Digital supplement to
Technology Handbook
INTERNET OF THINGS A look into the products, technologies and solutions shaping the market
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move? Factory of the Future
ts the virtual world operator in our own
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Technology Handbook | INTERNET OF THINGS
Using PC Gateways to Connect Legacy Systems Using an ultra-small, industrial PC that acts as an IoT gateway provides benefits such as communication, big data analytics and proactive maintenance By Joseph Yang, Advantech Director of Product Management
T
here are several reasons for the advance of the Industrial Internet of Things (IIoT). One is that the cost of connecting a device has fallen, thanks, in part, to the continuing drop in price for semiconductor technology. Another is that a benefit of communication is an increase in available data. This means that manufacturing floors have access to sensor and other data that machines generate. In turn, this allows better decision making about the health of a machine and a process. For example, having access to the Big Data analytics of a factory raises the possibility of tuning production to skew it to higher output and lower failure rates. Connectivity also enables two-way communication, with remote access, for monitoring and control of manufacturing devices and systems. This ability allows a factory to move from reactive maintenance to proactive maintenance, resulting in less unplanned downtime, greater productivity and lower costs. But there exists a stumbling block for many companies when it comes to achieving these benefits. According to IMS Research, about 85 percent of devices currently in use are legacy systems and often operates in stand-alone, isolated applications. Because these devices have long life spans, this means that many of the systems in place in factories today either lack any connection capability, use a proprietary protocol, or are otherwise unable to link up with the modern IIoT systems. To overcome this legacy device barrier, users can deploy an IoT Gateway to serve as a bridge between legacy devices and the wider world of systems, the cloud and the IoT. If you choose to pursue this option, be sure to select an IoT Gateway with the right physical and communication characteristics.
An illustration of how Advantech’s UNO line of IPC IoT gateways can be used to connect plant floor devices to the cloud for analysis.
Bridging the Gap An IoT gateway can overcome the legacy challenge by linking systems on the factory floor with the IoT and on to the cloud by supplying the missing communication capability.What’s more, since it is a single and separate add-on unit, it can be upgraded and changed out as needed. It also is possible to install such a solution in stages, deploying it first to those systems that provide the greatest return on investment and then rolling it out to others when doing so makes the most sense. An IoT gateway, like any communication solution, must be cost-effective. To see why, consider that it will be applied to legacy systems. This means it may be applied in situations where the other equipment is substantially or fully depreciated.Though this helps the bottom line of a manufacturing process, it places constraints on any upgrade or add-on. After all, any addition to an existing system could have a significant impact on the bottom line and profitability. That makes it imperative that the IoT gateway be cost effective. In addition, a gateway must offer wide and comprehensive protocol support. As
2 MANUFACTURING AUTOMATION · Technology Handbook Internet of Things
an add-on, a gateway will have to successfully interface with a variety of PLCs and other devices, which communicate via different interfaces and protocols.The gateway must be able to deal with all of these. The gateway should also handle data acquisition and protocol conversion of the data into an appropriate format. An industrial PC (IPC) can meet these IoT gateway requirements and satisfy several other important parameters. Critically, an IPC can be both rugged and compact. The first is a necessity because the application is an industrial one, therefore any device in this kind of environment will be exposed to temperature, humidity, vibration and dust extremes. An IPC is designed and built to work reliably in such conditions. As for the requirement that a solution be compact, that arises because any gateway will be an add-on to a legacy system. The amount of available space may be very limited, which means that a communication solution should take up as little space as possible. Because such space constraints can limit functionality of an IPC in such an application, it is preferable for the IPC gateway to have a flexible form factor and allow for configuration as needed. Finally, any IoT gateway must provide web and cloud access, as well as support for an HMI. The first option is important for any remote access. The second is extremely useful when changes are going to be made locally. Again, a solution based on an IPC can offer such capabilities.
Reaping the Benefits Advantech’s various UNO offerings are examples of such IoT gateways. This product family includes X86 systems (UNO-2271G and UNO-2272G) as well as others based on RISC and QUARK processors (UNO-1251G and UNO1252G). Visit www.Advantech.com for more information.
