Accelerating the Industrial Internet of Things
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1,141 case studies
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Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
ABC faced two major issues when utilizing the data collected. One is the size, complexity, and disparity of the data collected would take lot of man-hours to process and evaluate. Two is real-time data cannot be put into use due to the nature of data science analysis.
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Premium Appliance Producer Innovates with Internet of Everything
Premium Appliance Producer Innovates with Internet of Everything
Sub-Zero faced the largest product launch in the company’s history:It wanted to launch 60 new products as scheduled while simultaneously opening a new “greenfield” production facility, yet still adhering to stringent quality requirements and manage issues from new supply-chain partners. A the same time, it wanted to increase staff productivity time and collaboration while reducing travel and costs.
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New Business Models in Maintenance
New Business Models in Maintenance
Everything that can be automated will be automated, and it is up to us, as people, to learn how to adjust to this developmentWith the advent of the networking of processes and the Industrial Internet of Things, IT has further cemented its place in the production facilities of modern enterprises and is now set to revolutionise the way in which maintenance is approached. The Chamber of Industry and Commerce has its hands full when it comes to making sure that vocational and training concepts both accompany and keep up with these developments. Many employees are anxious, believing that the ongoing digitalisation of the world of work will result in greater job insecurity; a general misconception which regrettably continues to abound. The fact that digitalisation is set to provide both new opportunities and challenges, and that not every workplace is in danger, is often conveniently overlooked in the surrounding hype. It’s as if history is due to repeat itself every time any major industrial revolution occurs. Production workers begin to fear for their jobs and fear of change in the workplace remains high. Nevertheless, production is subject to constant change and we must all learn to adapt. Today, it is IT, in the wake of the IIoT, which stands to replace traditional rosters and blackboards. What’s more, the advent of employees directly communicating with machines via speech in order to reset them is also fast approaching. Voice-control has already gained general acceptance, but an even greater degree of trust in technology is required. If no changes are made to the way you work, the sudden advent of digitalisation may make it appear as though things are out of place or even missing. That isn’t to suggest that there was a time in which IT didn’t exist in the realm of production; such a statement wouldn’t be true, as evidenced by the fact that, in times past, maintenance staff spent an inordinate amount of time making their rounds accompanied by a programmer’s notebook, which had different editors to program components and helped to facilitate communication between human and machine. Nevertheless, the fact remains that the networking of processes continues to generate considerable uncertainty.Customised productionThe introduction of online marketing has resulted in a large percentage of industrial production being tailored to fit the customer. Affiliate marketing allows you to find out much more about your customers, their behaviour as consumers, and the underlying motives that drive their decision making. Thus, in certain sectors, it no longer makes sense to produce products, place them in storage units, and then wait until they are sold off. Instead, it is becoming the norm to make predictions according to customer decisions or trends. By using information gathered from CRM systems, customer feedback and digital sales statistics, it is possible to determine the colours, form, and features that a customer would desire a future product to have. It is also possible to produce products in such a way that the targeted customer immediately purchases them, thus resolving the need to store the products away until such a time as they are sold. Customised production places high demands on maintenance. Common topics that are frequently brought up in addition to classical and continual improvement processes include: - Preventive Maintenance- Corrective Maintenance- Condition-related maintenanceThe umbrella term ‘predictive maintenance’ is often used to encompass the topics listed above. Predictive maintenance is a strategy that is based on real-time data taken from production. It permits you to quickly recognise and respond to problems or results which were not visible in the past, but which are now, thanks to new advances in technology (e.g. condition monitoring), immediately detectable.What does the process of networking involve?When surveying a newly digitalised production hall for the first time, the first difference that one notices is that a specific IP address has been assigned to all automated devices connected to the network, which allows for data to be received and sent. These automated devices can be completely different from each other. It does not matter. What does matter (where plant or machine controllers are involved) is the PLC (programmable logic controller). A digital network topology looks as such: sensors, drives, and actuators move things around; robots weld, solder, press and pack; and HMI/SCADA systems supervise the processes. Then there are presses, drills, machine tools, milling processes, and much more. Generally, there is a different editor used to program each type of automated device type. There are very few uniform standards when it comes to software editors and thus automation engineers cannot use the same software to program a wide range of devices. Visual programming languages in DIN EN 61131-3 are regulated, however, each editor has its own special features and they are seldom compatible. Editors continue to be further developed if only for the purpose of continuously updating them to support current operating systems. Software developers are eager to offer their customers ongoing updates, the reason for which lies in the fact that customers do not have any reason to pay for software editors that have reached the end of their development. They will only pay for new developments. For maintenance staff, this trend necessitates them to undergo constant further training in order to understand and implement the latest functions and features brought out by the software developer. In that regard, it is interesting to note that, even as the number of people present in the production hall continues to decline, the number of maintenance staff continues to grow. This stands in stark contrast to the hype about the human factor becoming an obsolete element when it comes to production; on the contrary, the human factor will continue to grow in importance, especially when it comes to fixing unplanned malfunctions and errors that may occur to the complex machines and systems during production.All visions involving the future state of digital production thus have one thing in common and that is the fact that people will continue to play a vital role: the ability to understand the complex connections between numerous machines, controllers and programs, will continue to be a sure-fire guarantee of success.
