Unexpected downtime costs industries billions of dollars each year, and the challenges of aging assets combined with many experienced professionals at or near retirement age have companies looking at the promises of IoT technology for answers.
1) Deliver a connected digital product system to protect and increase the differentiated value of Haemonetics blood and plasma solutions. 2) Improve patient outcomes by increasing the efficiency of blood supply flows. 3) Navigate and satisfy a complex web of global regulatory compliance requirements. 4) Reduce costly and labor-intensive maintenance procedures.
Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.
But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.
Unmanned weather stations play an essential role in the effort to analyze and predict the world's ever-changing weather patterns. The unmanned stations collect and store large amounts of weather data and then download the data at regular intervals to a back-end host for analysis and long-term storage. The computing device housed in the weather station must be robust enough to work continuously for long periods of time while exposed to a wide range of temperatures. It should also be able to collect readings from various sensors that use different data transmission protocols, and have the capability to store large amounts of data.
Coordinating data in the age of digitalisation presents a real challenge, especially where production facilities are concerned. The task of maintaining the many and varied components used in production also entails working with a wide variety of different software packages (editors) Each change that is made to the software results in a new version that has to be securely stored – versions need to be properly managed and there can only ever be one version that is the latest authorised version. But how can you make sure that all changes that were made to the software now running on the machine/device were authorised?
Companies are facing greater challenges than ever before when it comes to making sure their cooling equipment operates at maximum efficiency. One of the challenges is the need to understand how equipment is performing to optimize their use, their health and to anticipate issues and failures. Having an HVAC service engineer who continuously monitors the chiller is unrealistic.
The current state of condition monitoring requires manual measurements that are compounded with aging equipment and the retirement of knowledgeable personnel.
“For us to maintain low costs and high customer satisfaction while providing improved response times, we need a better, faster way to resolve issues beyond dispatching onsite technicians,” explains Mark Hessinger, Executive Director of Worldwide Service at Gerber Scientific. Gerber faces a continuous need to train new personnel as they are brought into the service organization. A change in strategy for service allows Gerber to build a stronger technical support organization and a more efficient process to bring new field service engineers up to speed. “We have a lot of tenured employees in North America and Europe,” observes Hessinger. “In seven years, the loss of man years will accelerate, so we need to retain product knowledge before it becomes a greater issue and impacts our customers.” Hessinger and his team realized that they needed a solution to remotely connect to their products and identify, diagnose, and resolve issues. Ideally this would happen before their customers even become aware of a problem, reducing the dispatch of onsite technicians or improving first-time fix rates when onsite visits are required. By collecting data from their products deployed in production, the company could begin addressing the aging workforce issue by capturing and retaining information. Collecting information on consumables and parts could automate consumable resupply, optimize spare parts inventory, and enable Gerber to provide true preventive maintenance. “We do not have mean time between failure data because we don’t know how many hours our customers are actually using our products,” says Hessinger. “Some customers use our products a few hours a day, while others use them 24/7. Obtaining actual usage data will help us better plan our spare parts and the consumables required for run times.” Other capabilities identified to help build a business case for their initiative included minimizing product downtime, automating software patch distribution, offering value-added services, providing engineering with product usage data, and delivering remote training on product capabilities for distributors and new technicians.
Securitas wanted to give new and existing customers a proposition that was unlike anything they had offered before, a security system that broke the traditional mould but took advantage of the monitoring infrastructure that was already in place, including the manned response capabilities and alarm receiving centres.
National Instruments, in collaboration with companies like HPE, PTC, Flowserve and OSIsoft, are formulating a combined solution that can provide better asset health information.
The solution comprises various aspects such as sensor input and feature extraction with on-asset data acquisition, diagnostics on bearing, seal, and impeller failures and augmented reality for enterprise to assist on-site troubleshooting and repair amongst others.
Built on Bright Wolf’s Strandz platform and leveraging Amazon Web Services (AWS) cloud storage, Haemonetics won IoT Evolution App of the Year in 2015. Through their partnership with Bright Wolf, Haemonetics released HaemoCloud, connecting the blood supply chain from donation to transfusion. The new system works directly with their existing HaemoCommunicator suite – connecting all Haemonetics sensors and devices in order to format and transfer device information, as well as collect and manage operational data, and send it to the AWS cloud. HaemoCloud also integrates with hospital and other institutional information systems to store and share information with relevant hospital and IT staff, creating a seamless data experience for customers. Data collected in HaemoCloud will allow Haemonetics to build preventative maintenance algorithms and provide customers industry-leading device performance. The system’s flexible architecture also enables Haemonetics to take advantage of new market opportunities and grow with new offerings from Amazon Web Services (AWS) in the future.
Ozner is leveraging Ayla’s IoT cloud platform to better manage and maintain its connected filtration systems and to help expand its sales into international markets.
The Ayla Insights business intelligence and analytics tool was employed to obtain real-world customer data from the Ozner Water connected smart-filtration systems in use. The customer data collected through Ayla insights included additional maintenance and service checkpoints from the deployed systems.
