Accelerating the Industrial Internet of Things
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60 case studies
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Machine Condition Monitoring for a Caribbean Resort
Machine Condition Monitoring for a Caribbean Resort
A Caribbean resort has numerous buildings spread out across a scenic campus. One of the company's most important concerns is reliable air conditioning, as guests will be very upset if they are uncomfortable. Downtime is not an option. But if air conditioning equipment fails completely - a compressor, for example - the replacement has to be shipped in from another country at an inflated price. the resort realized that closely monitoring their equipment would enable preventative maintenance, and greatly extend the useful life of their air conditioning systems. But how do you monitor things like pumps and compressors when they have no network interface and they are scattered across a very wide area?
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American Eagle Achieves LEED with GE LED Lighting Fixtures
American Eagle Achieves LEED with GE LED Lighting Fixtures
American Eagle Outfitters (AEO) was in the process of building a new distribution center. The AEO facility management team decided to look at alternate options for lighting layout that could provide energy and maintenance savings. AEO would need a full-time maintenance employee just to replace burned-out fluorescent tubes.
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Data Capture for Afghanistan Forces
Data Capture for Afghanistan Forces
Electronic equipments on the field of Afghanistan provided information on the status of the vehicle and to identify potential threats surrounding it to the British Force. The monitoring and interpretation of this data requires robust and sophisticated digitization for data capture and communication.
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Service Transformation: Evolving Service Business in the IoT Era
Service Transformation: Evolving Service Business in the IoT Era
Manufacturers need to create new revenue streams while competing more effectively in the global market that seems fixated on lowest-cost production. Service revenue is becoming increasingly important to manufacturers to maintain profitability -- manufacturers want to capture upward of 30% of revenue from services, and 74% of manufacturing executive identified service as a significant driver of future revenues.
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Thingworx Helps EET Monitor Real-Time Energy Savings
Thingworx Helps EET Monitor Real-Time Energy Savings
Embedded Energy Technology (EET) wanted to build a dashboard for their customers to visualize the data analytics for the stream systems. They wanted the readings collected from the sensors to provide a complete picture of what is happening inside the component, and are displayed in a Web Portal that analyzes and presents the data in a concise format. The dashboard interface will also let customers set up email and text message alerts to be triggered when temperatures of the sensors customer select fall outside of the range they set. Summary reports are emailed monthly that highlight total energy savings, component health and month-over-month / year-over-year comparisons.
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Versiondog Comes for Coffee
Versiondog Comes for Coffee
“Well before it went live, we had worked out a clear plan for exactly how we were going to use the new versiondog versioning and data management software from AUVESY,” says Michael Mrugalla, who works in process automation at the Mainz plant. “We also had to think about what backups really meant for us. With all our field devices, control programs, drive systems, programming languages, file formats and software applications, we needed to know precisely what we have to back up in case a breakdown (e.g. a power outage) stops production. Because the whole point of making a backup is to be able to recover data quickly and easily when something goes wrong and continue working as if nothing had happened. But that means more than simply restarting production, it also means we need to be able to pick up where we left off with our ongoing process maintenance and optimisation.” It was particularly important to Nestlé that their backup strategy be built around a sin-gle continually active and universally appli-cable solution. And they wanted it to maintain a centralised backup of all the data necessary for both recovery and further development for all devices and all related projects (i.e. every piece of hardware and software). And the programs actually running on controllers need to correspond precisely with the data on the server. If not, the reason must be easily identifiable and the valid version always available to be reloaded onto the device.
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Continuous Casting Machines in a Steel Factory
Continuous Casting Machines in a Steel Factory
With a very broad range of applications, steel is an important material and has been developed into the most extensive alloy in the engineering world. Since delivering high quality is absolutely crucial for steel plants, ensuring maximum productivity and the best quality production are the keys to competitiveness in the steel industry. Additionally, working conditions in steel factories are not suitable for workers to stay in for long periods of time, so manufactures usually adopt various machines to complete the steel production processes. However, the precision of these machines is often overestimated and the lack of flexibility also makes supervisors unable to adjust operating procedures. A renowned steel factory in Asia planned to improve its Distributed Control System (DCS) of furnaces as well as addressing the problem of insufficient accuracy. However, most well-known international equipment suppliers can not provide a satisfactory solution and local maintenance because the project needed new technologies to more accurately control equipment operations. By implementing Advantech’s automated monitoring and control solution, steel factories can not only improve the manufacturing processes but can also allow users to add additional functions to the existing system so as to make sure the operation runs at high efficiency.
