Uncover actionable insights that drive operational improvement...Uncover actionable insights that...
Transcript of Uncover actionable insights that drive operational improvement...Uncover actionable insights that...
Industrial Internet of Things (IIoT) Applied SolutionsDiscover how digital transformation can turn real-time data into increased efficiency and reduce operating cost
Uncover actionable insights that drive operational improvement
Operational challenges
Devices/Equip-ment
Predictive Maintenance
•Machinesanddevicesoffernoconditionmonitoring,leadingtounexpecteddowntime
•Unabletoidentifyproblematicdevicesandschedulemaintenance
Sustainability
•Machineperformanceisnotmonitoredleadingtohigherenergyconsumption
•Lossesandleaksgoundetectedleadingtowastedenergy
•Undetectedissuescreatelatestagequalityissuesleadingtoscrappageandmaterialwaste
Globalcompetitionrequiresmanufacturerstostriveforoperationalexcellencetoensuretheyarecompetitiveandprofitable.Thisrequirescontinuousimprovementsintermsofgreaterreliability,reducedunscheduleddowntimeduetoequipmentfailures,lowermaintenancecosts,extendedequipmentlife,optimizedenergyconsumption,improvedsustainabilityandgreaterthroughput.
Manufacturesoftenoperatewithlittleinformationaboutthehealthandperformanceofdevicesandmachines.Thiscancreateatrialanderrorapproachtotroubleshooting,leadingtoexcessivedowntime,highermaintenancecostsandlowerefficiency.Manufacturersareincreasinglylookingtodigitallytransformtheiroperations,changingfrommanual-basedworkpracticestoautomated,digital,software-basedanddata-drivenwaysofworking.
IIoTapplicationsareenablingcompaniestoleveragetechnologyandexpertisetodigitallytransformoperations.Awealthofusefuldataistrappedinsidedevices,equipmentandmachines.IIoTtechnologiespresentsanopportunitytogaineasierandfasteraccesstoactionableinformationthatsupportsbetterdecisionmakingandoperationalperformance.
Alackofactionableinformationpreventsperformanceimprovementsinthedomainsofreliability,sustainability,productivityandsafety.Belowareexamplesoftypicaloperationalchallengeswecanassistwith.
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Productivity Improvements
•Criticalparametersrequiredtooptimizemachineperformancearenotmeasured
•Unplanneddowntimereducesequipmentavailabilityandproductivity
Safety
•Additionalcomponents,costsandcomplexityrequiredtoimprovesafety
•Greatercomplexitycompromisesproductivity
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IIoT opportunities
IIoTcreatesanopportunitytorevolutionizemanufacturingoperationsbyenablingtheacquisitionandaccessibilityofgreateramountsofdata,atfargreaterspeeds.Butobtainingadditionaldatafromtheplantfloorthroughabroadrangeofsensorsisjustthestart.Youmustbeabletoturnrawdataintoinformationthatcanproduceactionableinsightsthatenhanceoperations.Butinordertodothat,youfirstmust:
•Developacleardefinitionoftheproblemandscale
•Understandthecurrentsourcesofdataandpotentialmissingdata
•Createtheplanforhowinformationwillbecollectedandtransferredtoaction
•Calculatethereturnoninvestment(ROI)foryourIIoTapplication
FormanymanufacturersthereisstillnotaclearunderstandingofhowtheIIoTwillcreatequantifiableimprovementsfortheirbusiness.InvestmentsindigitalizationandIIoTtechnologycanbesignificant,butwhateverthesizeofcapitalexpenditure,itisimportanttoconsidertheROI.Someapplicationexamples:
•Anicecreammanufacturermadeaone-offinvestmentontechnologythatenabledthemtoanalyzemachineperformance,identifyleakages,andpreventunplanneddowntime.ThisinvestmenthelpedthemtoimproveOverallEquipmentEffectiveness(OEE)andincreasemachineproductionsignificantly,withaROIoflessthanthreemonths
•Aglobalmanufacturerinvestedinasolutionthatprovidedpredictivemaintenancetopreventreplacementofcostlycylinders.Thisnotonlyreducedmachinedowntimeandlaborcosts,butalsosavedthemanufacturerexpensivepartreplacements.TheROIwasoneyear
ToidentifyIIoTopportunitiesinyourorganization,areassuchastheautomationarchitecture,machinecontrolsystems,SCADA,safetysystems,PLCs,networkingtechnology,sensors,machineryhealthmonitoringandinstrumentationshouldbereviewed.
