Accelerating the
Industrial Internet of Things

Complex Discrete Manufacturing with ThingWorx Analytics

Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics
Complex Discrete Manufacturing with ThingWorx Analytics

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SIMILAR CASE STUDIES

Overview
ImageComplex Discrete Manufacturing with ThingWorx AnalyticsLeveraging Machine Learning To Enhance a Molding Process Involving IoT SolutionsSchneider Automation PLCsWorld leading zenon technology at Vipoll (Slovenia)Pitney Bowes Industrial InternetAvoid Unplanned Downtime with Predictive AnalyticsINSIDE SECURE | The Wild West of Mobile SecurityService Agility for a Connected World
Verified Vendor
SnapshotComplex Discrete Manufacturing with ThingWorx AnalyticsLeveraging Machine Learning To Enhance a Molding Process Involving IoT SolutionsSchneider Automation PLCsWorld leading zenon technology at Vipoll (Slovenia)Pitney Bowes Industrial InternetAvoid Unplanned Downtime with Predictive AnalyticsINSIDE SECURE | The Wild West of Mobile SecurityService Agility for a Connected World
Challenge

ABC faced two major issues when utilizing the data collected. One is the size, complexity, and disparity of the data collected would take lot of man-hours to process and evaluate. Two is real-time data cannot be put into use due to the nature of data science analysis.

In the third wave of industrial evolution, we had automation that produced large amounts of data. This data had high potential for analytic applications, but it was not easy to analyze because it was siloed in the machines where it was generated. With this project, we demonstrate that it’s not complex to send the data to the cloud using secure and reliable services that allow us to analyze the data in near-real time and build maching learning models to extract knowledge from it.

Schneider Automation wanted a solution to its PLCs on the factory floor so that they can meet cost target for manufacturing systems. The challenges were that the solution needed to connect smaller PLCs and embedded devices that have limited storages or processing capacities.
Vipoll aims to consolidate its market position and break into new markets not only in Slovenia but also internationally. A brewing customer needed to access the entire data from a production line. It was necessary to visualize the whole line and also to collect all its data, record that data transparently and make the data available to business users. The main focus was to grab data according to Weihenstephan standards. The Weihenstephan standards define which production data should be recorded at a filling plant and specifies how that data should be transferred.
The world's 1st-ever Industrial Internet platform, Predix, becomes a pathway for revenue generation and notable new cost savings for Pitney Bowes' production mail business. An ordinary mail business, this is not. Of the 150 million pieces of mail produced each day in the US, the majority go through Pitney Bowes machines.
Objectives • Create an innovative IT environment that supports the move toward a solution-provider business model • Enhance existing business processes and leverage the power of Big Data and predictive maintenance to become more proactive, customer oriented, and competitive • Leverage the SAP HANA® platform to transform and simplify the entire SAP® solution landscape

The researchers know from past experience that some banks do take security of their mobile applications seriously. These are the banks the researchers work with on a daily basis. Given no application in the sample set achieved an A or B rating, it emphasises how much in the minority these banks are.

CenturyLink wanted to accelerate design and delivery of IP-based enterprise services, drive all processes from a central catalog for improved service agility and position CenturyLink for SDN/NFV with an open, standards-based solution.
Solution

ThingWorx Analytics is a learning technology that automates advanced and predictive analytics. The technology uses proprietary artificial intelligence and machine learning technology to automatically learn from data, discover patterns, build validated predictive models, and send information to virtually any type of application or technology.

 

The data captured during the molding process is useful to build a machine learning model that will warn us when the quality of the product may be lower than the defined standard.