Extract Your Machine Intelligence With Advantech’s Industrial IoT Gateways
Seamless Connection, Aggregation, and Transmission Advantech’s wide selection of Industrial IoT Gateway Solutions are designed with Industry 4.0 technologies in mind. With their advanced communication capabilities, these smart factory solutions make connection to the cloud easy.
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Contact us today to discuss your requirements: 1-855-REXROTH (739-7684)
Technology Handbook | INTERNET OF THINGS
Order your free Factory Automation Resource Kit: www.boschrexroth.ca/factoryautokit For expert advice call 1-855-REXROTH (739-7684) or email us at info@boschrexroth.ca
O
DRIVEN TO SUCCEED
ver the last 20 years Amsler Equipment Inc., a familyowned company that builds heavy-duty machines has displayed a remarkable knack for making high-quality stretch blowmolding equipment, empty bottle load testers, spin trimmers and various downstream filling equipment and has built a tight partnership with the Drive & Control specialist, Bosch Rexroth Canada. Like all machine manufacturers, Amsler Equipment is continuously upgrading its offering to respond to evolving market demands and customer expectations. Rexroth had a very significant role in helping Amsler develop different technology improvements, like its next-generation L42X four-cavity linear stretch blow-molding machine. Bosch Rexroth has provided them with servomotors, drives and other electrical system components, to ensure optimal motion control. Rexroth controls technology allows the machinery to turn preforms into finished bottles. Additionally, Rexroth has been able to provide Amsler outstanding service, technical support and engineering assistance. Featured in this application is the 1,000 W heating lamps and oven controls, along with a double-acting clamp to move both mold halves away from the centerline upon opening. The L42X machine makes optimal use of Rexroth’s IndraDrive Mi drives, to implement game-changing transformation in the machine design, simplicity and performance. By using a Rexroth MLC (Motion, Logic and Control) controller, Amsler gets all the software architecture to control all the motion, logic and power distributed to the proper I/O connectors: “Now there’s just one power source in the cabinet that powers
A close-up to the Rexroth MLC controller and related components inside the L42X machine
all nine motors/drives, instead of one for each axis.”…says Paul Thiele, Technical Sales Consultant, Bosch Rexroth Canada. According to Heidi Amsler, the IndraDrive Mi has enabled Amsler to replace the new servo systems to make the machine faster, reduce its maintenance requirements, and freed up extra space inside to enable us to include new value-added features such as preferential heating and automatic neck orientation. All these enhancements add up to about a 10% improvement in the new machines performance, as well as an 85% reduction in cabinet space, making shipping and field startup much simpler and quicker. By incorporating the Rexroth IndraDrive Mi technology into the new blowmolder, the L42X machine is now perfectly compatible with the Industry 4.0 working environment based on the constant exchange and analysis of machine data between all the different pieces of automated equipment
4 MANUFACTURING AUTOMATION · Technology Handbook Internet of Things
employed at modern manufacturing plants. The Rexroth MLC control software provides the full view of the system, and gives Amsler the ability to look into each of the drives and their motion profiles to see if there is a problem on any specific axis. With the ability to see and analyze each axis, Amsler is able to compare the data received with previous data and recorded cycle times, enabling them to do a very detail analysis on these machines and to make necessary tweaks to reduce cycle-times. Amsler says: “When we were looking to develop this new machine we contemplated the idea of perhaps using other automation suppliers, but given our long and successful history with Bosch Rexroth Canada we decided that they were the best option for us. The outstanding work they have done with our new L42X machine fully validates our decision. Bosch Rexroth is a company that is demanding on itself as it is on its suppliers always raising the bar for service and technical excellence”.
You're ready. We're set. Let's move.