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Taking Oil and Gas Exploration to the Next Level
Taking Oil and Gas Exploration to the Next Level
DownUnder GeoSolutions (DUG) wanted to increase computing performance by 5 to 10 times to improve seismic processing. The solution must build on current architecture software investments without sacrificing existing software and scale computing without scaling IT infrastructure costs.
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Remote Temperature Monitoring of Perishable Goods Saves Money
Remote Temperature Monitoring of Perishable Goods Saves Money
RMONI was facing temperature monitoring challenges in a cold chain business. A cold chain must be established and maintained to ensure goods have been properly refrigerated during every step of the process, making temperature monitoring a critical business function. Manual registration practice can be very costly, labor intensive and prone to mistakes.
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Robot Saves Money and Time for US Custom Molding Company
Robot Saves Money and Time for US Custom Molding Company
ABB
Injection Technology (Itech) is a custom molder for a variety of clients that require precision plastic parts for such products as electric meter covers, dental appliance cases and spools. With 95 employees operating 23 molding machines in a 30,000 square foot plant, Itech wanted to reduce man hours and increase efficiency.
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Improving Asset Health Information
Improving Asset Health Information
Unexpected downtime costs industries billions of dollars each year, and the challenges of aging assets combined with many experienced professionals at or near retirement age have companies looking at the promises of IoT technology for answers.
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ZipLine
ZipLine
When connected devices, from simple IoT buttons to complex mining equipment, medical devices and more are distributed across organizations, sites, and locations with many roles and data types along with requirements for who can access which data, you've got an IoT Data Management, Access Control, and Device Lifecycle nightmare.
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Live Secure Technology Data Marketplace
Live Secure Technology Data Marketplace
The great promise of new connected concepts of industry like 'Industry 4.0' is their ability to deliver a historically unparalleled level of responsiveness and flexibility. While modern supply chains are already heavily integrated and designed to be fluid and fast moving, a large swathe of manufacturing still remains beholden to economies of scale, large production runs, and careful preplanning.The Industrial Internet of Things (IIoT) is set to change this by allowing small-batch or even custom manufacturing on a truly industrial scale. With machines whose functions are not set in stone, but flexible and determined by their operating software and with a new form of connectivity bringing industrial engineers, product manufacturers, and end users closer together than ever before. Ad-hoc adjustments to automotive parts, for example, during active product runs or the bespoke manufacturing of custom sneakers become very viable options indeed.Much of this remains a theoretical vision, but IUNO, the German national reference project for IT security in Industry 4.0 demonstrates the new capabilities in action with a secure technology data marketplace running a smart drinks mixer.
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Protecting a Stadium from Hazardous Materials Using IoT2cell's Mobility Platform
Protecting a Stadium from Hazardous Materials Using IoT2cell's Mobility Platform
There was a need for higher security at the AT&T Stadium during the NFL draft. There was a need to ensure that nuclear radiation material was not smuggled inside the stadium. Hazmat materials could often be missed in a standard checkpoint when gaining entry into a stadium.
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Human–Robot Control
Human–Robot Control
Industry 4.0 is changing the way manufacturing industry operates. Increasingly more manufacturers are leveraging advanced technologies such as robotics and automation systems to improve productivity and efficiency. As a result, human–machine interfaces (HMIs) are becoming more important in their role in the digital connectedness of humans and machines. However, using the wrong HMI can lengthen development times and increase implementation costs.
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How Sirqul’s IoT Platform is Crafting Carrefour’s New In-Store Experiences
How Sirqul’s IoT Platform is Crafting Carrefour’s New In-Store Experiences
Carrefour Taiwan’s goal is to be completely digital by end of 2018. Out-dated manual methods for analysis and assumptions limited Carrefour’s ability to change the customer experience and were void of real-time decision-making capabilities. Rather than relying solely on sales data, assumptions, and disparate systems, Carrefour Taiwan’s CEO led an initiative to find a connected IoT solution that could give the team the ability to make real-time changes and more informed decisions. Prior to implementing, Carrefour struggled to address their conversion rates and did not have the proper insights into the customer decision-making process nor how to make an immediate impact without losing customer confidence.