Connext DDS Micro implements a subset of the DDS API and features. However, it has all of the essential communication and data features of the full implementation, so in practice, a device running the resource-constrained version can be treated just like a device with the full version. Both Connext DDS and Connext DDS Micro are 100% compatible with the OMG DDS-RTPS wire protocol. Thus, any kind of device or sensor can be plugged into the network and communicate openly with regular nodes. Software Components - Connext DDS software
zenon offers equipment efficiency built around the individual needs of each user. A tailored workstation is the key to ergonomic and efficient working. zenon makes it easy to adjust projects according to individual user needs, whether in advance or during running operations. zenon’s strong network encryption, comprehensive user management and unique security mechanisms advance the Vipoll equipment. By deploying zenon, Vipoll equipment runs safely and securely so that customers can feel confident in the solutions and feel at ease.
Predix powers Clarity – Pitney Bowes’ new Industrial Internet software solution. Clarity improves inserting and mail operations by: • Monitoring asset health • Remotely diagnosing technical issues in real time • Helping increase asset utilization • Improving operations via machine resources and job scheduling • Improving SLA attainment via real-time adaptive scheduling
Technical implementation • Successful migration of the SAP Customer Relationship Management (SAP CRM) application to SAP HANA in just 2.5 months and with just 1.5 days of downtime • Great collaboration with SAP during all phases of the project

New European regulations are putting more requirements on organisations to keep their customers’ data safe. The basis of the requirement is that the customer owns their data and an organisation “borrowing” that data has a duty of care over the information and needs to use “state of the art” security to keep customer data from fallings into unauthorised hands. Any lapses in that duty can result in large fines (up to €20m or 4% of turnover, whichever is higher).

Ericsson provided a solution includes Ericsson Service Innovation Framework, including unified, catalog-driven OSS/BSS, automation of network design, provisioning, activation and problem resolution and implementation and consulting services, using industry standards for solution openness and best practices for business process efficiency. Software Components - Ericsson Service Innovation Framework
Customer

ABC Manufacturing operates 27 global manufacturing facilities, strategically located throughout the world, to provide direct support and services in close proximity to our international customers.

Systems integrators and manufacturers looking to use IoT Hub to have real-time capture of equipment data.

Schneider Electric SE is a European multinational corporation that specializes in electricity distribution, automation management and produces installation components for energy management with more than 167,000 employees worldwide.
Vipoll, a Slovenian machine manufacturer for the beverage industry.
The workhorses of industry, Pitney Bowes machines perform in 3,500 systems installed worldwide, many with more than 10 assets per site, operating 24/7.
KAESER KOMPRESSOREN SE

Mobile financial payment providers.

CenturyLink is the third largest telecommunications company in the United States, and is recognized as a leader in the network services market by technology industry analyst firms.
Solution TypeIOTIOTIOTIOTIOTITITIT
Solution MaturityCutting Edge (technology has been on the market for < 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Cutting Edge (technology has been on the market for < 2 years)Cutting Edge (technology has been on the market for < 2 years)
Data Collected
Data for a working parts of a machine
Equipment control and machine status in production line
IT data, voice streaming data
Supporting Files
Original Full Case Study Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab
Youtube Video ID

Use Cases
Use CasesFactory Operations Visibility & Intelligence Manufacturing System AutomationPerimeter Security & Access Control

Operational Impact
Impact #1

Data Aggregation - Cloud solutions enable aggregation of 'big data' to automatically detect patterns, anomalies, and flag machines for maintenance before downtime, manufacturing errors, or yield faults occurred.

Through Azure's services, a Windows Service was developed to connect IoT Hub geared to gather and compress CSV documents and other direct sensor information.

Data Aggregation - Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Flexible industrial control with complete line monitoring
Foundation for predictive maintenance. Simpler and more agile IT landscape and business processes

It is not recommended to build security solutions in-house; rely on a proven solution that gets exposed via their broad install base, and has teams dedicated to securing mobile applications.

Time-to-Market - Programming time, production time, and installation time are shortened during the introduction of new products.
Impact #2

Remote Device Diagnostics - Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.

A Machine Learning model was developed, fed with all the historical data that has been gathered by the control computer and joined with the customer labels that are retrieved one month later. This model will be retrained with new data when needed.

System Flexibility - Ongoing application development and improvements are relatively quick and inexpensive to implement due to the system's flexibility.
Adherence to Weihenstephan standards
Successful and smooth production launch of SAP CRM powered by SAP HANA.

It is important to plan ahead so that the risk is reduced and a remediation plan is in place to minimise any fallout both in terms of image and PR but also technically.