Your move? Factory of the Future Realizing the production of the future today Industry 4.0 changes the world of production and connects the virtual world to the real world of machines. We use our expertise as an operator in our own plants and as a provider of intelligent drive and control technologies to develop and continuously expand our Industry 4.0 solutions. Initial results show the advantages—among them are higher productivity, more individual production and more efficient human-machine interaction. This strong base creates new value networks and allows Industry 4.0 to become a reality in your company. Contact us today to discuss your requirements: 1-855-REXROTH (739-7684)
Order your free Factory Automation Resource Kit: www.boschrexroth.ca/factoryautokit For expert advice call 1-855-REXROTH (739-7684) or email us at info@boschrexroth.ca
Technology Handbook Internet of Things · MANUFACTURING AUTOMATION 5
Technology Handbook | INTERNET OF THINGS
Festo Motion Terminal: A revolution in pneumatics
D
igital pneumatics promises to profoundly change how machines and processes are designed and managed in both factory and process automation. It’s the biggest advance in pneumatics in a generation. It greatly simplifies the planning, installation, operation and maintenance of a pneumatic system. It can deliver cost and time savings, improve operational efficiency and productivity, reduce energy usage significantly and minimize downtime through preventive maintenance. It’s smart technology with self-learning capabilities that moves pneumatics squarely into the realm of Industry 4.0.
Software replaces hardware Festo has launched the age of digital pneumatics with the new Festo Motion Terminal (VTEM). Software in the form of motion apps, combined with new, flexible valve technology – both resident in the Motion Terminal – perform the functions of a conventional valve terminal while eliminating the need for up to 50 individual components in the compressed air system: sensors, pressure regulators, flow control and exhaust valves and more. The Motion Terminal embodies a valve design with multiple degrees of freedom for actuation, as well as integrated data acquisition and processing like a true cyber-physical system. Its unique technology includes valve electronics – the integrated stroke, pressure and temperature sensors that provide optimum control and transparent condition monitoring. VTEM valves are not restricted to performing a single function like standard valves. With the motion apps, each valve can be used to execute a wide range of functions.
Manage, optimize, revamp production Motion apps can optimize the performance of the pneumatic system through selectable pressure regulation and managing supply and exhaust flow control. There is a motion app that can perfectly synchronize multiple cylinders and continually fine-tune their performance. By managing the air supply, another app can eliminate the need for damping or end cushioning in pneumatic cylinders. Other apps can optimize energy use (reducing it by up to 70%), set selectable pressure levels which also saves energy, and perform diagnostics to detect air leakage and its precise location. The operator can set up, monitor and change processes via these apps, on a PC or PLC, rather than having to adjust or replace valves and other components manually for changes in production. The Festo Motion Terminal is a revolution in pneumatics. Here are three ways to find out more about the Motion Terminal: Click here to visit our VTEM website Or download our whitepaper on VTEM and other Festo Innovations: “New Ways to Increase Productivity with Smart Systems”. Click here. And don’t miss our videos: Click here and here and here
5300 Explorer Drive Mississauga, ON. L4W 5G4 Phone: 1 877 GO FESTO festo.canada@festo.com
www.festo.ca
6 MANUFACTURING AUTOMATION · Technology Handbook Internet of Things
Digitalized Pneumatics
World’s first in digitalized pneumatics: Festo Motion Terminal VTEM The Festo Motion Terminal VTEM is opening up radical new dimensions in the world of automation. It’s the world’s first valve to be controlled by apps. It combines the advantages of electric and pneumatic technology for numerous functions that currently require more than 50 positions. www.festo.com/motionterminal
Technology Handbook | INTERNET OF THINGS
See How Hollywood Sees Modular Connectivity
HARTING announced a newly developed short film to reintroduce their Han-Modular® product line to the industry. The protagonist of this new 90-second movie is an engineer who is struggling with a design. The solution is HARTING’s Han-Modular® series which is illustrated as a robot that transforms as the engineer’s design changes. The film was developed with a Hollywood agency based in Chicago, IL. “We wanted to do something different, something that the industry hasn’t seen before,“ said Christina Chatfield, Vice President of Marketing Communications and Digital Transformation of HARTING Americas, „At the same time, we wanted to do something that would excite and inspire engineers. We knew we had to do something big.“ This film marks the beginning of a new marketing campaign for the
product that focuses on the benefits of the product line, which includes space-savings, design flexibility, IIoT compatibility, and low-maintenance for the end user. “Han-Modular® is a very important product for the industry,“ said Cory Jenkins, Director of Product Management of HARTING Americas, „It was developed in 1996 with 6 modules. Now there are over 100 modules, and HanModular® remains our fastest growing product line.“
About HARTING The HARTING Technology Group, family owned and based in Germany, employs more than 4,300 people globally with subsidiaries and branch offices in 40 countries. With production facilities in Europe, Asia, Mexico and the United States, the Telephone 1 (855) 659-6653
HARTING.ca 8 MANUFACTURING AUTOMATION · Technology Handbook Internet of Things
HARTING portfolio of connectivity solutions focuses on multiple levels, from the machine to the device and into the communication infrastructure. The U.S. facility in Elgin, Illinois is one of three HARTING locations that manufactures the HIS product line (HARTING Integrated Solutions - backplanes) and custom cable assemblies. HARTING also has custom cable assembly capabilities in Mexico and Brazil. The company’s core business is intelligent and highperformance connection technology. HARTING works in almost all industrial markets with a focus on requirements for robust, reliable connectivity solutions. To view the film and learn more, visit Han-Modular.com
“Industrial Transformation Begins Here...” - Han-Modular® The biggest transformation the industry has never seen before
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Combine Different Media into One Customizable, Plug & Play Connector Solution Space-savings. Flexible. Low-Maintenance. IIoT-Capable. ■ See how you can save cost and time by downloading the Han-Modular® app.
