Accelerating the Industrial Internet of Things
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143 case studies
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Cutting-edge Predictive Analytics for HIROTEC Group
Cutting-edge Predictive Analytics for HIROTEC Group
Hirotec needed to ensure continuous operations and to minimize unplanned downtime in its manufacturing facilities. Unplanned downtime is costly and compromises Hirotec's ability to deliver its goods to customers on time.
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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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Data management as a part of your cybersecurity strategy
Data management as a part of your cybersecurity strategy
Coordinating data in the age of digitalisation presents a real challenge, especially where production facilities are concerned. The task of maintaining the many and varied components used in production also entails working with a wide variety of different software packages (editors)Each change that is made to the software results in a new version that has to be securely stored – versions need to be properly managed and there can only ever be one version that is the latest authorised version. But how can you make sure that all changes that were made to the software now running on the machine/device were authorised?
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No More Searching for Software
No More Searching for Software
Tasks such as manual documentation and the fact that new software and hardware is constantly being integrated to the automation network makes the lives of maintenance staff difficult.
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Version Control for Systems and Machine Production
Version Control for Systems and Machine Production
With the flood of data and numerous versions of software in the production environment of a firm, much time and effort is spent by workers searching, guessing or asking questions in order to solve issues.
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Digital Manufacturing Powers a Better Way to Build Trucks
Digital Manufacturing Powers a Better Way to Build Trucks
• Deliver customized vehicles for consumers, better and faster • Control costs by boosting manufacturing efficiency • Improve agility and scalability to support innovation and future production needs
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IoE Increases Operational Efficiencies and Improves Energy Management
IoE Increases Operational Efficiencies and Improves Energy Management
For many manufacturing companies today, the opportunity to connect people, process, data, and things created by the Internet of Everything (IoE) presents a new way to look at factory automation. The opportunity for digital innovation often arises when a company is expanding capacity or building a new production facility. Mahindra and Mahindra, one of India’s leading automakers, seized the opportunity to deploy a connected factory of the future at their new Chakan facility.
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Benteler Automobiltechnik automates plants & processes
Benteler Automobiltechnik automates plants & processes
Benteler Automotive is looking for a solution that can solve the following situations:- Operation of 70 plants in 29 countries with worldwide reliance on components- Identify a seamless way to connect people, process, data and things to expedite the production process
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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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RobotStudio Case Study: Benteler Automobiltechnik
RobotStudio Case Study: Benteler Automobiltechnik
ABB
Benteler has a small pipe business area for which they produce fuel lines and coolant lines made of aluminum for Porsche and other car manufacturers. One of the problems in production was that when Benteler added new products, production had too much downtime.
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 Transcode Creates a Vehicle Fleet Management solution with Intel IoT Gateway
Transcode Creates a Vehicle Fleet Management solution with Intel IoT Gateway
Problem: Inefficient vehicle fleet management hinders business efficiency, employee productivity, and revenue growth opportunitiesCompanies involved in managing huge fleets of vehicles continue to struggle in terms of efficiently managing fleet operations. On one hand, it has become increasingly difficult to manage and monitor an entire fleet of say, 500 vehicles, particularly in tracking their daily activities. Imagine how challenging it can be to track all of these vehicles on a daily basis – where they are located at a particular time, how fast they are moving, if they are following the workflow, etc. Business owners definitely want to be on top of monitoring their assets and ensuring that their entire fleet continues to perform based on their expectations to be able to generate better revenue.On the other, it has become a challenge as well for business owners to monitor their drivers’ behavior and daily productivity. Most, if not some, of these employees would just follow what they want – changing routes on a whim, driving too fast that puts their passengers or deliveries at risk, or stopping too long at a location that limits their productivity. Business owners need to ensure that their drivers are following business rules and policies because at the endof the day, they are themselves employees who should be governed by rules and regulations that are implemented by the company. Without a means to track their daily behavior, business owners would not be able to address productivity issues that affect in maximizing their daily revenue.Based on these challenges, Transcode developed an end-to-end solution that not only helps solve vehicle fleet management problems but can also ultimately serve asa blueprint for smart city transportation. The solution harnesses an IoT gateway based on Intel architecture to provide efficient data mining, intelligent navigation, and end-to-end communication between the entire fleet andthe company’s back-office system or fleet management center. Through this gateway, business owners can efficiently monitor and manage their vehicle fleet on a daily basis.
