IIoT-in-a-Box: Applicazioni di Internet of Things per l'automazione industriale Presented by Andrea Ceiner, Eurotech and Barbara Angelini, IBM at SAVE 2015 in Verona (Italy)

1. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IIOT-IN-A-BOX: Applicazioni di Internet of
Things per l’automazione industriale
Andrea Ceiner, Eurotech
Barbara Angelini, IBM

2. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IIOT ? INDUSTRY 4.0 ? SMART FACTORY ?
“The integration of complex physical machinery with
networked sensors and software … to optimize
operations”
Fabbrica Intelligente

3. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Due mondi che si avvicinano
IoT
IIOTOT IT

4. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
OT IT
LOW POWER
MILLIONS
CONNECTIONS
FEW MESSAGES x
CONNECTION
Near REAL TIME
LOW FOOTPRINT
HIGH PERFORMANCE
FEW CONNECTIONS
LARGE FOOTPRINT
MANY MESSAGES
PER CONECTION

5. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Non solo in fabbrica: «Non abbandonerai
più il tuo prodotto»

6. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Perché l’IoT ha impatto sull’automazione
industriale e nel manifatturiero ?
EFFICIENZA
• Perché è un’industria MATURA che deve trovare nuove leve
per fare EFFICIENZA nella PRODUZIONE
EFFICACIA
• Perché deve riconcepire i prodotti (SMART CONNECTED
DEVICES)
• Perché deve trovare nuovi MODELLI di BUSINESS (dal
PRODOTTO al SERVIZIO)

7. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IIOT: ne abbiamo davvero bisogno ?
Potenziale Manifatturiero
=
Valore produzione
--------------------------------
Grado utilizzo impianto

8. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Innovazione = Risolvere la complessità
@
Business
Applications
Sensors,
Actuators,
HMI, SCADA,
PLC
Multi-
Service
Gateway
?

9. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Incapsulare la complessità (OT & IT)
Business
Applications@
IoT Integration Platform
Operational
Technologies
Cloud-side
@
Enterprise
Information
Technologies
Data&Analytics Platform (PMQ,MAXIMO,…)
Sensors, Actuators,
HMI, SCADA, PLC
Multi-Service
Gateway

10. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IBM and Eurotech collaboration
IBM Business
applications
Building &
Energy
Management
Predictive
Maintenance
& Quality
Real Time
Monitoring
Enterprise
Asset
Management
Reporting &
Analytics

11. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IBM Predictive Maintenance and Quality è una soluzione preconfezionata cross-industry di business analytics:
 per monitorare indicatori di asset ed analizzare pattern storici di malfunzionamenti
 per anticipare, tramite analisi predittiva, malfunzionamenti di asset
 per indirizzare con ordini di lavoro just-in-time
PMQ analizza dati provenienti da multeplici sorgenti e raccomanda azioni, agevolando decisioni, basate su modelli comportamentali testati.
36
Industry Specific Solution: Predictive Maintenance & Quality

12. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0© 2015 IBM Corporation
PMQ analyzes data from multiple sources and provides
recommended actions, enabling informed decisions
Manufacturing
Data
Inventory
Data
Warranty
Data
Environmental
Data
Financial
Data
Operations
Data
Asset Mgmt
Data

13. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0© 2015 IBM Corporation
Predictive Maintenance and Quality provides several key
features
Maintenance
Analytics
Advanced Quality
Analytics
Open Architecture
Business
Intelligence
Real-time
Capabilities
Quick and Accurate
Decisioning
Maximo
Integration

14. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Key Business Values of Predictive Maintenance & Quality
RIDUZIONE COSTI
in Manufacturing…
 Reduced rework
 Reduced scrap
MIGLIORAMENTO DELLA PRODUTTIVITA’
MIGLIORAMENTO DEL VALORE DEL BRAND
in Distribution…
 Fewer recalls
in Field Warranty…
 Fewer claims
in Manufacturing / Procurement...
 Reduced rework
 Reduced scrap
 Increased capacity utilization
 More on-time shipments
 Higher assurance of delivery of quality products from suppliers
in Development...
 More product coverage, more effective coverage with existing
engineering resources
 Prioritization of most pressing issues
 Single effective process for entire enterprise
 Improved customer satisfaction
 Improved brand image
 Protect high-stakes, high volume product launches
 Higher top-line growth and customer retention

15. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
I clienti riportano i seguenti benefici
5%  in aircraft-on-ground events
1%  in overall maintenance costs
97% ability to predict delays & cancellations within 12 weeks
25%  in overall production line productivity
7 – 10%  in plant maintenance costs
10%  in paint yield
49%  of average inventory
97% fault recognition for specific assembly operation
60%  redundant service calls
87% accuracy within 48-hour warning about potential equipment failures
85% accuracy using analytical model to predict stuck pipe situations
23%  in operating expenses
10%-15%  in annual OPEX budget
1%-3%  in annual CAPEX budget
20-30%  in warranty claim processing times
45.5%  in unplanned maintenance
33%  anticipated in equipment and vehicle failures
34% accuracy predicting machine failures 2+ hours ahead of event
maintenance
finance
supply chain/procurement
customer service
warranty
production
product design
manufacturing
quality control
maintenance
production
data scientist/statistician
maintenance

16. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Global automobile and motorized equipment manufacturer
demonstrates ability to accurately predict production line equipment
failures
Need
Reduce unplanned downtime
on critical production lines.
Challenge: Big Data and Analytics is part of the company’s enterprise-wide
initiative to improve corporate decision making by transforming data into
actionable information. For one of the manufacturing divisions their goal was to
reduce, if not eliminate, unplanned downtime of critical production equipment.
Solution: Analyzed 16 months of production line data to develop predictive
models for machine failures. The company knew the causes of some of the
failures, but was eager to uncover additional patterns to identify causal factors of
failure. Pilot project was able to develop models to accurately predict 34% of
machine failures, specifically: 27% of machine failures occurring during production
time more than 8 hours in advance of the event and 7% of machine failures
occurring during production within 2 to 8 hours in advance of the event
Approach
Pilot project analyzing 16 months
of production data develop
predictive models for machine
failures
Results
accurately predict 34% of machine
failures 2 or more hours in
advance of the event

17. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
A major global steel producer based in Asia uses predictive analytics
to maximize productivity with preventive maintenance
45.5% reduction
in unplanned maintenance
Challenge: client theorized that 65 % of facility failures and product defects during the previous
three years could have been prevented with systematic preventive maintenance and early
warning and diagnosis of problems. However, given the lack of interconnectivity of and visibility
into production, quality and facilities data, the company found it challenging to anticipate
machine or facility failures and product defects.
Solution: Predict and prevent problems by applying analytics to a vast volume and variety of
near-real-time and historical production data. Detect and alert facilities managers to impending
machine malfunctions, allowing them to change production conditions or implement preventive
maintenance to avoid machine failure. The solution can also determine the root cause of quality
issues, helping the company manage conditions to avoid costly product defects.
Higher-quality steel and on-time delivery are helping this steel producer stay ahead of the
competition in a cutthroat market.
100s of millions
in opportunity cost savings by
delivering high-quality products
on time
Increases
productivity with near-real-time
monitoring and accurate alerts

18. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
Large Utility (Asia): helps electric power providers reduce
maintenance costs and optimize parts inventory.
Reduce
expensive damage resulting
resulting from unexpected
breakdown
Optimize
procurement model of major
equipment and warehouse
management of spare parts
Save
approximately 400M ¥ Yuan
(US$65M) of maintenance costs in
5 years
Challenge: Provider of information services and systems to the
equipment-intensive enterprises electric power industry sought
more effective management of clients’ capital equipment and
production assets. Specifically wanted to reduce unplanned
shutdown time, control and lower the operating costs, optimize
operating plans, and improve poorly integrated maintenance
systems.
Solution: IBM PMQ Predictive Maintenance and Quality to
accurately predict the equipment failure, optimize the warehouse
management of spare parts, lower procurement costs, and
improve efficiency of equipment utilization.

19. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
IIOT-IN-A-BOX
• telemetry for live data monitoring of ElectroMechanic Cylinder
• ElectroMechaninc Cylinder re-programming for an unexpected
urgent change in production schedule
Maximo
MQTT MQTT

20. Eurotech Group – Product Management – Contact: pm-global@eurotech.com Rev.: 2.0
www.eurotech.com
Grazie !
www.ibm.com