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Monitoring and Controlling Automatic Mixing and Dispensing Machines
Monitoring and Controlling Automatic Mixing and Dispensing Machines
As technology advances, textile manufacturing has been transformed from a labor-intensive to a partially or fully automated industry. Automation is significant in all segments of textile production - from spinning to printing, and textile machinery manufacturers are constantly searching for new technologies and automation processes will increase the productivity of their machines. The color paste mixing and dispensing machine is an essential part of the printing and dyeing process. With the advantage of automatically computerized controls and database management, the system can significantly improve its dispensing precision, working efficiency and production quality as well as reducing material consumption.
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Electric/Hybrid Vehicle Propulsion System
Electric/Hybrid Vehicle Propulsion System
Tecnalia is experienced in the automotive sector and in the development of controllers embedded in powertrain ECUs. Implementing three models that emulate the unavailable functioning and communications electronic control units (ECUs) for an electric/hybrid vehicle propulsion system.
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Machine Condition Monitoring for a Caribbean  Resort
Machine Condition Monitoring for a Caribbean Resort
A Caribbean resort has numerous buildings spread out across a scenic campus. One of the company's most important concerns is reliable air conditioning, as guests will be very upset if they are uncomfortable. Downtime is not an option. But if air conditioning equipment fails completely - a compressor, for example - the replacement has to be shipped in from another country at an inflated price. The resort realized that closely monitoring their equipment would enable preventative maintenance, and greatly extend the useful life of their air conditioning systems. But how do you monitor things like pumps and compressors when they have no network interface and they are scattered across a very wide area?
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Machine Condition Monitoring for a Distribution Center
Machine Condition Monitoring for a Distribution Center
A distribution center used a conveyor belt systems to transport a wide variety of products to appropriate locations. When all went well, products were delivered, stored and shipped back out with a minimum of trouble. But a breakdown in any of the motors running the conveyor belts could interfere with operations and cause unacceptable shipping delays. The distribution center decided to use remote monitoring and decision analytics to predict where and when, preventative maintenance could keep small problems from ballooning into major disruptions.
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Controlling and Monitoring Tobacco Plants in China
Controlling and Monitoring Tobacco Plants in China
Without the aid of computers, calculating production volume in a tobacco plant is troublesome and error-prone. PC-based monitoring systems that automatically collect production data and keep records can greatly improve in-factory logistics management and machinery maintenance. Combined with the use of networking communications, a Manufacture Executive System (MES) can be developed to improve the overall management of the factory. Our customer is a branded tobacco producer in China. When they came to Advantech, their production lines were already automated with the deployment of Programmable Logic Controllers (PLCs). However, they were still dependent on manual labor to count the amount of cigarettes and other materials, and their engineers had to manually check and record the data-logs stored in the PLCs to produce analyses for repair and maintenance purposes. But with Advantech’s PC-based monitoring machines, installed next to manufacturing machines, related data is shown on touch screens and transmitted to the control center, helping to reduce errors and improve management efficiency.
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Remote Monitoring and Control for a Windmill Generator
Remote Monitoring and Control for a Windmill Generator
As concerns over global warming continue to grow, green technologies are becoming increasingly popular. Wind turbine companies provide an excellent alternative to burning fossil fuels by harnessing kinetic energy from the wind and converting it into electricity. A typical wind farm may include over 80 wind turbines so efficient and reliable networks to manage and control these installations are imperative. Each wind turbine includes a generator and a variety of serial components such as a water cooler, high voltage transformer, ultrasonic wind sensors, yaw gear, blade bearing, pitch cylinder, and hub controller. All of these components are controlled by a PLC and communicate with the ground host. Due to the total integration of these devices into an Ethernet network, one of our customers in the wind turbine industry needed a serial-to-Ethernet solution that can operate reliably for years without interruption.
