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ICC 2020: Breaking the Myth of Industry 4.0 with Ignition

In this session, Automation Excellence gives viewers a simple approach to Industry 4.0, its principles, the components involved which include elements of both OT and IT, and the Ignition Platform.

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ICC 2020: Breaking the Myth of Industry 4.0 with Ignition
Ramnath S Mani
Managing Director, Automation Excellence
Breaking the Myth of
Industry 4.0 with
Ignition
Industry 4.0 – What it means
Industry 4.0 – The OT – IT Divide
Industry 4.0 – Industrial Transformation
Industrial Transformation means something different for every organization, but
it always incorporates essential concepts, some of which include:
 Cross-disciplinary collaboration and shop-to-top engagement
 Thoughtful alignment of processes within functional groups throughout the organization
 More extensive sharing of enterprise data in and beyond the enterprise
 Managing data from device to Cloud
 Ability to use all sorts of data, structured to unstructured
 Advanced analytics from multiple sources, including third-party apps
 Open and secure communication
 First Step is Digitization of Factories
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ICC 2020: Breaking the Myth of Industry 4.0 with Ignition

  • 2. Ramnath S Mani Managing Director, Automation Excellence
  • 3. Breaking the Myth of Industry 4.0 with Ignition
  • 4. Industry 4.0 – What it means
  • 5. Industry 4.0 – The OT – IT Divide
  • 6. Industry 4.0 – Industrial Transformation Industrial Transformation means something different for every organization, but it always incorporates essential concepts, some of which include:  Cross-disciplinary collaboration and shop-to-top engagement  Thoughtful alignment of processes within functional groups throughout the organization  More extensive sharing of enterprise data in and beyond the enterprise  Managing data from device to Cloud  Ability to use all sorts of data, structured to unstructured  Advanced analytics from multiple sources, including third-party apps  Open and secure communication  First Step is Digitization of Factories
  • 7. Industry 4.0 – Steps 1. All devices on the factory floor (regardless of manufacturer) seamlessly and instantly need to communicate. 2. All information from devices in various protocols and connectivity have to be brought to a common IT understandable language and IT compatible protocol. 4. “Big Data” is able to enter the factory from the outside world, providing systems with statistics about consumer buying habits and automatically increasing production at times of year when data trends indicate that demand for a product is at its highest. 5. Tapped into a global data stream, the factory of the future can not only automate smart processes to meet its own internal objectives, but can anticipate opportunities and failures based on external events before they occur. 6. Facilitates Multi-location sites to be inter-connected for overall visibility. 7. Fundamental steps manufacturer to prepare for seamless integration when the Internet reaches the factory: Get Digital Get Automated Get Connected Get Real-Time, Remote Access Get Internet-Friendly Tools
  • 8. Industry 4.0 – Smart Manufacturing (OT + IT)  The Future of Manufacturing is in Industry 4.0 & IIoT.  Industrial organizations see the value of uniting the factory floor with the executive offices  To implement needs mass Digitization  New products addressing these challenges that will replace existing products  Vision Document for the Company from Top Down – CEO the Architect  Ensure that company’s management, including top management (e.g. CEO and CFO), IT management (CIO) and OT management (production or unit management), commit themselves to IT/OT convergence and actively support the initiative  Your digital strategy must be driven by a clear understanding of the customer’s needs and the way your products relate to them.  Building IIOT from grounds Up - IIoT starts with Plant Floor & Field Devices
  • 9. Industry 4.0 – Smart Manufacturing (OT + IT) With Industry 4.0 being the buzzword on the industry’s lips right now,  it’s easy for manufacturers to fall into the trap of believing that Digitisation requires a complete overhaul.  In contrast, taking small and strategic steps to digitisation can prove more beneficial for most manufacturers. Remember, this is evolution, not revolution.  Upgrading to Industry 4.0 in manageable steps not only allows businesses enough time to make well- researched and considered decisions, but also gradually introduces employees to the new technology around them.  This step-by-step approach also enables manufacturers to see precisely how Digitisation is adding value to their processes, and by reducing complexity, makes it possible to easily connect other machinery down the line – saving time and money.
