The document discusses an event streaming architecture designed for Industry 4.0, emphasizing the integration of various technologies such as Apache Kafka, NiFi, and Flink for real-time data processing and analytics. It highlights key use cases for optimizing manufacturing processes, reducing costs associated with downtime and quality issues, and enhancing overall operational efficiency. The architecture aims to support intelligent edge capabilities and facilitate data-driven decision-making across manufacturing plants.

1. Event Streaming Architecture
for Industry 4.0
Abdelkrim Hadjidj - Sr. Data Streaming Specialist
Jan Kunigk - Principal Architect & Field CTO EMEA

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The Industry 4.0 economics
Source: American Society of Quality
Cost of Quality
20 Percent of Sales
Source: Deloitte
Plant Downtime Costs
$50 Billion Per Year
Source: AlixPartners
Quality & Recall Costs
$22B Recall Costs (US/16)
Source: Nielsen Research
Stopped production cost
$22,000 Per Minute
Source: McKinsey
Big Data, Streaming
IOT-Enabled Analytics
10% - 20% cost of quality
reduction
Source: Deloitte
5% - 20% equipment cost
reduction

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Key Industry 4.0 Use Cases
•Harmonization of screw
tightening in all plants
•Re-calibrate manufacturing
robots
•Saving in-fab sensor points
forever (batch data)
Process 360
Process
Monitoring
Predictive
Maintenance
Quality Event
Forensic Analysis
Quality & Yield
Optimization
•Optimize concentration of
cutting fluids
Use Case Examples
•Single-point access to critical
information and control
•Reduce, downtime, scrap and
late shipment costs
•Reduce equipment downtime
and maintenance costs
•Reduce scope of service
campaigns and warranty costs
•Optimize process variables to
improve yields and quality
Benefits
•Cycle time monitoring of CNC
machines

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DATA-IN-MOTION REFERENCE ARCHITECTURE
MiNiFi Apache Kafka Apache NiFi Apache Kafka Apache Flink
DATA SYNDICATION
SERVICE BY KAFKA
Kafka Topic
syndicate-
transmission
Kafka Topic
syndicate-
speed
Kafka Topic
syndicate-
temp
Kafka Topic
syndicate-
geo
DATA COLLECTION
AT THE EDGE
C++ agent
US-West Fleet
C++ agent
US-Central Fleet
C++ agent
US-East Fleet
INGEST GATEWAY
POWERED BY KAFKA
gateway-west-
raw-sensors
gateway-central-
raw-sensors
gateway-east-
raw-sensors
DATA FLOW APPS
POWERED BY NIFI
Kafka Topic
syndicate-
battery
Kafka Topic
syndicate-
start/stop
Kafka Topic
syndicate-
acceleration
Kafka Topic
syndicate-
idle
SUBSCRIBING STREAM
PROCESSING APPS
PROCESSING APP 1
PROCESSING APP 2
PROCESSING APP 3
Apache
Flink
Structured
Streaming
Kafka Topic
syndicate-
oil
Kafka Topic
syndicate-
breaks

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Two main challenges
Traditional solutions are local and limited
● Single process focused analysis
○ Analytics performed at each plant, refinery..
○ Missed opportunity to detect globally
connected (eg. quality, optimizations)
● No condition-based analysis
○ Existing edge analytics check if a sensor is
within control (quasi hardcoded thresholds)
○ Sensor data should be correlated to
reference data
(productivity data, maintenance schedule)
● Simplicity and Manageability
○ No tooling = embedded coding nightmare
Many data sources increase complexity
● Data from different time universes
○ Alignment of timeseries and timestamped
data (Sensor to Quality inspection)
○ Network conditions makes time
management even harder (late arrivals)
● Real time analytics & CEP at scale
○ Trends and aggregates are more
meaningful than events
● Prediction and RCA requires AA/ML
○ High data volume/cardinality
○ Data calibration is a requirement for ML/AI