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■ Free up your time by taking advantage of HARTING’s assembly business.
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Technology Handbook | INTERNET OF THINGS
As Easy as … RFID
R
FID is a key technology for IIoT and cloud logistics. It might seem simple at first, but it can quickly get difficult if deployed incorrectly or not understood. Complexity is a key factor that keeps management from considering RFID when driving strategic initiatives in company operations. With its new IOLink-capable RFID read/write heads, Pepperl+Fuchs is giving integrators and OEMs cause to reconsider.
Pepperl+Fuchs’ new IO-Link RFID heads are available in three housing styles. They can be connected via an Ethernet IO-Link master—or directly to a PLC
Plug-and-Play Identification “Easy” and “RFID” are not normally used in the same sentence. But Pepperl+Fuchs’ new read/write heads are changing that. By default, these devices communicate in “easy mode.” This allows data to be read directly from tags without a handshake procedure. Further, the read/write heads can be easily connected to any IO-Link master. This simple and universal connectivity reduces the work required for device integration and data processing. It is perfect for less-experienced RFID users but is still powerful enough to handle most identification applications. Along with easy mode, an auto-start function is also activated by default. This further reduces commissioning time by automatically enabling tag data to be read as soon as the read head is powered. No control values have to be sent to the device, and no additional function blocks need to be programmed. Data is easily compiled in the controller. Continuing the theme of simplicity, a standardized IO-Link interface on all of the new RFID read/write heads enables connectivity to most common bus systems. Devices can be connected directly to a PLC with an integrated
IO-Link master inside the main cabinet or on the machine itself with any fieldmountable IO-Link master. IO-Link connectivity also gives users more flexibility when it comes to device configuration. Intuitive configuration tools are available that allow read/write parameters to be adjusted and then stored in the non-volatile memory of the reader until the next change.
Complete System Solution The new Pepperl+Fuchs RFID read/ write heads come in three housing styles. Each has unique advantages based on the application requirements, and a variety of tags are also available. Available read/write head housing styles: • Flat pack: IQT1-FP-IO-V1 • Flat rectangular: QT1-F61-IO-V1 • Cylindrical: IQT1-18GM-IO-V1 An end-to-end IO-Link system solution of RFID components and IO modules enables communication between all levels and paves the way
10 MANUFACTURING AUTOMATION · Technology Handbook Internet of Things
for IIoT applications. With the recent release of its new Ethernet IO modules with integrated IO-Link master (ICE18IOL-G60L-V1D), Pepperl+Fuchs offers the perfect connectivity between read/write heads and PLCs. The ability to connect up to eight IO-Link devices reduces costs per channel and makes data transfer more efficient.
RFID without the Complexity Pepperl+Fuchs’ new IO-Link RFID read/write heads—connected to an Ethernet IO-Link master—offer a complete, flexible system solution. With easy mode and auto-start functionality, they reduce complexity and make advanced identification attainable, even for users with limited RFID experience.