  • 10. Industry 4.0 – Value Chain Things Gateways/ Networking Infrastructure Wireless/Wired Communication Services Fast Data/ Big Data Analytics Enterprise Applications Controllers, transmitters, valves Gateways, Routers, Mobile Devices Network Service Provider Data Centre, Servers, storage CRM, ERP, BI, HR Light Speed Smoke Vibration Push button Temperature Water Level Humidity Pressure Altitude Motion Speed PLC SCADA MES … Sensors/ Devices PROFINET MODBUS CANBUS Others .. IoT Concept ( Backend) IoT Concept ( Frontend) Gateway Edge Cloud Desktop Tablet Mobile
  • 11. Industry 4.0 – New IIoT Architecture What do companies need to move to an IIoT architecture? There are 6 core success factors … 1. Decouple Devices From Applications 2. Superior OT Solution 3. Single Source of Truth 4. Plug-and-Play Functionality 5. Eliminate Cutovers 6. Scale with Unlimited Licensing
  • 12. Industry 4.0 – New Architecture (OT + IT)  Fundamental concept to IIoT and IT-OT convergence is to decouple Devices from Applications  Open architecture that decouples applications from devices enable enterprise to get needed data without interrupting operations at plants  Conventional System architecture : intelligent devices such as PLCs coupled to applications through proprietary protocols Conventional Architecture IIoT New Architecture
  • 13. Industry 4.0 – IIoT Architecture What do companies need to move to an IIoT architecture? There are 6 core success factors … 1. Decouple Devices From Applications 2. Superior OT Solution 3. Single Source of Truth 4. Plug-and-Play Functionality 5. Eliminate Cutovers 6. Scale with Unlimited Licensing
  • 14. Industry 4.0 – Ignition Platform supports The Ignition platform supports those features. That’s why Ignition is perfect for positioning your company for IIoT, Perfect for converging OT & IT, And perfect for shifting to the Pull economy. It lets you pull the modules & tools you need, It’s a superior OT solution that leverages proven IT technologies And it addresses the goals of the Open Process Automation initiative for an open, standards- based, secure, and interoperable control system.
  • 15. Industry 4.0 – Ignition - Universal Platform One Universal Platform for IIoT, SCADA and More Ignition is the only IIoT Platform 1. With built-in tools for creating full featured SCADA systems 2. Ignition is modular, so you can easily add fully integrated software modules for building industrial applications such a SCADA, Alarming, Reporting software and more .. 3. With Ignition you can connect to all your IIoT Data, rapidly develop any kind of industrial application and instantly web-launch clients to virtually any device – all without limits
  • 16. Industry 4.0 – Platform and Ecosystem What is an ecosystem? • Open networks of strategic business partners • A company’s competitiveness network of cooperators, suppliers, institutions, customers and other stakeholders • “Typically ecosystems are built around intellectual property stemming from one core partner.” – Eric Schaeffer, Industry X.0
  • 17. Industry 4.0 – Ignition for Industry 4.0 Level 4 Level 1 Level 2 Level 3 Business Planning & Logistics Control Sense & Manipulate Level 0 Actual Production Process Ignition MES Add In • OEE • SPC • Scheduling • Recipe • Track and Trace Ignition Standard Capabilities • Connect to PLCs • SQL bridge module for tracking and historical data logging • Real time data display via charts and graphs • Reporting module • Alarm module
  • 18. Industry 4.0 – Use Cases – Customer 1  Global Manufacturer 6 Business Units with more than 950 plants worldwide.  Vision to achieve Industry 4.0 driven by Central of Industrial Excellence Centre  Made comparative studies and chose Ignition as the Platform  Selected by 1 business unit in India and executed on a line  On successful execution executed in other business units successfully  Found it very useful as being an Enterprise Level Licence with unlimited Users and Tags which makes the Total Cost of Operation low.
  • 19. Industry 4.0 – Use Cases - Customer 2  Working through a partner in South East Asia  Global Electronic Manufacturer with plants in US, Asia, China  Connected 127 machines with PLCs from Allen Bradley, GE Fanuc etc. and Industrial PCs.  Able to connect some of the machines that are 40+ years old  Collecting Real-time Data of availability, Performance and Quality, system providing accurate OEE numbers in the dashboard with drill down capabilties  “We have seen 7% improvement in our backend equipment OEE and 17% improvement in MTTR. We have seen at least 15% reduction in downtimes in the front end equipment. Overall it has been a positive experience” “