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Apache NiFi
• Over 300 Prebuilt Processors
• Easy to build your own
• Parse, Enrich & Apply Schema
• Filter, Split, Merger & Route
• Throttle & Backpressure
• Full data provenance from acquisition to
delivery
• Diverse, Non-Traditional Sources
• Eco-system integration
Advanced tooling to industrialize flow development
(Flow Development Life Cycle)
FTP
SFTP
HL7
UDP
XML
HTTP
EMAIL
HTML
IMAGE
SYSLOG
FTP
SFTP
HL7
UDP
XML
HTTP
EMAIL
HTML
IMAGE
SYSLOG
HASH
MERGE
EXTRACT
DUPLICATE
SPLIT
ROUTE TEXT
ROUTE CONTENT
ROUTE CONTEXT
CONTROL RATE
DISTRIBUTE LOAD
GEOENRICH
SCAN
REPLACE
TRANSLATE
CONVERT
ENCRYPT
TALL
EVALUATE
EXECUTE

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How NiFi can help?
Large set of OOTB connectors
MQTT, OPC-UA, AMQP, ..
S3, ADLS, PubSub, ..
FTP, JDBC, NoSQL, Search, ..
UI based fast development
Salable distributed system
MiNiFi agents
Java / C++ lightweight agents
Edge collection (NiFi connectors)
Edge processing (Filtering,
compression, encryption, etc)
C&C: Central command and control
Security
Hub & Spoke architecture
From Edge to Cloud/DC
Site to Site protocol (S2S)
Backpressure, Latency, Throughput,
queuing
End-to-End lineage and security

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How Flink can help?
Time Management
IoT network challenges
Event time management
Late arrival management
State Management
Enrichment
Combining knowledge
State of components
Performance at scale
Industrial Internet to grow 2X faster
than any other data
Data preparation
Filtering, enriching, aggregation,
joining

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NiFi-Flink integration
• Direct integration via Site to Site
• Simple, NiFi is just a Flink source
• How to handle data spike or Flink
outage. NiFi is not a data store!
• Point to point: what if the same data
is needed by several Flink apps
• Native integration via Kafka API
• Requires installing/managing
another distributed system
• Kafka retention can save your life
with data spikes or Flink outage
• Easy to build pipelines with several
steps and intermediate topics

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INTELLIGENT EDGE
Event Streaming Edge2AI Architecture for Industry 4.0
Analyze
•Self-Service Business
Intelligence (BI)
•Enterprise Analytics
Learn
• Historical sensor data
• Historical maintenance records
• Historical usage characteristics
• Historical failures
Model Inputs
Enterprise Transaction
Data
MES, ERP, Maintenance, Supply
Chain, Warranty, Design, etc.
E
N
R
I
C
H
Edge Collection/Analytics
Transmission
Connected Process/Plant 1
Sensors
PLCs
Historians
SCADAs
Connected Process/Plant N
Sensors
PLCs
Historians
SCADAs
Feedback
REAL-TIME
ACTION
ACT CDSW
Standard plants solutions
Edge to Cloud

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End to End pipeline
Plant 2
Plant 1
Plant 3
Enterprise
sources
IoT
Errors
Aggregates
Alertes
Other data
ETL
Analytics
Cross Plants Enterprise Analysis Real Time Analytics
Complexity Reduction

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Why is it important?
And what does it have to do with ML?
item item itemitem item item

13. Demo

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Standards solutions and EdgeToAI architecture
Characteristic Standard solutions Cloudera
Corporate Positioning Real-Time Analytics in the Factory Streaming Platform for Enterprise
Analytics
Market Position IOT Platform Event and Streaming Management
Platform
Analytics Scope Edge Enterprise and cross-factory
Data Ingestion Factory Edge: Specialized for
Machine data
From Edge to Cloud/Data Center,
Enterprise flow management
(MiNiFi/NiFi)
Data Storage None Enterprise Data Lake
Data Processing Edge Batch and Real Time, with advanced
time and state management capabilities

15. 15
Conclusion

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TH N Y U