End-to-end Service Delivery - Deeper integration of information across departments and business units improves internal collaboration and end-to-end customer service.
Impact #3

Data Analytics - Data mining, prognostics, diagnostics, and embedded intelligence are used to make ABB's production line smarter so that they can meet their customer's needs.

A Power BI dashboard was developed to see the curves and the Azure Machine Learning-trained model results as executed in Stream Analytics for each piece in real time.

Real-time supervision of Overall Equipment Effectiveness (OEE)

Device binding is a technique to lock an instance of the mobile application to a particular phone. This stops the application being cloned. It also helps control access to back-end servers as user credentials can be locked to a given device.

Total Cost of Ownership - Total cost of ownership is lowered due to reduction in IT cost.

Quantitative Benefit
Benefit #1

ThingWorx Analytics was able to quickly analyze billions of points of information to determine that a particular failure pattern occurred when product line 2 was running operation 4467ANX when the ambient temperature was between 77 degree celsius and 79 degree celsius.

Clarity helps drive up to 20% increases in machine yield over time.
5 times faster database response times
Benefit #2
Up to 10% machine efficiency and 20% call center activity reduction.
Benefit #3
Up to 15% savings on parts replacement and 10% tech support time-savings.

Technology
Hardware
SoftwareThingworx AnalyticsThingworx 8GE Predix IoT Platform
Tech PartnersINSIDE Secure

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Gateways
Devices & Equipment
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency

Overview
ImageComplex Discrete Manufacturing with ThingWorx AnalyticsLeveraging Machine Learning To Enhance a Molding Process Involving IoT SolutionsSchneider Automation PLCsWorld leading zenon technology at Vipoll (Slovenia)Pitney Bowes Industrial InternetAvoid Unplanned Downtime with Predictive AnalyticsINSIDE SECURE | The Wild West of Mobile SecurityService Agility for a Connected World
Verified Vendor
SnapshotComplex Discrete Manufacturing with ThingWorx AnalyticsLeveraging Machine Learning To Enhance a Molding Process Involving IoT SolutionsSchneider Automation PLCsWorld leading zenon technology at Vipoll (Slovenia)Pitney Bowes Industrial InternetAvoid Unplanned Downtime with Predictive AnalyticsINSIDE SECURE | The Wild West of Mobile SecurityService Agility for a Connected World
Challenge

ABC faced two major issues when utilizing the data collected. One is the size, complexity, and disparity of the data collected would take lot of man-hours to process and evaluate. Two is real-time data cannot be put into use due to the nature of data science analysis.

In the third wave of industrial evolution, we had automation that produced large amounts of data. This data had high potential for analytic applications, but it was not easy to analyze because it was siloed in the machines where it was generated. With this project, we demonstrate that it’s not complex to send the data to the cloud using secure and reliable services that allow us to analyze the data in near-real time and build maching learning models to extract knowledge from it.

Schneider Automation wanted a solution to its PLCs on the factory floor so that they can meet cost target for manufacturing systems. The challenges were that the solution needed to connect smaller PLCs and embedded devices that have limited storages or processing capacities.
Vipoll aims to consolidate its market position and break into new markets not only in Slovenia but also internationally. A brewing customer needed to access the entire data from a production line. It was necessary to visualize the whole line and also to collect all its data, record that data transparently and make the data available to business users. The main focus was to grab data according to Weihenstephan standards. The Weihenstephan standards define which production data should be recorded at a filling plant and specifies how that data should be transferred.
The world's 1st-ever Industrial Internet platform, Predix, becomes a pathway for revenue generation and notable new cost savings for Pitney Bowes' production mail business. An ordinary mail business, this is not. Of the 150 million pieces of mail produced each day in the US, the majority go through Pitney Bowes machines.
Objectives • Create an innovative IT environment that supports the move toward a solution-provider business model • Enhance existing business processes and leverage the power of Big Data and predictive maintenance to become more proactive, customer oriented, and competitive • Leverage the SAP HANA® platform to transform and simplify the entire SAP® solution landscape

The researchers know from past experience that some banks do take security of their mobile applications seriously. These are the banks the researchers work with on a daily basis. Given no application in the sample set achieved an A or B rating, it emphasises how much in the minority these banks are.