Danius Silgalis Product Marketing Manager, Intelligent Systems
dsilgalis@us.pepperl-fuchs.com
Simplifying integration. Providing flexibility. Opening communication. RFID Read/Write Heads with IO-Link Plug-and-play identification
Easy mode reduces complexity without
compromising performance
End-to-end IO-Link system from a single source
www.pepperl-fuchs.com/pf-rfid-io
PERSPECTIVES
ACCELERATING THE TRANSFORMATION TO INDUSTRY 4.0 BY IVO MALTIR
T
he theoretical benefits of Industry 4.0 are wellknown, but how can we speed up its adoption and what practical tools are available to those who want to establish a factory of the future? Ivo Maltir, vice president of Desoutter, a specialist in industrial assembly solutions, examines the challenges and opportunities involved. Digitalization is becoming increasingly common as manufacturers of components and systems develop ways to make their products more intelligent. The potential benefits in terms of increased efficiency and responsiveness in a production environment are already clear, but there is still uncertainty about how and when the full benefits of the fourth industrial revolution — Industry 4.0 — will materialize. There are several factors that need to coalesce in order for Industry 4.0 to become a reality. Strong political and economic incentives, the correct investment in skills and training, and the availability of advanced tools that make implementation easy will all affect the pace of adoption. Global contrasts Around the world, the economic, political and technological drivers for Industry 4.0 adoption vary considerably. In countries like Germany and the U.K., Industry 4.0 is viewed as the route that will lead to the emergence of the smart industry, where people, devices, objects and systems combine to form dynamic,
self-organizing networks of production – made possible by technological advances which constitute a reversal of conventional production process logic. For the U.S., the emphasis is more on the role of big data in effecting collaboration, and Industry 4.0 has become synonymous with the Industrial Internet of Things (IIoT). Over the next five years, the U.S. is expected to invest more capital into the digitalization of manufacturing than any other nation or region. Meanwhile in China, where labour and materials costs are rapidly increasing, digitalization is being championed as a means to transform outdated
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production methods. Many Chinese manufacturers are still operating in the age of Industry 2.0. However, the political impetus for change is evident in China Manufacturing 2025, a government plan to transform the country into an advanced production nation by the middle of this century. This initiative will see heavy investment in internet architecture, Big Data and Cloud computing, leading to more intelligent factories. The pace of change necessary here is incomparable with other developed nations — China is looking to take a careful, methodical approach to the digitalization of manufacturing,
seeking partnerships with more experienced nations along the way.
Successful Industry 4.0 implementation requires strong Industry variations Adoption of Industry 4.0 principles also leadership. The person at the top varies between industries. The automomust set the example and be seen to tive sector is well-advanced in the adoption of automation, data interchange embrace change, commit to it, and and advanced production technologies, communicate it in a compelling way. being motivated by high volume, high quality, cost sensitive manufacture. This sector views process control as the means to further improve the quality of production processes while also reducing operating expenses. In component production plants, Industry 4.0 implementation offers considerable potential, especially in predictive maintenance. Continuous recording and analysis of process data allows plant and system failures to be predicted, inefficient developments to be corrected, and productivity to be improved. By contrast, the aerospace industry has been slower to adapt automated over manual processes. The reasons are clear enough — production is characterized by relatively small volumes, large components and accessibility problems during assembly. All these factors are barriers to change. Nevertheless, the need to limit quality costs and cycle times, to exclude human factors as a source of error as far as possible, and to become more efficient generally are key drivers. Major aerospace OEMs are beginning to embrace intelligent software and digital networking, with advanced assembly tools making a key contribution. The potential for small changes to make a big difference are particularly evident in this sector — a one-per-cent improvement in fuel efficiency represents a saving of US$2 billion for the airlines. Taking the industry as a whole, common drivers are needed to bring innovative products to market more quickly. Industry 4.0 offers the means to completely digitalize the product development life cycle. This in turn allows manufacturers to provide customers accurate traceability, quality control and cost-effective new products. Individual responsibilities In addition to global and industry sector differences, the successful adoption
of Industry 4.0 is reliant on the human factor – our willingness to understand, embrace and deliver change. According to Harvard Business Review’s From Data to Action report, the most difficult aspect for organizations to change on the route to smarter factories is their internal culture. Successful implementation of Industry 4.0 therefore requires strong leadership. The person at the top must set the example and be seen to fully embrace change, commit to it, and communicate it in a compelling way. The philosophy of making fact-based decisions using quantitative manufacturing data will need to be coached into all levels of management. Indeed, everyone at every level of the organization needs to understand how they will benefit from Industry 4.0. For example, the use of collaborative robots (cobots) for unergonomic, complex or repetitive tasks does not signal the rise of the machines and unemployment. It means that manual and automated processes within production can interact with each other in the most effective way. It means protecting operatives from genuine health issues associated with repetitive tasks. In addition, real-time production monitoring renders many manual interventions unnecessary — freeing up time for personnel to undertake more profitable value-added work. Tooling up A smart factory requires a vast range of products embedded with systems, sensors and actuators that are all linked to one another via the Internet, including assembly tools. These tools need to support the transition from traditional ways of working to a more digitized workplace where optimization delivers economies and efficiencies we are only just beginning to exploit.