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Predictive Analytics Generates Greater ROI for Customers
Predictive Analytics Generates Greater ROI for Customers
Manufacturing plants are running at a much higher capacity utilization than ever before. Often, it is a 24 hour a day, seven days a week operation. With downtime costing plants up to US$20,000 a minute, they cannot afford disruption to their processes. In fact, a single occurrence can cost a plant upwards of US$2 million.
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Greater Detroit Transit Agency Monitor Bus Fleet
Greater Detroit Transit Agency Monitor Bus Fleet
When you have up to 200 buses on the streets for 23 hours each day, it’s essential to constantly monitor your vehicles to ensure the highest levels of on-time performance and safety. For the Suburban Mobility Authority for Rapid Transit (SMART), that challenge was growing increasingly difficult as its automatic vehicle location (AVL) system aged. The AVL uses a radio network to create a two-way communication link between each vehicle and SMART’s operations center where dispatchers can monitor vehicle locations, schedule performance, and other metrics.“Our AVL was 20 years old,” explained Mel Evans, IT manager for SMART. “We were relying on a legacy analog radio network that used three leased towers and a slice of frequency that was being retired. While this infrastructure was satisfactory 20 years ago, it wasn’t keeping pace with SMART. We wanted more reporting and we wanted real-time information that we could share with our public ridership.”One option was to upgrade from analog to digital signals and increase the number of towers. Evans noted that this would be cost-prohibitive. “At approximately $1 million each, the upgrade strategy was too expensive for our agency,” he said. “It became clearer that we needed to consider a different strategy that involved an entirely new AVL solution.”
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VMI Group
VMI Group
With field engineers servicing sophisticated tire production machines around the globe, tire machine specialist VMI felt the need to secure access to the Programmed Logic Controllers on installations. This leading Dutch tire machine manufacturer realized that a centrally administered password key protection scheme would safeguard intellectual capital and machine investments for the future.
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Mowic’s TrackIce Freeze Out Ice Problems On The Road Using RF Technology
Mowic’s TrackIce Freeze Out Ice Problems On The Road Using RF Technology
Mowic saw an opportunity to reduce the operating costs of spreading salt on roads. Not knowing what terrain you’ll face affects traffic patterns, wears down brake systems, and most importantly is very dangerous. In addition to added time and danger on the roads, it’s no small cost to municipalities to run trucks for salt distribution.
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Routing and Logistics for Fleets - Greenlight SmartRoute
Routing and Logistics for Fleets - Greenlight SmartRoute
SmartRoute powered by Sirqul is a routing and optimization solution that enhances a fleet’s operational efficiency, enabling each vehicle and driver to maximize the amount of cargo they can pick up and deliver while minimizing miles, hours, and overall cost.
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Ride-Sharing Service for One of the Largest Car Manufacturers
Ride-Sharing Service for One of the Largest Car Manufacturers
A youth transportation service was developed and launched for a local community car-sharing service leveraging Sirqul's platform and technology.
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Building Smart IoT-Connected Railways
Building Smart IoT-Connected Railways
• Difficult environment. Communications equipment on trains must function properly in harsh conditions, such as environment temperatures ranging from -25°C to +85°C, according to the EU standard EN50155.• Railway regulations. All products in a train must adhere to strict standards, relating to working vibration, power consumption, and lifetime.• Lengthy process. Time to market in the railway industry can take years from concept to mass production, so product design requires a solid long term vision.
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Richmond Cars
Richmond Cars
Richmond Cars faced a number of challenges in regards to their business communications:Site-to-site trafc and incoming calls were increasing, and Richmond needed to understand this in order to manage their response accordingly without just increasing headcount.They wanted to really understand call traffic, customer demand and service levels as customer service is imperative – Richmond's reputation depends on excellent customer relationships.As they grow and add additional sites, their communications system also needs to be scalable. Drive revenue generating services through outbound calling. 