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Industry Example Challenge Solution Opportunity Benefit
Factory Automation
Frequentreplacementofrodlesscylindersresultingincostlydowntimeandlosses
Monitorhealthstatuswithsimpletwo-positionsensorstomeasuremovementanddampingspeedofshockabsorbers
•Predictfailuresofcylindersandcomponentsbeforetheyhappen
•Reduceunexpecteddowntimeeventsthatcostproduction
Food & Beverage
Highcompressedairandsteamconsumptionandlowenergyefficiency
Monitorairandsteamflowandpressureprofile,andotherparameterstodeterminethecausessuchaswasteorleaks
•Reducedpneumaticairconsumptionandimprovedenergyefficiency
Tire Manufacturing
Increasedmachinecycletimeisreducingthroughput
Monitormachinecomponentcycletimeandkeyparameterssuchassteamtemperature,pressureandflowtodeterminethecauseofincreasedcycletime
•AbletomakeinformeddecisionstoimproveOverallEquipmentEffectiveness(OEE)
Automotive
Increasingmachinesafetyaddscomplexityandreducesproductivity
Isolatethreesafetyzonesfromasinglevalvesystem,reducingcomplexityandcomponents,andanalyzeproductiondatatoconfirmanycompromise
• Increasedsafetywithoutcompromisingmachineproductivity
IIoT applications
EmersonhasbeenapplyingIIoTtechnologyforseveralyears.Ourexpertsunderstandyourindustryandapplicationrequirements.TheyareexperiencedinidentifyingopportunitiestoimplementIIoTsolutionsthatwillprovidetheperformancegainsyouneed.HerearesomeexamplesofhowwehavehelpedourcustomerstoimplementIIoTonkeyapplicationsthathavecreatedsignificantbenefits.
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Industrial automation and machine control capabilities
IntegratedsolutionsincludingIIoTapplicationsfromasingleautomationproviderhelptosimplifythedesign,commissioning,procurement,andlifecyclemanagement,leadingtolowercostsandgreateroperationalefficiency.Emersonistheleadingindustrialautomationcompanythatoffersacompletemachineautomationandcontrolportfolioincludingintelligentsensorsanddevices,controlsystemsandHMI/SCADA,fluidcontrolandpneumatics,motioncontrollers,safetysystems,wiredandwirelessnetworkdevices,andmore.
IIOT
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FTW
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ON
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CO
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VITY
FLUID CONTROL PNEUMATICS
PLC/PAC
SCADAHistorianGateway Cloud Storage & Analytics
IP20 I/O
Machine Network (Ethernet)Industrial Switch
Rodless Cylinder with Linear Position Sensors
Visualization & Dashboards
FilterRegulator
WirelessTransmitter
WirelessGateway
EdgeGateway/Controller
Mobile & Web HMI
ServersMachineLearning
Safety
ProductionReliability & Maintenance
Sustainability
BCFlow Pressure Temp pH Level
W.A.G.E.S. Sensors - Water, Air, Gas, Electric & Steam
Particles
IP20 SafetyI/O FRL with
Safety Valve
MOTION CONTROL
AC Motor
SYSTEM ARCHITECTURE
ON/OFFValve
ControlValve
PositionSensor High
PressureRegulator
W.A.G.E.S.Sensors
MotorizedValve
Angle SeatValve
AsepticValve
FRL
Fieldbus Network
ProportionalValve
Fieldbus Network
VFD/VSD Servo Drive
Servo Motor
FRL with Pressure & Flow Sensors
PLC/PACHMI
Factory Network (Ethernet)
Valve Solenoid Valve
Positioner
LimitSwitch Box
IP65 I/O & Valve System IP65 I/O & Valve System
Cylinder withPosition Sensors
IP65 I/O & Zoned Safety Valve System
Cylinders with Position Sensors & Mechanical Locking Units
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IIOT
&SO
FTW
AR
EC
ON
TRO
L &
CO
NN
ECTI
VITY
FLUID CONTROL PNEUMATICS
PLC/PAC
SCADAHistorianGateway Cloud Storage & Analytics
IP20 I/O
Machine Network (Ethernet)Industrial Switch
Rodless Cylinder with Linear Position Sensors
Visualization & Dashboards
FilterRegulator
WirelessTransmitter
WirelessGateway
EdgeGateway/Controller
Mobile & Web HMI
ServersMachineLearning
Safety
ProductionReliability & Maintenance
Sustainability
BCFlow Pressure Temp pH Level
W.A.G.E.S. Sensors - Water, Air, Gas, Electric & Steam
Particles
IP20 SafetyI/O FRL with
Safety Valve
MOTION CONTROL
AC Motor
SYSTEM ARCHITECTURE
ON/OFFValve
ControlValve
PositionSensor High
PressureRegulator
W.A.G.E.S.Sensors
MotorizedValve
Angle SeatValve
AsepticValve
FRL
Fieldbus Network
ProportionalValve
Fieldbus Network
VFD/VSD Servo Drive
Servo Motor
FRL with Pressure & Flow Sensors
PLC/PACHMI
Factory Network (Ethernet)
Valve Solenoid Valve
Positioner
LimitSwitch Box
IP65 I/O & Valve System IP65 I/O & Valve System
Cylinder withPosition Sensors
IP65 I/O & Zoned Safety Valve System
Cylinders with Position Sensors & Mechanical Locking Units
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ScheduleanIIoTIntroductorySessiontolearnhowtoreducemachinerydowntime,increaseequipmentreliability,enhancesafety,makeenergyefficiencysavingsandimproveproductionefficiency.
EmersonIIoTIntroductorySessionsprovidetheopportunitytolearnhowtobuildsuccessfulIIoTstrategies,turnactionableinsightsintooperationalimprovementsandcalculateareturnonyourIIoTinvestment.Signuphere:go.emersonautomation.com/IIoT-introductory-sessionsYourlocalcontact:Emerson.com/contactus