Return From Covid

It almost sounds like a ’50s SciFi movie.

For a couple of months into the Covid pandemic, my inbox collected a steady stream of press releases about what this or that company was doing to either fight the coronavirus or prepare workplaces and workforces for the return to the office. That mighty river has turned into a stream at the end of summer.

The CTO of a Siemens company on NPR’s Tech Nation with Moira Gunn (good podcast, by the way) and I have interviewed Siemens about its combining of technologies to provide for safer workplaces in light of infectious viruses.

Then I received this note from Marty Edwards, VP of OT Security, Tenable, whom I’ve known for years as a reputable security specialist. “Prediction: Workers who return to the office may well bring new vulnerabilities with them.”

“While many critical infrastructure workers who operate, manage and secure the OT that underpins our economy can’t bring their work home, some of their colleagues certainly can. It’s likely that functions such as sales, marketing, HR, finance and legal of many essential services –food and beverage, manufacturing and pharmaceutical companies — have shifted to a remote-work model. When stay-at-home orders are eventually lifted, many of these folks will return to their offices with equipment that will be re-connected to corporate networks. With this comes the added risk of new vulnerabilities and threats being introduced to either the IT or OT side of mission- and safety-critical operations. During this transition, it’s imperative security teams have visibility into where the organization is exposed and to what extent, enabling them to effectively manage risk on a day-to-day basis. Put simply, the security challenges aren’t gone once everyone is back in the office.”

I have not worked in an office for years, unless you call a coffee house an office. But, many people will be returning to offices in the next few months. They will expect safe workspaces. As will all the factory workers (think about the morons running meat processing plants).

It took a while for cybersecurity to catch up with the sudden working-from-home IT challenge. Now, we’ll have millions returning to the corporate intranet bringing who knows what (computer) viruses with them. Another type of security to deal with.

One way or another, engineers will be busy dealing with this crisis for many months. Probably along with all their other work.

HPE Shows Company’s Investment In People, Environment, and Doing Business the Right Way

This recap of Hewlett Packard Enterprise’s (HPE) annual Living Progress Report for 2019 wraps up thoughts and coverage of all the many virtual conferences I experienced in June. The communications teams from all the companies worked hard and had to experiment in real time to bring out the best alternative to just completely shutting down.

These thoughts center on ethics—something given my experience in business I thought I’d never be writing about. If there were two institutions within which I worked where ethics was merely a word in the dictionary, they were business and church.

Thankfully that situation is changing, and this report from HPE is encouraging. I’ve met many people within the company. I don’t think this is superficial marketing-speak.

The report demonstrates HPE’s ongoing commitment to being a force for good by equipping customers with sustainable technology solutions, upholding HPE’s own high Environmental, Social and Governance (ESG) standards across its value chain, and prioritizing company culture to fuel business outcomes by unlocking the innovation of team members.

“Our team members’ passion, ingenuity and resilience enable us to create technology solutions to tackle the many pressing challenges facing society today,” said HPE President and CEO Antonio Neri. “Current discussions around systemic racism, inclusion, and diversity demonstrate the importance of taking bold actions to create a more equitable and sustainable future. We are proud of our progress and committed to do more as a company and in partnership with our peers, customers, and partners.”

In 2019, HPE intensified its strategic focus on culture and launched the “Work That Fits Your Life” program to support a more inclusive workplace that values team members’ experience inside and outside of the workplace. New benefits include six months of paid parental leave for mothers and fathers, career reskilling and transition support, and a company-wide shortened work day once a month on “Wellness Friday”.

From the release:

HPE is investing in human capital because it wants to be a place where people can learn, develop skills and do career-defining work. HPE’s Executive Committee developed the “Work that Fits your Life” program in partnership with its Board of Directors, 54% of whom identify with one or more diverse groups. One of the key goals of the program was to drive inclusion in the workplace. And, the company began tying diversity metrics to executive compensation to further embed inclusion and diversity into the organization.

In 2019, HPE’s employee engagement score rose 10 percent and has risen an unprecedented 18 percent since 2017, and its team members clocked their one millionth hour of company-supported volunteer time since 2016. In addition, HPE offered opportunities to engage with more social impact activities through the inaugural HPE Accelerating Impact initiative.