Meanwhile, Ayla engineers built Ozner a mobile app that lets Chinese customers remotely control their own filtration systems using popular social networks, such as Weixin (aka WeChat).
Protocol Conversion and Front-end Data Processing The data collected by a typical unmanned weather station includes temperature, rainfall and snow accumulation, air pressure, humidity, and ultraviolet intensity. One of the tasks that the UC-7420 unit must handle is protocol conversion, since there is no guarantee that the devices collecting the weather data all use the same protocol. In addition, the UC-7420 can be used to do preliminary data processing before downloading data to the central computer. MOXA's UC-7420 is ideally suited for these tasks, since the user can easily embed a C program that is custom written for the devices used at the station. If future changes involve adding or removing devices, the programmer simply needs to modify the C code, recompile it, and then download the executable program over the network to the UC-7420 unit. Connecting to the Network and the Internet In addition to being programmable, the UC-7420 also offers users an array of connection options. To begin with, data entering the serial ports from attached sensors can be processed and then forwarded through one or both of the dual Ethernet ports to the LAN. One of the serial ports can also be connected to a V.90 or GPRS modem for PPP connections, and a PCMCIA port is available for installing a wireless LAN card for 802.11b/g networks. By including multiple connection options in the UC-7420's design, user's gain the flexibility needed to connect from virtually anywhere. Combinations of connection types can also be used to provide redundancy. For example, if unavoidable network problems cause an interruption in service, the user can connect by modem. CompactFlash Storage Space One of the dilemmas faced when creating a "small" computer is how to provide users with adequate storage space. For unmanned applications, it is best if the storage device does not contain moving parts. Although hard drives may seem to last forever for day-to-day use, we cannot make this assumption for continuous use at remote locations. The UC-7420 overcomes this problem by providing a CompactFlash slot. If needed, flash memory cards with storage capacity of up to several gigabytes can be used to store data until it is convenient to transfer the data to a central computer.
What are the benefits of AUVESY’s data management and software solution, versiondog, when it comes to version control and change management? versiondog – YOUR SOLUTION Access all data necessary to create a complete backup Categorise backups according to content, storage location and identifiers Detect changes – SmartCompare – display differences in comprehensible form Document changes and make it easy for users to track changes throughout a project’s lifecycle Automatically check whether the versions currently running in production are the correct ones Ensure that users are working with the latest version Standardised interfaces Comparison between backup & backup Comparison between backup & version Comparison between version & version
Smart sensors in combination with embedded based chiller data infrastructure delivers real-time, historical and predictive insights into chiller health and maintenance needs.
*This is an IIC testbed currently in progress.* SUPPORTING MEMBERS IBM, National Instruments, SparkCognition SOLUTION Provide a multi-vendor, cloud-based predictive maintenance solution that proves out new business models. The Condition Monitoring and Predictive Maintenance Testbed will offer continuous online measurements, automated analysis, and balance of plant coverage. TESTBED INTRODUCTION The Condition Monitoring and Predictive Maintenance Testbed (CM/PM) will demonstrate the value and benefits of continuously monitoring industrial equipment to detect early signs of performance degradation or failure. CM/PM will also use modern analytical technologies to allow organizations to not only detect problems but proactively recommend actions for operations and maintenance personnel to correct the problem. Condition Monitoring (CM) is the use of sensors in equipment to gather data and enable users to centrally monitor the data in real-time. Predictive Maintenance (PM) applies analytical models and rules against the data to proactively predict an impending issue; then deliver recommendations to operations, maintenance and IT departments to address the issue. These capabilities enable new ways to monitor the operation of the equipment - such as turbines and generators - and processes and to adopt proactive maintenance and repair procedures rather than fixed schedule-based procedures, potentially saving money on maintenance and repair, and saving cost and lost productivity of downtime caused by equipment failures. Furthermore, combining sensor data from multiple pieces of equipment and/or multiple processes can provide deeper insight into the overall impact of faulty or sub-optimal equipment, allowing organizations to identify and resolve problems before they impact operations and improve the quality and efficiency of industrial processes. Through this testbed, the testbed leaders IBM and National Instruments will explore the application of a variety of analytics technologies for condition monitoring and predictive maintenance. The testbed application will initially be deployed to a power plant facility where performance and progress will be reported on, additional energy equipment will be added and new models will be developed. It will then be expanded to adjacent, as yet to be determined, industries.
To get to market quicker, Hessinger and his team decided to buy a solution rather than build one. By choosing PTC® Axeda® software, Gerber was able to quickly implement their smart solutions. “We chose PTC Axeda because their Softwareas-a-Service (SaaS) solution would get us to market fast,” says Hessinger. “We felt confident that we could connect to a range of products while ensuring safety, security, and compliance.” Gerber Scientific uses PTC Axeda software to drive its next-generation service delivery model, branded as GERBERconnect™. Gerber Technology is the first to offer the GERBERconnect solution, initially rolling out the offering to customers of their GERBERcutter ® XLc7000 and Z7 automated cutting machines. GERBERconnect enables Hessinger’s team to monitor its customers’ machines and detect problems before they interrupt production. GERBERconnect enables Gerber’s cutters to “call home” when potential errors are sensed. Gerber technicians then remotely and securely access a customer’s system for further proactive fault detection and troubleshooting.