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E.ON Gets Faster, Lower Cost Cycles with OpFlex Solutions
E.ON Gets Faster, Lower Cost Cycles with OpFlex Solutions
E.ON's plants ran 4000+ hours per year, now see fewer than 1000+ hours of profitable operation. E.ON needed a fast, reliable and low-cost cycle plants.
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OneWireless Enabled Performance Guarantee Test
OneWireless Enabled Performance Guarantee Test
Tata Power's power generation equipment OEMs (M/s BHEL) is required to provide all of the instrumentation and measurement devices for conducting performance guarantee and performance evaluation tests. M/s BHEL faced a number of specific challenges in conducting PG tests: employing high-accuracy digital communications for instrumentation, shortening setup and dismantling time, reducing hardware required, making portable instrument setup, avoiding temporary cabling work and the material waste costs
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Automation of the Oguz-Gabala-Baku water pipeline, Azerbaijan
Automation of the Oguz-Gabala-Baku water pipeline, Azerbaijan
The Oguz-Gabala-Baku water pipeline project dates back to plans from the 1970’s. Baku’s growth was historically driven by the booming oil industry and required the import of drinking water from outside of the city. Before the construction of the pipeline, some 60 percent of the city’s households received water for only a few hours daily. After completion of the project, 75 percent of the two million Baku residents are now served around the clock with potable water, based on World Health Organization (WHO) standards. The 262-kilometer pipeline requires no pumping station, but uses the altitude differences between the Caucasian mountains and the capital to supply 432,000 m³/d to the Ceyranbatan water reservoir. To the people of Baku, the pipeline is “the most important project not only in 2010, but of the last 20 years.”
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Condition Based Monitoring for Industrial Systems
Condition Based Monitoring for Industrial Systems
A large construction aggregate plant operates 10 high horsepower Secondary Crusher Drive Motors and associated conveyor belts, producing 600 tons of product per hour. All heavy equipment requires maintenance, but the aggregate producer’s costs were greatly magnified any time that the necessary maintenance was unplanned and unscheduled. The product must be supplied to the customers on a tight time schedule to fulfill contracts, avoid penalties, and prevent the loss of future business. Furthermore, a sudden failure in one of the drive motors would cause rock to pile up in unwanted locations, extending the downtime and increasing the costs.Clearly, preventative maintenance was preferable to unexpected failures. So, twice each year, the company brought in an outside vendor to attach sensors to the motors, do vibration studies, measure bearing temperatures and attempt to assess the health of the motors. But that wasn’t enough. Unexpected breakdowns continued to occur. The aggregate producer decided to upgrade to a Condition Based Monitoring (CBM) sensor system that could continually monitor the motors in real time, apply data analytics to detect changes in motor behavior before they developed into major problems, and alert maintenance staff via email or text, anywhere they happened to be.A wired sensor network would have been cost prohibitive. An aggregate plant has numerous heavy vehicles moving around, so any cabling would have to be protected. But the plant covers 400 acres, and the cable would have to be trenched to numerous locations. Cable wasn’t going to work. The aggregate producer needed a wireless solution.
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The Kellogg Company
Kellogg keeps a close eye on its trade spend, analyzing large volumes of data and running complex simulations to predict which promotional activities will be the most effective. Kellogg needed to decrease the trade spend but its traditional relational database on premises could not keep up with the pace of demand.
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IBM Builds Brand and Boosts Results through B2B Content Marketing
IBM Builds Brand and Boosts Results through B2B Content Marketing
IBM
IBM's challenge was to reach and engage IT professionals at midsize businesses and demonstrate its relevance to the marketplace. IBM sought to be top of mind as a problem solver and solution provider with affordable, easy-to-implement solutions for companies that lack extensive IT staffs and sophisticated infrastructure environments.
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MICROMEDIA’S ALERT ASSISTS AIR LIQUIDE’S SCADA SYSTEM FABVIEW
MICROMEDIA’S ALERT ASSISTS AIR LIQUIDE’S SCADA SYSTEM FABVIEW
WIN-911’s partner product ALERT is a key element in the Supervisory Control and Data Acquisition (SCADA) system “FabView” from Air Liquide. Air Liquide is the second largest supplier of industrial gasses in the world. This SCADA alarm notification system is specifically designed to monitor, among other things, the distribution of gas in a semiconductor manufacturing plant located in Dresden Germany. Like most operations of its type, this facility can’t afford much downtime in its distribution facility.If ALERT detects a leak in a pipeline, the system evaluates how severe the leak is and transfers the data back to the central site or home office. Once the information is back in the main office, the SCADA alert system then transcribes the data into understandable messages to which employees can respondappropriately.