This year’s Living Progress Report also, for the first time, details racial diversity statistics of its team member population, an important step in being transparent and addressing systemic bias and inequality in our society.

HPE announced that it would make its entire portfolio available as-a-service by 2022, a consumption model that can bring significant energy efficiency gains and cost savings to its customers by eliminating overprovisioning and allowing customers to pay for only what they use. In addition, service-based models allow HPE to maintain chain of custody over equipment to ensure recovery and refurbishment, reducing physical waste and the need to source substances of concern. In 2019, 88% of the nearly four million assets returned to HPE’s Technology Renewal Centers were given a new life, but shifting to more consumption-based solutions is predicted to dramatically reduce the consumption of unnecessary IT assets.

HPE remained on track to meet all of its 2025 climate targets, having reduced its carbon footprint by 47% in just four years. The company also introduced a new emissions reduction target for its transportation logistics footprint – aiming to reduce the footprint by 35% by 2025. It also continued to see opportunity to help customers thrive in a carbon constrained world – with efficient IT products and services representing nearly USD $7.7 billion in revenue in 2019.

HPE continued to hold suppliers to high environmental, social and ethical standards. In 2019, HPE’s supply chain audit and assurance improvement program touched over 133,000 workers and the company guided 51% of its suppliers on how to set their own science-based climate targets. In addition, HPE sought to promote inclusion and diversity through its supply chain by spending approximately USD $1 billion with small enterprises and minority, women and veteran-owned businesses in the United States.

Emerson Integrates Augmented Reality into Plantweb Optics

Emerson marketing called us together for a virtual press conference and demonstration of its take on Augmented Reality (AR) integrated with it Plantweb Optics asset performance platform. I’ve seen many demos of AR over the past many years. The technology inspires imaginative thinking, but somehow companies have just not managed to make it ready for prime time.

Emerson’s evidently is. Not only could they show a demo, it is due to be released later this summer with the next release of Plantweb Optics software. Better yet, it does not require glasses or other peripheral equipment other than the smart phone or device people are already using.

The tag line from Emerson: Analytics and live remote assistance improve productivity and safety.

What does it do, really? Well, it delivers enhanced access to real-time diagnostics and analytics, as well as live remote assistance, to industrial plant workers responsible for maintaining and optimizing plant equipment. With AR technology integrated into Plantweb Optics, companies can improve productivity, collaboration and operational performance, without being limited by shortages of skilled workers or travel restrictions.

“Successful digital transformation programs that lead to Top Quartile performance have people and work practices as a key focus. Adopting innovative technology like augmented reality and institutionalizing best practices enable workers to add more value than ever to operational and business performance,” said Stuart Harris, group president for Emerson’s digital transformation business. “With these new Plantweb Optics technologies, customers can experience significant improvements in equipment reliability and the safety of their facilities.”

Plantweb Optics leverages artificial intelligence, machine learning analytics, and data contextualization to provide real-time visibility into plant reliability and operational performance. Unlike standalone AR solutions that require custom engineering, AR is integrated into Plantweb Optics, providing immediate access to a wealth of data and translating into easier, less costly implementation and a faster return on investment. For use by manufacturers in the life sciences, food and beverage, chemical, metals and mining, power and water, pulp and paper and energy industries, Plantweb Optics is part of Emerson’s award-winning Plantweb digital ecosystem of technologies, software and services.

Augmented reality for Plantweb Optics transforms the way field technicians accomplish complex tasks through enhanced situational awareness, live remote assistance and analytics delivered in context of the plant. As a field technician walks an industrial plant with a mobile device, Plantweb Optics uses spatial computing technology to map assets and provide technicians with critical maintenance information relevant to their location. Plantweb Optics overlays real-time analytics, equipment health status and technical support documentation on their field of view, so technicians can safely resolve issues sooner.

The augmented and virtual reality market is projected to grow annually at 40% from 2017 through 2025, according to multiple research reports. Much of this spending will come from manufacturers around the globe using AR technology to help upskill their workforce for digitalized operations.