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Refinery Saves Over $700,000 with Smart Wireless
Refinery Saves Over $700,000 with Smart Wireless
One of the largest petroleum refineries in the world is equipped to refine various types of crude oil and manufacture various grades of fuel from motor gasoline to Aviation Turbine Fuel. Due to wear and tear, eight hydrogen valves in each refinery were leaking, and each cost $1800 per ton of hydrogen vented. The plant also had leakage on nearly 30 flare control hydrocarbon valves. The refinery wanted a continuous, online monitoring system that could catch leaks early, minimize hydrogen and hydrocarbon production losses, and improve safety for maintenance.
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Using Data to Make Operators and Maintenance Staff Efficient
Using Data to Make Operators and Maintenance Staff Efficient
Some of Elipse's customers have very large plants, and when the technicians are out in the plant, they cannot see the status of plant instrumentation. When doing calibrations or inspections, they have to radio back to the control room, which slows the work and can extend downtime.
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The Power of Balancing Technology
The Power of Balancing Technology
Accurate balancing of the turbochargers used in cars and commercial vehicles is vital to ensure engine efficiency and longevity and it is carried out in both the manufacturing and remanufacturing of these units. If not measured and corrected through the balancing process, turbochargers will be noisy and in severe cases bearing failure can occur.
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NESTLÉ USES WIN-911 PRO MOBILE ALERTS FOR REFRIGERATION ALARMS RESULTING IN LESS
NESTLÉ USES WIN-911 PRO MOBILE ALERTS FOR REFRIGERATION ALARMS RESULTING IN LESS
Nestlé needed to minimize downtime at their ice cream freezing facilities. Prior to the installation of WIN-911, offsite technicians took up to an hour to respond to alarms which could serve as a health hazard.
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Refinery Wirelessly Monitors Junction Box Pressure
Refinery Wirelessly Monitors Junction Box Pressure
The refining company needed to continuously monitor the pressure in Z-Purge junction boxes around the refinery. These junction boxes were maintained at a low positive pressure to prevent process gasses from entering the junction boxes. These junction boxes are widely distributed throughout the plant. Previously these junction boxes were manually monitored by operators on periodic rounds in the refinery.
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Wireless Improves Efficiency in Compressed Air Systems
Wireless Improves Efficiency in Compressed Air Systems
Hollingsworth and Vose wanted to improve the efficiency of their compressed air system, lower the electricity expense component of manufacturing cost in their commodity industry, and conserve energy leading to lowered greenhouse gas emissions. Compressed air systems degrade over time and become leaky and inefficient. Hollingsworth and Vose wanted to increase the frequency of system inspections without paying the high cost of manual labor.
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Improving Instrument Recovery Time and Reducing Downtime
Improving Instrument Recovery Time and Reducing Downtime
PTC
While in the midst of developing SYMPHONY®, a fully automated slide staining system for standard Hematoxylin and Eosin (H&E) staining, Ventana realized that they required a remote service solution to ensure that customers received an exceptional level of service. However, with a tight timeline to develop and launch this new product, there was some reluctance to integrate additional software. “There was some internal reluctance toward implementing the remote service technology with our SYMPHONY instrument given the short timeframe,” explains Greg Dameron, Director of Development at Ventana. “In fact, the executive team informed me that if the software would delay the SYMPHONY launch by even one day, then we would not implement it at all.” The company began evaluating commercial remote service offerings, seeking a solution that would provide value to customers without disrupting system stability. “Our products are based on stability, so we needed the remote service technology to be stable as well,” says Dameron. Ventana sought to reduce instrument downtime to fewer than 24 hours by remotely monitoring all field instrumentation on a 24/7 basis. This would enable the abilities to remotely diagnose and repair issues, provide “over-the-shoulder” troubleshooting and training for users, and track inventory to automatically replenish reagents in real time. “We felt strongly that delivering remote service would help us achieve a response time that we could not otherwise meet,” says Dave Flaten, Vice President and General Manager of the Primary Staining business unit at Ventana. “We believed that it would become an integral part of the product line.”