The premise for the security system was that it should be extremely user friendly and accessible to a diverse target market. For this reason the dedicated gateway incorporates GPRS and broadband connectivity, making it possible for those without a fixed broadband connection to benefit from a monitored alarm.
Customers can be from any industry whose manufacturing processes are highly automated.
Haemonetics Corporation is the leading global provider of blood and plasma supplies and services. Our comprehensive portfolio of devices, information management, and consulting services offers blood management solutions for each facet of the blood supply chain — from plasma and blood collectors to hospitals.
Ozner Water International Holding is part of a large Chinese company that develops, manufactures and sells water-purification systems.
For all devices from any manufacturer
Combining embedded based chiller data and an AI engineer results in a move from maintenance to prevention and predictability. Optimizing asset health, minimizing asset failures and understanding optimal maintenance programs are critical to reducing operation cost, improving customer service and creating service-level agreements.
Gerber Technology, a business unit of Gerber Scientific, Inc., develops and manufactures the world’s leading brands of integrated software and hardware automation systems for the sewn products and flexible materials industries. These systems automate and significantly improve the efficiency of information management, product design and development, and pre-production and production processes. The company offers specialized solutions to a variety of end-user markets including apparel, aerospace, transportation interiors, furniture, composites, and industrial fabrics.
|Solution Maturity||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)||Mature (technology has been on the market for > 5 years)||Mature (technology has been on the market for > 5 years)||Mature (technology has been on the market for > 5 years)||Emerging (technology has been on the market for > 2 years)||Emerging (technology has been on the market for > 2 years)||Cutting Edge (technology has been on the market for < 2 years)|
Flowserve sensors can monitor a range of variables such as temperature, pressure, flow rate, vibration and power.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
versiondog is designed to safeguard all industrial automation system project data and other data types. versiondog is designed to work with all your data and automation systems - PLCs, CNCs, HMIs, SCADAs, robots, motion controls, inverters, and all kinds of machine code.
|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|| Open in new tab|| Open in new tab|
|Youtube Video ID|
|Use Cases||Asset Health Management (AHM)||Process Control & Optimization (PCO)||Predictive Maintenance (PdM)||Process Control & Optimization (PCO)||Cybersecurity ||Predictive Maintenance (PdM)||Machine Condition Monitoring||Process Control & Optimization (PCO)||Perimeter Security & Access Control |
Intelligent edge-to-cloud predictive maintenance system technology help workers be more productive, lower the cost of maintenance, and improve overall uptime.
Integrated across multiple information systems to share information with hospital and IT staff.
Expand its knowledge of customer requirements and use the information for future product improvements. Anticipate many more of its customers’ needs before they became service problems or system malfunctions
Multiple connection options for greater networking versatility. Maintenance personnel can monitor from a remote location
An important piece of the puzzle of your cyber security strategy
Optimizing asset health.Minimizing asset failures.
Develop new predictive maintenance analytics modeling techniques
Reduced field service visits in Australia, China, Europe, and the United States
Home security alerts by SMS, email and app notifications.
A smart system of devices providing critical operational data for service and support.
Allow customers to control and monitor their filtration systems anytime, anywhere—and communicate with Ozner customer service—via smartphone and their favorite social network.
Programmability gives system integrators infinite possibilities. No fan, no hard drive design for longer MTBF. CompactFlash slot for adding gigabytes of storage space
Document standard and secure architecture patterns and data formats for predictive maintenance in the Industrial Internet era.
Resolved issues to avoid downtime before customer is even aware
Broadband and GPRS connectivity for broad accessibility.
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Conquer long-distance maintenance and service concerns as the company expands beyond China into international markets
Reduce operation cost, improve customer service and create service-level agreements
Regionalized and reduced overall inventory levels. Ensured next-day part delivery.
Enable increased number of procedures per facility per day.
Improved first-time fix rate by 5%
Reduced downtime and unexpected maintenance calls.
Increased customer satisfaction.
|Software||Amazon Virtual Private Cloud (VPC)Amazon Elastic Compute Cloud (Amazon EC2)Amazon Route 53Amazon Simple Storage Service (Amazon S3)Bright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud||Ayla Networks IoT Platform||Axeda Machine Cloud|
|Tech Partners||PTCHewlett Packard Enterprise (HPE)||Amazon Web Services||IBMSparkCognitionIndustrial Internet Consortium (IIC)||Intamac|
IoT Snapshot: Hardware
|Processors & Boards|
|Sensors & Actuators|
IoT Snapshot: Software
|Software as a Service|
|Platform as a Service|
|Infrastructure as a Service|
IoT Snapshot: Service
|Construction & Buildings|
|Equipment & Machinery|
|Logistics & Warehousing|