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Ergin Tuganay [Nortal] | Role of Time Series Historian in Industry 4.0 | InfluxDays Virtual Experience London 2020

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The road to your digitalization journey and the Fourth Industrial Revolution is paved with data integrations. Data is needed when clarifying the big picture, aspiring for predictive maintenance, optimizing and de-bottlenecking processes, or implementing new systems (such as MES or APS). Themes like Industrial Internet of Things (IIoT) or Industry 4.0 are built on moving and combining data, making it accessible in real time. Without data silos, you have a complete, accurate and centralized view of your assets and their current state and health. The ability to visualize your asset performance and process efficiencies anytime and anywhere makes you agile and able to react quickly.

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Ergin Tuganay [Nortal] | Role of Time Series Historian in Industry 4.0 | InfluxDays Virtual Experience London 2020

  1. 1. NORTALGROUPNORTAL.COM ROLE OF TIME- SERIES HISTORIAN IN INDUSTRY 4.0 J U N E 2 0 2 0
  2. 2. Ergin Tuganay INDUSTRY 4.0 PARTNER, HEAD OF INDUSTRY 4.0 15+ years of experience on a wide range of areas in industrial automation and data driven technology. Combining business development and leadership background with in-depth, hands-on competency in traditional OT (PLC, DCS, SCADA, OPC, MES/MOM) and latest IT (Edge, Cloud and Big Data) architectures, he has helped several global scale industrial clients in digitalizing their manufacturing operations. Among others, Ergin has a certification of competencies in MES/MOM Methodologies (MESA CoC) and Microsoft Azure. ergin.tuganay@nortal.com
  3. 3. Agenda Role of Time-series Historian in Industry 4.0 1. Trends and Challenges 2. Time-series Historian in Digital Manufacturing Platform 3. Nortal Approach for Ecosystem Development 4. Case 1 - Time to Awesome™ in Hydropower Visualization 5. Case 2 – InfluxDB in Full-scale Manufacturing Platform 6. Why InfluxDB for Industry 4.0 Solutions?
  4. 4. Company History 2010 20162011 201220092005 20062000 2000 Webmedia established in Estonia Group company established 2006 Operations initiated in Serbia and Finland 2009 Qatar operations initiated 2010 Oman operations Initiated 2011 Acquisition of Finnish company CCC Oy (established in 1985) 2012 Rebranding of Webmedia and CCC as Nortal 2016 Acquisition of the Swedish company Element AB 2017 Nortal opens offices based in UAE and USA 2018 Nortal opens office in Germany 2017 2018 2005 International operations initiated Acquisition of Dev9 in US Sustained growth through organic measures and selected acquisitions 2020 Selling MA business in Sweden 20201985 1985 CCC Oy established in Finland
  5. 5. Distributed global delivery ON-SITE OFF-SITE FINLAND GERMANY US GCC AFRICA Estonia Lithuania Serbia Estonia Lithuania Serbia Estonia Lithuania Serbia Estonia Lithuania Serbia Estonia Serbia 10 COUNTRIES 850+ SPECIALISTS 30+ YEARS IN INDUSTRY
  6. 6. How? We simplify complex processes for better experiences and a seamless society. + Digital Healthcare + Digital Commerce + Digital Government + Industry 4.0
  7. 7. Multi-cloud competence
  8. 8. Trends and Challenges
  9. 9. NORTALGROUPNORTAL.COM MERGING OF THE PHYSICAL AND DIGITAL • The physical world is being digitized into a cyber-physical system. • Objects have “digital twins”, virtual representations of themselves, which contain the same information as their physical manifestations.
  10. 10. NORTALGROUPNORTAL.COM SILOED DATA • Company data is siloed and useless, because shop-floor operations and top-floor business strategy are not integrated. • Data islands are also created as legacy systems are layered with new, non-interoperable technologies.
  11. 11. NORTALGROUPNORTAL.COM FROM ON-PREMISE MONOLITHS TO CLOUD ECOSYSTEMS • Conventional monolith ERP- and MES-systems have lost business relevance and agility, and have become bloated, fed by the objective of achieving an all-encompassing megasuite. • Efficient ecosystems are taking their place.
  12. 12. NORTALGROUPNORTAL.COM AGING WORKFORCE • Aging of the workforce is impacting a number of industries. Retirement of experienced workers will create a skills gap. • It is crucial that the knowledge and experience accumulated by more senior workers is captured and made accessible to the new workforce.