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Hybrid Energy Solutions
Hybrid Energy Solutions
HMS
As a power supplier, Enerwhere needed to make sure that their equipment is operational 24/7 and that power can be supplied at all times. Enerwhere needed to know how to do continual maintenance and know how much power is consumed by each customer.
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TOBYHANNA ARMY DEPOT DEPLOYS WIN-911 SOFTWARE WITH TRIDIUM’S NIAGARA PLATFORM
TOBYHANNA ARMY DEPOT DEPLOYS WIN-911 SOFTWARE WITH TRIDIUM’S NIAGARA PLATFORM
The installation of WIN-911’s alarm notification software at the Tobyhanna Army Depot was done as part of an overall energy efficiency project. In the early 2000s, the base worked to decentralize their coal-fired steam heating plant. This project included the construction of 10 boiler rooms housing 21 new boilers, as well as 37 air rotation units installed in various buildings. The entire infrastructure had to be integrated into HMI/SCADA systems and the existing control systems had to be upgraded. Ameresco, a leading independent energy efficiency company, was selected to head the project. Ameresco, in turn, specified WIN-911’s alarm notification system as the software platform used to instantly alert staff of any problems.
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Coca-Cola Refreshments, U.S.
Coca-Cola Refreshments, U.S.
Coca-Cola Refreshments owns and manages Coca-Cola branded refrigerators in retail establishments. Legacy systems were used to locate equipment information by logging onto multiple servers which took up to 8 hours to update information on 30-40 units. The company had no overall visibility into equipment status or maintenance history.
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IIC Condition Monitoring & Predictive Maintenance Testbed
IIC Condition Monitoring & Predictive Maintenance Testbed
The current state of condition monitoring requires manual measurements that are compounded with aging equipment and the retirement of knowledgeable personnel.
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WERMA GAUDLITZ Success Story in China
WERMA GAUDLITZ Success Story in China
Gaudlitz was looking to achieve a lean management and production approach so as to improve production efficiency. Workers in the night shift were also taking a very long time to collect data.
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Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.
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A Cloud-based Machine Performance Assistant
A Cloud-based Machine Performance Assistant
Printing International is building pad printing machinery to print on all kinds of plastics, glass, ceramics, porcelain, on caps and closures, medical devices and pharmaceuticals. 4 Key Project Requirements: • Transparency on machine performance • Worldwide service network • Remote support, contractual availability • IT security
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Wireless Vibratory Data Acquisition System for Maintenance
Wireless Vibratory Data Acquisition System for Maintenance
In the framework of its predictive maintenance offering, ONEPROD part of the ACOEM group provides monitoring solutions that allow to avoid unexpected breakdowns in industrial production tools. Traditionally ONEPROD was using wired data acquisition systems. However they were costly and hard to install in harsh environments or explosive zones, like in the oil & gas and mining industry. To cover the distance to connect and power the monitoring equipment considerable lengths of cable are required especially in industrial spaces with difficult access. Developing a wireless data acquisition system became a key success factor in the ONEPROD strategy in order to avoid any cabling issue and to improve the safety of the staff in charge of portable measures.
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ASD Healthcare Delivers True Connected Care
ASD Healthcare Delivers True Connected Care
ASD Healthcare’s Cubixx connected refrigeration solution was initially aimed at larger hospitals and pharmacies, utilising Wi-Fi or local area networks (LAN) for connectivity. With phase two, Cubixx would be rolled out to smaller practices and patients homes. The issue for ASD Healthcare was finding a single connectivity provider to cover the entire U.S., and facilitate international expansion.
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CONDITION MONITORING
CONDITION MONITORING
Parker wanted the ability to apply a common cloud-based remote monitoring platform across many applications. Compressed air can be expensive and inefficient, so Parker’s innovative Transair piping system was chosen as the initial host product. Parker had a unique chance to create a solution that would help facility managers understand their compressed air systems’ key performance so that they could efficiently manage and optimize this critical system.
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