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PC-based PAC solution for material handling AGV optimization
PC-based PAC solution for material handling AGV optimization
Widely used across many industries, Automated Guided Vehicles (AGV) have been scooting around factory floors for decades. Thanks to evolving technologies like sensors, wireless networks and automatic control technologies, their guidance methods and physical dimensions continue to evolve and now small lightweight trackless AGV are being rolled out.An American AGV System Integrator (SI) was designing a Laser Guided Vehicle (LGV) for a material handling system in an automotive assembly plant. Since the plant’s existing AGV system used an expensive PLC-based control system there weren’t enough functions to meet the new control requirements, the company decided to upgrade and shift to a compact PC-based PAC control system ideal for the new compact vehicle design, capable of integrating with upper management systems using a single software application to replace the original two software applications.
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Bus Manufacturers to Realize a Smart Factory
Bus Manufacturers to Realize a Smart Factory
China's Yutong Bus Group is a large-scale manufacturing company. Its enterprise scale and sales performance continuously ranks first in the nation’s bus industry, and its bus products are exported to more than a hundred countries and regions. In order to improve the manufacturing process and carry out the transparent production control, the company planned to upgrade the existing manufacturing floor into the advanced and efficient factory. In addition to using MES as the production management system, it was also necessary to adopt panel PCs as the HMI and to establish a network communication in the manufacturing site. On account of stability, the IT department of this company excluded commercial computers and decided to choose the industrial product which has the advantages of high-performance and low failure rates. The factory is a complex and harsh environment, so this project required providing different kinds of panel computers with rugged features for different machine uses, offering wired and wireless network devices to create a complete communication link, and the related modules to acquire peripheral data. Therefore, to ensure this stability, the system integrator used industrial grade wireless devices with wider network coverage and higher power output.
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Parts Quality Gets Robotic Boost
Parts Quality Gets Robotic Boost
When manufacturers, such as the world's top car makers and automotive parts suppliers, produce components in their factories, traditional QA testing has been limited to verifying the quality of random parts pulled off the line throughout the day.It was time consuming to perform the detailed tests required, and defective parts could get through despite randomized tests.If a defective part caused a recall or accident, manufacturers could face costly litigation or irreparable damage to their reputation.
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The Power of Virtual Reality becomes Real in Japan
The Power of Virtual Reality becomes Real in Japan
To ensure business continuity in the event of an outage, AW Engineering (AW-E) wanted to upgrade the virtual desktop infrastructure (VDI) environment to the latest technology and build in a high level of redundancy.
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Transport of the Future at Heathrow
Transport of the Future at Heathrow
Ultra Global was developing a ULTra Personal Rapid Transit (PRT) system for Heathrow airport. A single board embedded computer which can provide the performance, reliability and scalability to handle PRT system's communication and security requirements is needed.
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Carmaker Holds the Keys to Network Security
Carmaker Holds the Keys to Network Security
FAW-Volkswagen Automotive Company (FAW-VW) required a high number of communication terminals due to its rapid development. FAW-VW also faced challenges in security management, IT Operation and Maintenance (O&M) costs, and employees work efficiency. FAW-VW needed terminal security protection with reliable access control and user rights management and comprehensive network protection.
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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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Carfinder: Real-time Vehicle Tracking for AUDI
Carfinder: Real-time Vehicle Tracking for AUDI
IBM
A growing range of models and ever-shorter development cycles increase the demands on the manufacturing process. As a result, tracking vehicles inside and outside manufacturing facilities is essential for delay-free quality assurance and to provide transparency throughout all manufacturing steps in the automotive industry.
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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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Honeywell Business Unit Runs Smoothly with Speedier Supply Chain
Honeywell Business Unit Runs Smoothly with Speedier Supply Chain
Provide rapid, efficient order processing and delivery of automotive aftermarket parts throughout North America.
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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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