2

Evaluating IoT Solutions for Small to Mid-Size Manufacturers

Key Topics to Cover with Your IoT Partners

By Rose of Sharon DeVos

3

Today’s Discussion

• 8 Topics for creating your list of requirements

• 3 Primary approaches to data collection

• 9 Solutions to consider

• 5 Steps to select an IoT Machine Data Solution Provider

Machine Monitoring

Manufacturing Operations

Management (MOM)

Manufacturing Execution System

(MES)

Machine Data OEE Software (Overall Equipment

Effectiveness)

IoT Platform

Manufacturing Analytics

4

List Your Requirements

1. Statement of Purpose

2. Which machines

3. Other processes monitored in parallel

4. Data requirements, How & What

5. Visualization needs – People & Platforms

6. HMI – Human Machine Interface

7. Flexibility for creating dashboards, views, drilling

8. Security requirements, internal & external

5

Statement of Purpose

Metalforming company currently enters their machine running start and stop times, as well as production data, at a workstation on the shop floor.

We want to automate data collection where possible to reduce downtime, improve visibility, improve on-time delivery and increase overall equipment efficiency.

6

Machine/Asset List

• What do you want to connect?

Create spreadsheet of all machines/assets you want to connect (include planned purchases)-

• Machine ID : 101• Type: Punch Press• Make: TRUMPF • Model: TRUPUNCH 6000L • Serial Number: 87878787878• Controller type: Siemens Sinumerik 840d CNC Control• Model Year: 2005

Legacy equipment (generally over 15 years old) may need hardware boards. New equipment will be capable of direct connection.

7

Non-Machine Processes monitored together

• Manual assembly work

• Other manual processes

• Work centers in your ERP system

Do you want to see you entire process flow in one place? Eventually add sensors, vision systems, etc.. to capture, but may just want to see what you’re currently entering in your ERP system along with machine data.

8

Data RequirementsHow to automate basic data collection from machines

• Direct connections native to controllers• OPC• MTConnect• Fanuc controls• Other machines, OEM specific

• Hardware needed – I/O Devices• Boards to collect signals (branded boards from IoT vendor, Raspberry

Pi, etc.)

9

Data RequirementsWhat data to collect

• Machine Data• State Data

Reported by machine: Idle, incycle, estop, feedhold

• Custom DataProgram number, overrides, tool ID

• Process DataElements from sensors for machine health like temperature, vibration, current draw, pressure, load

• Job Data • Used to identify operational activity, the basis of performance indicators

Opstep, product standard, Job #, part #, description, sales order #, quantworkcenter, product line, etc.

• Operator States• Non-operational states which the machine cannot identify

• Downtime reasons like no material, full chip bin, breaks, meetings• Override conditions like setup, maintenance

• Shift Data

10

Visualization Needs

• Physical Platforms• Large Displays in Work Areas

• Existing computers

• Hand-held devices, phones, tablets

• App based

• People / Job Function Views & alerts• CEO/Management

• Quality

• Operators by department

• Production management

11

HMI: Human Machine Interfaces

What platform will the operator use to enter data and see information?

• A new program which may be more intuitive than current ERP• Job data is pushed from ERP to new program, operator selects• Or – new program is separate from ERP, Operator scans work orders into both ERP and IoT

platform (can be a temporary solution until integration)

• In current ERP • New fields for operator in-put• A link that opens window for new data input• A frame for new data input

• Integration may be• Non-Existent: Job data is either manually entered, scanned or not entered by operator• From ERP to machine data solution only• Bi-directional – ERP sends job data to machine data solution, the machine data solution sends

work detail records (times, counts) to the ERP.

12

Flexibility for Creating Dashboards, Reports, Notifications

• Company admin creates and maintains

• Can be created by managers, supervisors

• Can drill down from reports, notifications to root causes

• Notification options • Emails

• Pop-ups in current ERP

• Windows pop-ups

• Texts

13

Security Requirements

• User Security

• Data Security• Edge

• Cloud

• On-Premise

14

Vendors Involved

• IoT Platform – core program, database management

• 3rd party integrators –

• ERP company – Integration options/experience

• Machine OEM / controller info.