CenturyLink wanted to accelerate design and delivery of IP-based enterprise services, drive all processes from a central catalog for improved service agility and position CenturyLink for SDN/NFV with an open, standards-based solution.
Solution

ThingWorx Analytics is a learning technology that automates advanced and predictive analytics. The technology uses proprietary artificial intelligence and machine learning technology to automatically learn from data, discover patterns, build validated predictive models, and send information to virtually any type of application or technology.

 

The data captured during the molding process is useful to build a machine learning model that will warn us when the quality of the product may be lower than the defined standard.

Connext DDS Micro implements a subset of the DDS API and features. However, it has all of the essential communication and data features of the full implementation, so in practice, a device running the resource-constrained version can be treated just like a device with the full version. Both Connext DDS and Connext DDS Micro are 100% compatible with the OMG DDS-RTPS wire protocol. Thus, any kind of device or sensor can be plugged into the network and communicate openly with regular nodes. Software Components - Connext DDS software
zenon offers equipment efficiency built around the individual needs of each user. A tailored workstation is the key to ergonomic and efficient working. zenon makes it easy to adjust projects according to individual user needs, whether in advance or during running operations. zenon’s strong network encryption, comprehensive user management and unique security mechanisms advance the Vipoll equipment. By deploying zenon, Vipoll equipment runs safely and securely so that customers can feel confident in the solutions and feel at ease.
Predix powers Clarity – Pitney Bowes’ new Industrial Internet software solution. Clarity improves inserting and mail operations by: • Monitoring asset health • Remotely diagnosing technical issues in real time • Helping increase asset utilization • Improving operations via machine resources and job scheduling • Improving SLA attainment via real-time adaptive scheduling
Technical implementation • Successful migration of the SAP Customer Relationship Management (SAP CRM) application to SAP HANA in just 2.5 months and with just 1.5 days of downtime • Great collaboration with SAP during all phases of the project

New European regulations are putting more requirements on organisations to keep their customers’ data safe. The basis of the requirement is that the customer owns their data and an organisation “borrowing” that data has a duty of care over the information and needs to use “state of the art” security to keep customer data from fallings into unauthorised hands. Any lapses in that duty can result in large fines (up to €20m or 4% of turnover, whichever is higher).

Ericsson provided a solution includes Ericsson Service Innovation Framework, including unified, catalog-driven OSS/BSS, automation of network design, provisioning, activation and problem resolution and implementation and consulting services, using industry standards for solution openness and best practices for business process efficiency. Software Components - Ericsson Service Innovation Framework
Customer

ABC Manufacturing operates 27 global manufacturing facilities, strategically located throughout the world, to provide direct support and services in close proximity to our international customers.

Systems integrators and manufacturers looking to use IoT Hub to have real-time capture of equipment data.

Schneider Electric SE is a European multinational corporation that specializes in electricity distribution, automation management and produces installation components for energy management with more than 167,000 employees worldwide.
Vipoll, a Slovenian machine manufacturer for the beverage industry.
The workhorses of industry, Pitney Bowes machines perform in 3,500 systems installed worldwide, many with more than 10 assets per site, operating 24/7.
KAESER KOMPRESSOREN SE

Mobile financial payment providers.

CenturyLink is the third largest telecommunications company in the United States, and is recognized as a leader in the network services market by technology industry analyst firms.
Solution TypeIOTIOTIOTIOTIOTITITIT
Solution MaturityCutting Edge (technology has been on the market for < 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Mature (technology has been on the market for > 5 years)Cutting Edge (technology has been on the market for < 2 years)Cutting Edge (technology has been on the market for < 2 years)
Data Collected
Data for a working parts of a machine
Equipment control and machine status in production line
IT data, voice streaming data
Supporting Files
Original Full Case Study Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab Open in new tab
Youtube Video ID

Use Cases
Use CasesFactory Operations Visibility & Intelligence Manufacturing System AutomationPerimeter Security & Access Control

Operational Impact
Impact #1

Data Aggregation - Cloud solutions enable aggregation of 'big data' to automatically detect patterns, anomalies, and flag machines for maintenance before downtime, manufacturing errors, or yield faults occurred.