  13. 13. Nortal Approach for Ecosystem Development
  14. 14. Do not build everything from scratch Manage product selections centrally Favor products that expose high-quality APIs Avoid complex tailoring of COTS products Do not publish native product APIs directly to consumers P R I N C I P L E S BE PRODUCT- FRIENDLY
  15. 15. Do not fear the cloud, embrace it Cloud is here, but so is on-prem still in most companies Build a proper, secure hybrid-cloud environment instead of drilling holes in individual projects Edge gateways can handle IoT traffic directly Clouds have advanced logging and analysis capabilities Logs can be pushed to on-prem if needed P R I N C I P L E S PREPARE FOR HYBRID-CLOUD
  16. 16. Focus on core domain and domain logic Define business domains, entities and their relationships Collaboration between technical and domain experts Publish the domain as Domain APIs Speak the same language as API consumers Hide the complexity of underlying products Provide a uniform user experience for API consumers P R I N C I P L E S USE DOMAIN- DRIVEN DESIGN
  17. 17. “Smart endpoints and dumb pipes” Lightweight API Management over heavy ESB Keep number of services manageable Extend the core products beyond their original capabilities Build only loosely coupled APIs Agree on cross-team API design guidelines P R I N C I P L E S USE MICROSERVICES TO BUILD APIS
  18. 18. Microservices without DevOps and high level of automation are impossible to manage Build pipelines carefully and create reusable templates Include test automation and secops into pipelines Build environments using Infrastructure-as-Code (IaC) Use IaC for everything, not just applications (API Management, networking, analytics pipelines) Only data needs to be backed up, other backups not needed P R I N C I P L E S BUILD PROPER DEVOPS PIPELINES
  19. 19. Strategic Planning Assumption “By 2024, 50% of MES solutions will include industrial IoT (IIoT) platforms synchronized with microservices-based manufacturing operations management (MOM) apps, providing near-real-time transaction management, control, data collection and analytics.” Gartner “Magic Quadrant for Manufacturing Execution Systems”, Rick Franzosa, 29 October 2019
  20. 20. Time-series Historian in Digital Manufacturing Platform
  21. 21. Functional hierarchy of systems in an industrial company
  22. 22. The role of process data historianTYPICAL STATUS • Shipped as part of automation system SCADA level • Used by production operators and engineers for near real-time monitoring and troubleshooting the process • Plays a critical role in production monitoring and reporting • Runs often on proprietary technology difficult to scale or integrate by 3rd parties
  23. 23. TYPICAL STATUS Companies who have implemented traditional MES-project, likely already have consolidated onpremise Historian. Runs often on exactly the same technology as SCADA historians, but just stretched to site-level. The role of process data historian
  24. 24. TYPICAL CHALLENGES • Data in siloes • Scalability issues: technical and commercial • Limited built-in tools • Difficult to integrate • Poor developer experience • Lack of developer community • Vendor lock-in The role of process data historian
  25. 25. It all builds on integrations and data Your ”swiss army knife” for industrial integrations • Solution for both real-time, historical, event and metadata • PLC, DCS, HMI/SCADA • MES-systems • Process Historians • Files (XML, CSV, etc) • Support for multiple interfaces: • 150+ automation devices (Siemens, Beckhoff, GE, Allen Bradley, Mitsubishi, Omron, WAGO, Modbus and many more) • SCADA- and OPC-systems: OPC Classic, OPC UA • Relational Databases (ODBC / JDBC) • File systems (FTP, SMB, etc.) • REST, MQTT, AMQP Crafted from rock-solid edge and cloud components
  26. 26. The Next Evolution of Manufacturing digitalization Manufacturing Digital Platform (Cloud) IntegrationandConnectivity Manufacturing Operations Management Apps Process Monitoring and Optimization Apps SharedServices Data Engineering & AI/ML Tools Edge Runtime Gateway + Apps
  27. 27. CASE 1 TIME TO AWESOME™ IN HYDROPOWER VISUALIZATION POWERED BY INFLUXDB AND MICROSOFT AZURE 28
  28. 28. THE CHALLENGE Poor usability of the collected raw data from the plants Lack of easy-to-use, self service tools for visualization, alerting and ad-hoc analysis Difficult to compare performance between the plants
  29. 29. Dashboard and alert builder Easy-to-use, self-service tool for users to creating dashboards, ad-hoc analysis alerting rules Real-time visualization and alerting Real-time updating trends, KPIs from all powerplants and notifiying users about deviations by email or chat Data ownership and future development Shared data pipeline with Azure Data Platform enabling future AI/ML based analytics HYDROPOWER REAL-TIME VISUALIZATION