• Hardware suppliers• Boards

• Sensors

• IT company - infrastructure

15

Non-Technical Key Info

• Ownership, age and experience of company

• Industry experience

• R&D investment strategy for new features

• Customer support, hours

• Site visits to customers

• Number of employees (past year, current)

• Last three years growth (or not)

• Cost per machine initial and on-going

16

3 Primary Approaches to Collect Machine Data

NativeConnections

I/O (Input/Output) Device

Hardware

Electrical

17

Native Connections

Advantage: May have as 250 data points available, no additional cost for hardware

Disadvantage: Complex to connect, IoT platform must put unalike data in one database for use

SINUMERIK 840

Connections that are already on your equipment

FOCUS

18

I/O Device - HardwareAppliance on machines that communicates with gateway via

cellular or Wi-Fi on USB, standard RS-232 or ethernet

Advantage:Simple installSame data points from unalike machinesWorks on old equipment, but can also go on new

Disadvantage: limited data inputs, 4, 8, 16 typical – but do you need more than this anyhow?

At minimum need signals for:

Machine On/Off- Electrical- Switch

Part completedMerlin AX760-MTC

Machine Metrics

19

Electrical

Advantage: No interruption during install. Quick uptime/downtime data.

Disadvantage: Not as many data points available. Does not use any PLC info.

Sensor on circuit for each machine, data aggregator and cellular gateway

Amper.xyz

20

Comparison of 9 Providers of Machine Data Software

How do they collect data?Are they primarily cloud (providing hosting)

or on-premise?

21

How do you collect machine data?

Native Connections – YesCloud

Name: IoT Platform

MTConnect, OPC UA and from CNC Machine controls such as FANUC based controls with FOCAS, Mitsubishi M70, Marubeni Citizen-Cincom M700, Heidenhain 530, Heidenhain640, and Siemens Simuneric840D

IoT Gateway with hardware collecting data for other machines

Machine Metrics Sensr Trx

Native Connections – NoCloud

Name: Manufacturing Analytics

Wireless sensor attached to all machines for key data collection

Pre-configured sensors for faster implementation.

Can use encrypted wireless or cellular services.

Amper.xyz

Native connections – NoOn-Premise to Cloud

Name: OEE & Machine Monitoring

Appliance for electrical circuit monitors electrical signatures and “learns” modes, start, stop, run, setup.

Non-invasive, no IT

Uses cellular services or Wi-Fi

22

How do you collect machine data?

Native Connections – NoCloud

Name: Monitoring Solutions

4, 8 and 16 input send signals via wi-fi to a master receiver

FreePoint Memex CIMCO

Native Connections – YesOn-Premise

Name: Machine DataCollection

MDC-Max collects data directly and though the use of hardware

Native Connections – YesOn-Premise

Name: OEE Software

Native connections to hundreds of data points in

✓ OPC US

✓ Fanuc FOCAS

✓ Siemens

+ 16 point data collecting hardware for other machines

Primary On-Premise

23

How do you collect machine data?

Native Connections – YesOn-Premise

Monitoring & DNC

✓ MTConnect

✓ OPC/UA

✓ FANUC FOCUS

✓ Mazak

✓ Heidenhain

✓ Okuma

✓ Siemens

✓ Haas

+ Hardware

FactoryWiz Predator Scytec

Native Connections – YesCloud + On-Premise

Machine Monitoring, OEE Software

✓ MTConnect

✓ OPC/UA

✓ FANUC FOCUS

✓ Mazak

✓ Heidenhain

✓ Okuma

✓ Siemens

✓ Haas

✓ THINC

✓ PLC/PMC data map available

+ Hardware to MTConnect

Native Connections – Yes

On-Premise

Manufacturing Data

Collection

✓ MTConnect

✓ OPC/UA

✓ FANUC FOCUS

+ Hardware to MTConnect

24

1. Create your requirements.

2. Interview top 4-5 companies with answers to top questions.

3. Invite 3 for demos.

4. Visit (2) customers if possible, one from each of your top 2.

5. Make a deal & get started!

Steps to Select your IoT Machine Data Solution Provider

25

IIoT Automating Solutions

I can help you create your IoT requirements and walk though this process so that you select the best partner(s) for IIoT.

Rose of Sharon DeVosOwner & CEO

devos@iiotautomating.com630-465-2270

Advocate for Manufacturers on their IoT Journey