate plant systems safely and efficiently, and prepare customers to accommodate the changing state and age of the industrial workforce.
“Our specialization in software and services that increase operator performance builds on Emerson’s market leadership in automation control systems,” said Dustin Beebe, president and CEO at ProSys. “By working together as one, we can provide even more operational and financial value to customers.”
Beebe will join Emerson Automation Solutions as vice president, control and operator performance.
The ProSys software portfolio supports Emerson’s Operational Certainty program designed to help industrial companies achieve Top Quartile performance in areas of safety, reliability, and production.
Terms of the acquisition were not disclosed.