Through Azure's services, a Windows Service was developed to connect IoT Hub geared to gather and compress CSV documents and other direct sensor information.

Data Aggregation - Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Flexible industrial control with complete line monitoring
Foundation for predictive maintenance. Simpler and more agile IT landscape and business processes

It is not recommended to build security solutions in-house; rely on a proven solution that gets exposed via their broad install base, and has teams dedicated to securing mobile applications.

Time-to-Market - Programming time, production time, and installation time are shortened during the introduction of new products.
Impact #2

Remote Device Diagnostics - Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.

A Machine Learning model was developed, fed with all the historical data that has been gathered by the control computer and joined with the customer labels that are retrieved one month later. This model will be retrained with new data when needed.

System Flexibility - Ongoing application development and improvements are relatively quick and inexpensive to implement due to the system's flexibility.
Adherence to Weihenstephan standards
Successful and smooth production launch of SAP CRM powered by SAP HANA.

It is important to plan ahead so that the risk is reduced and a remediation plan is in place to minimise any fallout both in terms of image and PR but also technically.

End-to-end Service Delivery - Deeper integration of information across departments and business units improves internal collaboration and end-to-end customer service.
Impact #3

Data Analytics - Data mining, prognostics, diagnostics, and embedded intelligence are used to make ABB's production line smarter so that they can meet their customer's needs.

A Power BI dashboard was developed to see the curves and the Azure Machine Learning-trained model results as executed in Stream Analytics for each piece in real time.

Real-time supervision of Overall Equipment Effectiveness (OEE)

Device binding is a technique to lock an instance of the mobile application to a particular phone. This stops the application being cloned. It also helps control access to back-end servers as user credentials can be locked to a given device.

Total Cost of Ownership - Total cost of ownership is lowered due to reduction in IT cost.

Quantitative Benefit
Benefit #1

ThingWorx Analytics was able to quickly analyze billions of points of information to determine that a particular failure pattern occurred when product line 2 was running operation 4467ANX when the ambient temperature was between 77 degree celsius and 79 degree celsius.

Clarity helps drive up to 20% increases in machine yield over time.
5 times faster database response times
Benefit #2
Up to 10% machine efficiency and 20% call center activity reduction.
Benefit #3
Up to 15% savings on parts replacement and 10% tech support time-savings.

Technology
Hardware
SoftwareThingworx AnalyticsThingworx 8GE Predix IoT Platform
Tech PartnersINSIDE Secure

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Gateways
Devices & Equipment
Wearables

IoT Snapshot: Software
Software as a Service
Artificial Intelligence
Platform as a Service
Cybersecurity
Infrastructure as a Service

IoT Snapshot: Service
System Integration
Hardware Development
Software Development
Network Connectivity

Industries
Heavy Vehicle
Automotive
Transportation
Energy
Construction & Buildings
Equipment & Machinery
Mining
Chemicals
Other

Functions
Discrete Manufacturing
Process Manufacturing
Maintenance
Logistics & Warehousing
Product Development
Quality Assurance
Other

Connectivity Protocols
6LoWPAN
AMQP
ANT
Alljoyn
BACnet
Bluetooth
Brillo
Cellular
CoAP
DDS
DNS-SD
DigiMesh
EnOcean
Ethernet
FirstNet
Hypercat
IO-Link
IPSO
IPv6
IoTivity
KNX
LPWAN
LWM2M
LoRaWAN
LonWorks
M-Bus
MQTT
Modbus
NFC
Neul
oneM2M
PROFIBUS
RFID
RS-232
RS-422
RS-485
Satellite
Sigfox
Thread
UDP
UPnP
Weave
WebSocket
Wi SUN
Wi-Fi
WirelessHart
XMPP
Z-Wave
ZigBee
Other frequency