  30. 30. NORTAL TELEMETRY SERVICE Cold Store Config, state and cache Hot Store Stream processing POWERPLANT 1 PLC / SCADA OPC Server PLC / SCADA POWERPLANT 2 PLC / SCADA OPC Server PLC / SCADA POWERPLANT 3 PLC / SCADA OPC Server PLC / SCADA IoT Edge IoT Edge IoT Edge IoT Hub APPLICATIONS Azure Databricks Grafana Data Engineers Production Personnel Web App Admin
  31. 31. 32 REAL-TIME DASHBOARD WITH TREND AND ACTUAL VALUES
  32. 32. 33 DRILL DOWN TO SELECTED TIME RANGE
  33. 33. 34 AD-HOC FILTERING OF INDIVIDUAL TAGS
  34. 34. 35 AD-HOC INVESTIGATION OF UNEXPECTED EVENTS
  35. 35. CASE 2 INFLUXDB IN FULL-SCALE MANUFACTURING DIGITAL PLATFORM POWERED BY INFLUXDB AND MICROSOFT AZURE 36
  36. 36. THE CHALLENGE Lack of vision and roadmap for implementing manufacturing solutions as as part of overall digitalization. Fear of outdated options and vendor lock-in. Heavily tailored ERP- system and its tightly coupled role in manufacturing Several areas for improvement identified: • Work-in-progress tracking • Production planning • Production dispatching • Real-time production reporting tracking
  37. 37. Consists of technologies, solutions, and practices to enable capabilities to take steps towards data driven operations Freedom to manage the platform independently, with selected partners who follow the guidelines Architecture principles include e.g. being agile, balancing speed and stability, ensuring scalability, and having an open mindset with respect to robustness MANUFACTURING DIGITAL PLATFORM
  38. 38. MILL 2 MILL 1 TELEMETRY SERVICE IoT EdgePLC / SCADA OPC Server PLC / SCADA PLC / SCADA PLC / SCADA OPC Server PLC / SCADA PLC / SCADA IoT Hub Cold Store Config, state and cache Hot Store LABEL PRINTING SERVICE EQUIPMENT SERVICE PRODUCTION BATCH SERVICE ORDER SERVICE BUSINESS APPS PRODUCTION PLANNING PRODUCTION EXECUTION WAREHOUSE OPERATIONS PROCESS MONITORING & ANALYSIS … PRODUCT TRACEABILITYStream processing IoT Edge REST API Notfications
  39. 39. 40 Telemetry Service Collect and store data from equipment and provide it for different consumers for further analysis. The data can be used to build multiple types of application and knowledge services to inform different stakeholders where you have room for improvement. This helps in setting new targets and goals for improving your manufacturing operations and your supply chain. InfluxDB HTTP API
  40. 40. 41 2. See shop floor operations and WIP inventories in real-time There is no need to print out work instructions and production orders on the shop floor. The orders and instructions are in digital format and they are always up to date. One of the biggest waste in the factory is people walking after information and doing non-productive tasks due to the lack of information. People inherently want to work smarter and concentrate on productive tasks instead of wasting their time on trivialities. Modern digital tools help to achieve that and motivate people. 1. Plan, dispatch, track and re-plan production orders Customers, regulators and suppliers demand shorter lead times, high quality and full delivery accuracy. Seeing the progress of customer and production orders in real time lets you react to unexpected events before delays or delivery accuracy issues happen. Ideally the production schedule is fixed as early as possible and everyone sticks to the plan. However, when unexpected equipment failures, raw material problems or resourcing problems occur, they happen so fast that the only way to deal with them while still securing the promised delivery dates is to change the production schedule. Real-time visibility and trending data make fast reactions possible and ideally customers will not notice any difference in deliveries. 3. Capture and provide historical data from equipment and manual workflows for analysis Means to collect and store the relevant data from equipment and workflows and provide it for different consumers for further analysis. The data can be used to build multiple types of application and knowledge services to inform different stakeholders where you have room for improvement. This helps in setting new targets and goals for improving your manufacturing operations and your supply chain.
  41. 41. Why InfluxDB for Industry 4.0 Solutions? 42
  42. 42. Why InfluxDB as Industrial Data Historian? • Strong community and buy-in from developers • Good support for integrations via Telegraf, REST and SDKs. • Battle-proven product, used in multiple other domains as well • Flexible deployment options • Technical & commercial scalability • Local buffer node running in the deapths of edge networks • Site historian running in plant datacenter • Enterprise historian running either in enterprise data center, private or public cloud • Enables to start small and grow with the business
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