Industrial automation and Industry4.0 presentation with predictive maintenance

1. INDUSTRY4.0
UniConvergeTechnologies Pvt. Ltd.
(UCT)

2. KaushlendraSingh Sisodia
• IITK Alumnus
• 19+ year Industry experience
• Presently working as Director of UniConverge
Technologies Pvt. Ltd.
• Worked with many MNCs
• Ericsson AB, Sweden (for 7 years)
• SASKENCommunicationTech., Bangalore
• UbiNetics India Pvt Ltd, Bangalore
• STMicroelectronics Pvt. Ltd, Noida

3. What to discuss today?
•History of Industrial Revolutions
•Brief about Industry4.0
•IoT and it's applications in Industry4.0
•Convergence of AllTechnologies in context of
Industry4.0 (ML, data analytics and computer vision
AR/VR)
•Present status of Industry4.0 worldwide and in India
•Conclusion
•Q&A
3

4. Industrial revolution
4

5. Industrial Revolution History

6. Industrial Revolution History

7. How analytics evolved in the industrial context

8. Analytics evolution towards real-time, predictive,
and prescriptive

9. Industry 4.0
9

10. Industry 4.0

11. Industry 4.0

12. Why IoT is a game changer for Industrial analytics

13. Real-time Connected Supply Chain

14. Industry 4.0 solutions by business function

15. The Internet of Things & Manufacturing
• IoT applications in mfg. and factory settings expected to
generate $1.2 to $3.7 trillion of economic value annually by
2025.
• IoT will revolutionize manufacturing processes.
• IoT will revolutionize manufactured products and product
systems.

16. IoT and Manufacturing Processes
IoT will generate 4 primary forms of value in terms of
manufacturing processes:
1. Supply Chain Management;
2. Operating Efficiency;
3. Predictive Maintenance;
4. Inventory Optimization.

17. IoT and Supply Chain Management
IoT can help manufacturers better manage their supply chains.
• BMW: Knows the real-time status of all machines producing all
• parts/components from all suppliers going into vehicles.
• Toyota: Reduces recalls by knowing exactly what machine produced
• which components of which vehicles.
• HP: Integrates network analysis and data visualization into its supply
chain management and monitoring; has reduced the time for supply
chain management projects by up to 50%.

18. IoT and Manufacturing Operating Efficiency
• IoT provides manufacturers a comprehensive view of what’s
occurring at every point in the production process and helps
make real-time adjustments.
• Will increase manufacturingproductivityby 10-25%.
• Producing up to $1.8 trillion in global economic value by 2025.

19. IoT and Manufacturing Operating Efficiency
Explosionof low-cost sensor technologies has made every
manufacturingprocess and componenta potential data source.
Ford: Placed sensors on virtually every piece of production
equipment at its River Rouge facility.
GM: Uses sensors to monitor humidity conditions during
vehicle painting; if unfavorable, the work piece is moved
elsewhere in plant or ventilation systems adjusted.
Raytheon: Keeps track of how many times a screw has been
turned in its factories.
Merck: Improves vaccines by conducting up to 15 billion
calculations to determine what environmental and
process factors influence quality of final product.

20. IoT and Predictive Maintenance
Monitor the status of production equipment in real-time.
Intel: Uses predictive modeling to anticipate failures, prioritize
inspections, and cut monitoring costs, save $3M.
Ford: Downstream machines can detect if work pieces they
receive are off in a particular minute dimension,
indicating possible problems in upstream machines.
GE: “Brilliant Factories” initiative doubled production of defect-
free dishwashers and washing machines.

21. IoT and Predictive Maintenance
• IoT expected to reduce factory equipmentmaintenancecosts
by up to 40%.
• Expected to reduce equipmentdowntimeby up to 50% and is
expected to reduce capital equipment investment costs 5%.
• Generating economicvalue of $630B annuallyby 2025.

22. IIoT Growth:Why Now?

23. WhatComprises IoT Networks?
Information
Technology
(IT)
Operational
Technology
(OT)
Smart
Objects

24. IoT Networking
24

25. Study of Some Industrial Surveys
25
• How much Industries are ready for IoT?
• What is Present Status and what is coming in future?

26. Industrial Analytics to play a crucial role in
organizations in 5 years
Question: What role does Industrial Data
Analytics play in your organization?

27. Biggest benefits of Industrial Analytics
Question: What are the biggest benefits of Industrial Data Analytics for your company?*

28. Usecases and Practical Implementation

29. 29
Data Logger Architecture

30. 30
Data Logger Example

31. 31
Predictive Maintenance of Solar Panel

32. 32
Value of Monitoring
• Increased frequency and duration of power generation outages
• Increased operational expenses
• Risk of not knowing if the system is underperforming
• Cannot easily compare actual against expected energy generation
• Cannot benchmarkexpected performance of different technologies
• Maximizing solar energy production and revenue
• Measures performance from strings, inverters and generation meters
• Identifies low performance and reduces power loss
• Increases operational productivity for reduced total cost of ownership
Plants without Solar Monitoring
Plants with Solar Monitoring

33. Process Flow of Steel Plant

34. Industrial Revolution

35. AFTER INSTALLATION OFVIBRATION SENSORS

36. Present Scenario

37. Instances of failure

38. EXPECTEDSCENARIO

39. Technologies used in Industry4.0

40. Robotics

41. VR,AR, Remote Control

42. Reducing
Inventories
↔
Production
MGMT SW
(MES,APC,
ERP)

43. Reducing
Inventories
↔
Production
MGMT SW
(MES,APC,
ERP)

44. IOCL
Predictive
maintenance
solution

45. UCT
Products
Perspective

46. UCT’s Penetration

47. DATA AGGREGATOR AND MONITORING
SYSTEM
IOT Based Control and Monitoring
System
Industrial IOT Gateways,
Machine to Machine Cloud
Industrial Data Logger
 Compact DIN Rail Mounting
 MODBUS RTU RS-485
 SD Card Data Recording
 Plug and Play Device
 Cloud Ready Gateway
 Real TimeMonitoring and Logging
 Industry Compliant
 Modular Architecture

48. DATA AGGREGATOR AND MONITORING SYSTEM
IOT Based Control and Monitoring System

49. Conclusion / Q&A
49

50. THANKS
• E-mail: kaushal@uniconvergetech.in
• URL: www.uniconvergetech.in
UniConverge Technologies Pvt. Ltd.