As part of this transition, intelligent tools must provide support to operators as they adapt to Industry 4.0 ways of working. In the past, an assembly worker was valued because they could perform the same task competently on the same line day after day. In a smart factory, that same worker may be required to rivet body panels one shift and wire up a lighting system on the next. Traditional training in all these skills takes time, and the pace of technological change can render such learning obsolete very quickly. Looking ahead, many specialists are already developing the next generation of tools that can deliver Industry 4.0. capabilities and support the smart factory model. We confidently predict that tomorrow’s operating platform will deliver a major step change in multitool management, offering far greater connectivity and flexibility than is currently possible. Final thoughts Industry 4.0 may have some way to go, but it is gathering pace. Governments around the globe acknowledge its potential to deliver wealth and job security and are taking positive steps to help their industry-base make the transition. Forward-thinking companies also recognize they have to invest in the latest technologies if they want to achieve long-term improvements in production efficiency. There is also a growing awareness of the human factor, and how we need to make sure that people are equipped with the right tools to be more flexible and adaptable. If we want these things to happen more quickly, then we must all play our part in accelerating the transformation. | MA This article is based on Desoutter 4.0, Accelerate your transformation, an eBook published to coincide with Desoutter’s centenary.
Technology Handbook Internet of Things · MANUFACTURING AUTOMATION 13
TECHNOLOGY
AUTOMATING REAL-TIME DEMAND-DRIVEN SUPPLY CHAINS Consider technology with value-added capabilities for a layered approach BY JOHN MAHER
S
adly, the number of large, multinational manufacturers who are still using spreadsheets and manual processes to manage their largest cost centre, production operations, remains common. These manufacturers have reverted to spreadsheets for two reasons. First, there is no reliable “single version of the truth” from any one
system they can draw upon. Secondly, manufacturing software packaged with enterprise resource planning (ERP) systems lack flexibility; they don’t really work the way the manufacturer needs them to and fail to provide meaningful access to real-time and accurate data. While ERP software is a critical business tool for managing transactions – and translating data into financial insights – it often falls short in managing the
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activities behind those transactions. Also falling short are other software products such as MRP, APS, and FCP systems due to a singular focus, rigid transactional design, and inability to support modern manufacturing methods including lean, constraints management, and demanddriven manufacturing. A lean, layered approach to transformation Manufacturers continue to invest in technologies to transform their environment through digitization, synchronization, and ubiquitous visibility. Increasing numbers of manufacturers are taking advantage of more flexible
and highly configurable Cloud technologies that allow them to affordably layer on value-added capabilities, rather than “rip-and-replace” expensive enterprise systems. A layered approach goes hand-inhand with the lean and continuous improvement principles inherent in modern demand-driven manufacturing. Layering technology allows manufacturers to approach transformation to modern methods pragmatically and achieve significant wins. For many modern demand-driven manufacturers, transformation begins at the core of their business: Throughput. That is, how quickly and cost-effectively can you get your product into the hands of the customer. Toward that end – and the most common application of layering technology I’ve experienced – is the layering of a manufacturing system of record MSOR on top of the ERP system to automate and – this is critical – synchronize planning, scheduling and production execution. Synchronization of all production-related elements is the key to eliminating costly downtime, driving end-to-end production flow and