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Sparking Growth with IT Refresh
Sparking Growth with IT Refresh
Due to Finder's steady growth in the market, Finder needed to upgrade its IT infrastructure to meet the requirements such as increase data availability and storage capacity plus ensure a robust business continuity plan. Any new solution also had to be scalable to match a future expansion of the business.
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New Backup System Solves Legacy Problems
New Backup System Solves Legacy Problems
Midea's outdated IT infrastructure in some sites could no longer keep pace with company's growth, putting operational reliability at risk. The legacy data backup system could not backup at some production sites. Some sites were still using the x86 server’s local hard disks as the backup media, resulting in limited backup size. The existing backup system was inefficient.
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Rolls Out Second-Gen Automotive Switch with BroadR-Reach
Rolls Out Second-Gen Automotive Switch with BroadR-Reach
Carmakers are facing the next wave of automotive connectivity. Cars will extend their reach, tapping our homes, talking to nearby cars and connecting to myriad other devices. New challenge is to meet bandwidth demands.
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Improving Production Line Efficiency with Ethernet Micro RTU Controller
Improving Production Line Efficiency with Ethernet Micro RTU Controller
Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies.System Requirements• Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks• Interoperable with ABB Real-TPI• Small form factor appropriate for deployment where space is scarce• Remote software management and configuration to simplify operations
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Fusion Middleware Integration on Cloud for Pharma Major
Fusion Middleware Integration on Cloud for Pharma Major
Customer wanted a real-time, seamless, cloud based integration between the existing on premise and cloud based application using SOA technology on Oracle Fusion Middleware Platform, a Contingent Worker Solution to collect, track, manage and report information for on-boarding, maintenance and off-boarding of contingent workers using a streamlined and Integrated business process, and streamlining of integration to the back-end systems and multiple SaaS applications.
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Advanced Elastomer Systems Upgrades Production
Advanced Elastomer Systems Upgrades Production
In order to maintain its share of the international market for thermoplastic elastomers AES recently expanded its Florida plant by adding a new production line. While the existing lines were operating satisfactorily using a PROVOX distributed control system with traditional analog I/O, AES wanted advanced technology on the new line for greater economy, efficiency, and reliability. AES officials were anxious to get this line into production to meet incoming orders, but two hurricanes slowed construction.
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Asset Management helps NASCAR Drive Down Costs
Asset Management helps NASCAR Drive Down Costs
Hendrick Motorsports wanted to coordinate information across 6 warehouses, track usage of approximately 150 components on each car and get the system up and running within four months.
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Davenport Energy Reduces Idle Time by 80% with FleetOutlook
Davenport Energy Reduces Idle Time by 80% with FleetOutlook
Davenport Energy was looking for a way to better track and manage their large, diverse fleet of vehicles by delivering real-time data and providing the ability to track, locate and manage their drivers while out in the field.
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Improving connectivity to remote areas with Rennicks MTS
Improving connectivity to remote areas with Rennicks MTS
Rennicks’ solutions experienced issues with communications in Scotland, where poor network coverage in remote locations was causing problems for some of its Variable Message Signs (VMS). Loss of connectivity meant more site visits had to be made to manually adjust signs, which was proving to be costly while the root cause of the problem was not being addressed.
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Smart SCADA-based Emergency Plume Gamma Monitoring System
Smart SCADA-based Emergency Plume Gamma Monitoring System
During 2010, a total of ten nuclear power stations were chosen to have their legacy Emergency Plume Gamma Monitoring Systems (EPGMS) replaced. Servelec Controls has over twenty years’ experience in the provision of EPGMS to the nuclear power generation industry.The primary function of EPGMS systems is to provide essential information to an emergency team on site to assist in the assessment of the local population's radiation dose in the unlikely event of an accidental release of radioactivity.
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Transformation for IoT Business Model in Connected Industrial Vehicles
Transformation for IoT Business Model in Connected Industrial Vehicles
PTC
CNH Industrial wanted to put IoT-enabled viechles onto the market. Whether monitoring a single machine or integrating an entire fleet, operators are able to track the status, speed, and movement of machines and their performance and also receive alerts on issues that may require service by a qualified technician to improve uptime and overall effectiveness of the vehicle.
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