With live remote assistance, field technicians can be virtually shadowed by experts, either on-site or off-site, from Emerson, their own company or another service provider. Experts can talk, type or augment the technician’s mobile display with graphics to guide the next action. Live remote assistance enables technicians and experts to collaborate for safe troubleshooting and repairs, regardless of location and without travel costs. Live remote assistance sessions, best practices and notes from experienced engineers and step-by-step troubleshooting procedures can be logged into a knowledge library for use by all engineers at a site. The knowledge library is a resource for companies to standardize procedures and ensure engineers of all experience levels understand an asset’s history and are using best practices for safe, efficient operations.

Survey Shows Humans Perform 72% of Manufacturing Tasks

Survey Shows Humans Perform 72% of Manufacturing Tasks

My response to automation and robot dystopian writers is that for the most part these technologies have removed humans from dangerous and monotonous manufacturing work. Humans are freed to do things using their heads as well as their hands. This report from A.T. Kearney and Drishti further contradicts hype about accelerating factory automation; demonstrates the need for greater investment in the human workforce.

According to new data released today by A.T. Kearney and Drishti, humans still perform 72 percent of manufacturing tasks. This data, from a survey of more than 100 manufacturing leaders, suggests that despite headlines about robots and AI replacing humans in factories, people remain central to manufacturing, creating significantly more value on the factory floor than machines.

Respondents also noted that there’s an almost universal lack of data into the activities that people perform in the factory. This analytical gap severely limits manufacturers’ ability to make informed decisions on capacity planning, workforce management, process engineering and many other strategic domains. And it suggests that manufacturers may overprioritize automation due to an inability to quantify investments in the human workforce that would result in greater efficiencies.

“Despite the prominence of people on the factory floor, digital transformation strategies for even the most well-known, progressive manufacturers in the world remain largely focused on machines,” said Michael Hu, partner at A.T. Kearney. “This massive imbalance in the analytics footprint leaves manufacturers around the globe with a human-shaped blind spot, which prevents them from realizing the full potential of Industry 4.0.”

While manufacturing technology has seen increasing innovation for decades, the standard practices for gathering and analyzing tasks done by humans – and the foundation of holistic manufacturing practices like lean and Six Sigma – are time-and-motion study methodologies, which can be directly traced back to the time of Henry Ford and have not been updated for the digital age.

“The principles underlying these 100-year-old measurement techniques are still valid, but they are too manual to scale, return incomplete datasets and are subject to observation biases,” said Prasad Akella, founder and CEO of Drishti. “In the age of Industry 4.0, manufacturers need larger and more complete datasets from human activities to help empower operators to contribute value to their fullest potential. This data will benefit everyone in the assembly ecosystem: plant managers, supervisors, engineers and, most importantly, the operators themselves.”

Additionally, the survey respondents noted the significant overhead needed for traditional data gathering methodologies: on average, 37 percent of skilled engineers’ time is spent gathering analytics data manually.

“Humans are the most valuable asset in the factory, and manufacturers should leverage new technology to extend the capabilities of both direct and indirect labor,” said Akella. “If you could give your senior engineers more than a third of their time back, you’d see immediate gains. Instead of spending so many hours collecting data, their attention and capabilities would remain focused on the most critical decisions and tasks.”

The survey also revealed the flip side of human contributions to manufacturing systems: Survey respondents noted that 73 percent of variability on the factory floor stems from humans, and 68 percent of defects are caused by human activities. Perhaps as a result, 39 percent of engineering time is spent on root cause investigations to trace defects – another manual expenditure of time that could be greatly reduced with better data.

“The bottom line is that better data can help both manufacturers and human operators across the board,” said Hu. “Data illuminates opportunities for productivity and quality improvements; simplifies traceability; mitigates variability; and creates new opportunities for operators to add even greater value. Humans are going to be the backbone of manufacturing for the foreseeable future, and the companies that improve their human factory analytics are the ones that will be best positioned to compete in Industry 4.0.”

To view the full report, click.

A.T. Kearney is a leading global management consulting firm with offices in more than 40 countries.

Maintenance, Simulation, Safety Highlight Honeywell Announcements at ARC Forum

Maintenance, Simulation, Safety Highlight Honeywell Announcements at ARC Forum

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.”

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