ultimately increasing throughput. The MSOR leverages the ERP system for its intended purpose – transactional data – but its core function is to drive end-to-end production flow. It leverages synchronization technology to align all elements needed to execute an order, utilizes constraints management to optimize the pace of production, collaborates with the extended supply chain to automate replenishment, and enables real-time, universal, enterprisewide visibility. Instead of collecting data for data’s sake, the MSOR curates data from multiple sources then serves it up in ways that help the manufacturer achieve goals that are meaningful to them such as predictive maintenance, reducing lead times and improving inventory flow. As a result, we’re seeing new Industrial Internet of Things (IIoT) enabling intelligent devices springing up all over the shop floor. As a side benefit – but not one to be understated – these intelligent devices are not only making it easier to gather much-needed data, but they are also improving the productivity of individual workers on the shop floor. For example, instead of requiring a work center operator to decipher a spreadsheet-based production schedule (that is probably out-of-date within minutes of being released) and then adjusting work accordingly, a MSOR dynamically adjusts production schedules to reflect up-to-the-minute information on orders, priorities, delivery schedules and production flow. One extrusion equipment manufacturer deployed a MSOR to reduce stock outs of stocked parts by 25 per cent and returned to profitability for the first time in three years. In another case, and after only a month, a steel wire manufacturer achieved an all-time production record and attributed the performance increase to the new MSOR. Similarly, the largest wood products producer in the U.S. experienced a 20 per cent bump in capacity and a 10 per cent increase in throughput after implementing a MSOR. These quick ROI-producing improvements were not made by replacing large enterprise systems, rather by layering specialized, performance-producing software.
Synchronization matters Manufacturers are responding to more enterprise-level requests for synchronization to provide a real-time, single version of the truth to all. Access to order status, priorities, production schedules, replenishment across multiple facilities, supplier networks, and outsourced/contract manufacturers is possible thanks to both the MSOR and Industrial Internet of Things (IIoT) technologies. As mentioned, a MSOR benefits manufacturers because it synchronizes equipment, processes, data, and people to drive uninterrupted production flow. IIoT technologies are a valuable part of this equation because they standardize the data from multiple, disparate sources (systems, machines, sensors, etc.) providing the ability to universally access, aggregate and analyze the data. The next step is to synchronize data from these sources and apply the appropriate contextual insight. For example, a machine goes down on the shop floor. Understanding the environmental conditions associated with the machine’s location – temperature, humidity, particle count, etc. – could lend valuable insight into the issue as would the age and maintenance history of the equipment. Imagine the value to the manufacturer in synchronizing these data elements for immediate root cause analysis. IIoT technologies serve up this level of detection detail to drive corrective action while the MSOR is adapting the schedule in real time to maintain promise dates. Trusted version of the truth Synchronization technology enables the MSOR to become the trusted “single version of the truth” accessible to all. And synchronization technology curates data to make the IIoT actionable with decision-driving information that is instantly available to improve production flow, address quality issues, mitigate downtime events and more. It’s never too late to prepare your organization for a better future. By synchronizing all activities and resources to actual demand, modern demand-driven manufacturing synchronization technologies and a MSOR can help you reach your most important KPIs. Perhaps finally, we can now retire spreadsheets and operate in real time. | MA
Technology Handbook Internet of Things · MANUFACTURING AUTOMATION 15
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IT’S FAST, IT’S EASY AND IT’S FREE! SOFTWARE: Why small business environments cannot follow the enterprise approach. p.24
CYBERSECURITY: Keeping plant floor secure in ADVANCED WARNINGS: your the Industrial Internet of How the connected industry can help you predict and prevent failures. p.20
TECHNOLOGY: Cloud and Fog computing will advance SCADA systems. p.22
INDUSTRY WATCH: Making sense of Big Data, IIoT and Industry 4.0. p.10
BACKSTORY: Boost your business by expanding into international markets. p.30
Things era. p.12
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