Mercedes-Benz and his partner GAZ chose Siemens to be its maintenance partner at a new engine plant in Yaroslavl, Russia. The new plant offers a capacity to manufacture diesel engines for the Russian market, for locally produced Sprinter Classic. In addition to engines for the local market, the Yaroslavl plant will also produce spare parts.
Mercedes-Benz Russia and his partner needed a service partner in order to ensure the operation of these lines in a maintenance partnership arrangement.
The challenges included coordinating the entire maintenance management operation, in particular inspections, corrective and predictive maintenance activities, and the optimizing spare parts management. Siemens developed a customized maintenance solution that includes all electronic and mechanical maintenance activities (Integral Plant Maintenance).
The key business challenges are:
- Effective prevention of derailments
- Reduction of oil spills on railroad transportation of crude oils
- Alerts to first responders depending on material carried
- Public safety answering points (PSAPs) and State Emergency Response Commissions (SERCs) need to know the schedule, load, and location
- Flawless communication between PSAPs and first responders
A recent study on maturity of Asset Efficiency from Infosys and the Institute for Industrial Management (FIR) at Aachen University revealed that 85 percent of manufacturing companies globally are aware of asset efficiency, but only 15 percent have implemented it at a systematic level. Current challenges include lack of instrumentation of the assets, missing real-time data analytics, lack of context due to missing information from other systems, and lack of a holistic focus with other aspects of efficiency like energy, utilization, operations, and serviceability.
To collect asset information efficiently and accurately in real-time and run analytics to make the right decisions
Lordan needed a manufacturing automation system that could identify bottlenecks, reduce downtime and waste, and improve overall equipment effectiveness (OEE). Requirements included the ability to view overall throughput and track mission-critical manufacturing information in real time directly from the production floor, rather than rely on periodical assessments.
While on-site in Pavlodar, Kazakhstan, the DAQRI team of Business Development and Solutions Architecture personnel worked closely with KSP Steel’s production leadership to understand the steel production process, operational challenges, and worker pain points.
A potent innovator of filtration technology, the company had little experience with information technology, and no in-house expertise for bringing digital products to market. The company needed an information technology partner with deployment experience spanning industrial hardware, protocols, and the cloud to assist in their journey to becoming a connected products solution provider.
Fuel delivery has always had some built-in inefficiency. Like most fuel and lubricant distributors, Retif Oil & Fuel followed a keep full model when restocking fuel tanks and was spending too much money topping off customer fuel tanks and making emergency deliveries. Without an accurate view of customer fuel stocks it was impossible to determine who needed fuel or how much they actually needed.
The telematic solution provides this vital premium-adjusting information. The solution also helps detect and deter vehicle or trailer theft – as soon as a theft occurs, monitoring personnel can alert the appropriate authorities, providing an exact location.
“With more and more insurance companies and major fleet operators interested in monitoring driver behaviour on the grounds of road safety, efficient logistics and costs, the market for this type of device and associated e-business services is growing rapidly within Italy and the rest of Europe,” says Franco.
“The insurance companies are especially interested in the pay-per-use and pay-as-you-drive applications while other organisations employ the technology for road user charging.”
“One million vehicles in Italy currently carry such devices and forecasts indicate that the European market will increase tenfold by 2014.
However, for our technology to work effectively, we needed a highly reliable wireless data network to carry the information between the vehicles and monitoring stations.”
In 2016, Kevin Stoddard, a managing partner, had a problem. InControl’s customers required sensors on several equipment distributed across multiple sites and locations. To accomplish this, InControl needed a cost-effective solution fast. They also needed this solution to be intuitive for the equipment owners, highly secure, and broadly capable of delivering custom analytics to clients around the world.
The Integral Plant Maintenance concept from Siemens was tailored to production specific needs. The primary goal was to meet the customer's strict availability requirements. This was accomplished with an optimized maintenance management system. Through predictive maintenance, line downtime is selectively avoided, and planned downtime is used to perform the necessary maintenance work.
The service solution from Siemens is also responsible for other tasks, including:
- Preventive maintenance
- Corrective maintenance
- Optimizing the supply and stocking of spare parts
As they were working out the concept, the local maintenance experts were able to draw on the extensive knowledge base of Siemens' global expert network. They received optimal support in implementing the Siemens Integral Plant Maintenance standard through coaching sessions and process mapping workshops. Siemens maintenance experts realise planned and unplanned maintenance activities on two shift operation geared with a performance based contract. Performance Indicators includes plant availability and per-unit maintenance costs
Synapt’s team developed the end-to-end Connected Railroad solution that sends alerts along with preventive measures to first responders, departments in charge. It makes use of several sensors, including accelerometers, gyroscope, seal lid openers, and motion sensors.
*This is an IIC testbed currently in progress.*
Bosch, GE, IBM, Intel, KUKA, National Instruments, PTC
High Tech, Industrial Manufacturing, Discrete and Process Manufacturing, Automotive, Aerospace, and other segments with high value fixed/moving assets
Study of an asset - Failure mode analysis prediction using engineering knowledge - Mapping and modelling of the asset accordingly - Development of a platform stack for real-time data collection from the asset and overall system and data analytics
Many industries have assets that are critical to their business processes. Availability and efficiency of these assets directly impact service and business. Using predictive analytics, the Asset Efficiency Testbed aims to collect real-time asset information efficiently and accurately and run analytics to make the right decisions in terms of operations, maintenance, overhaul and asset replacement. Infosys, a member of the Industrial Internet Consortium, is leading this project, with contribution from Consortium members Bosch, GE, IBM, Intel, KUKA, National Instruments and PTC.
Asset Efficiency is a vertical testbed, making it possible for the testbed to be applied to multiple solutions. The testbed will launch in two phases. In the first phase, the testbed will be created for a moving solution, in this case, aircraft landing gear. The focus of this phase will be on the creation of stack and the integration of technologies. In the second phase, the testbed will address fixed assets, like chillers, with the goals of finalizing the architecture and opening up the interfaces.
The Asset Efficiency Testbed monitors, controls and optimizes the assets holistically taking into consideration operational, energy, maintenance, service, and information efficiency and enhance their performance utilization. The Asset Efficiency Testbed offers numerous benefits including: Condition Monitoring that helps in determining an optimal maintenance schedule, the reduction in downtime thus improving overall productivity of assets, reduction in capital and operational expenditures, and efficient energy utilization.
• IoT connectivity: Cisco® 819 Industrial Router with WiFi access point
• Fog application execution environment: Cisco IOx
• Fog application: LeaderMES
• IoT security: policy-based network controls, IOx application security
Employing DAQRI SMART HELMET™ and visual markers at process-observation points, KSP Steel engineers could access two new capabilities.
1. Just-in-place AR data visualization: Workers could safely access necessary information at the point of need, without wasted travel time or an interruption of situational awareness.
2. Portable Process Data: Workers can select an AR data visualization for a given observation point and pin it to their AR display, independent of the unique marker. This decouples the dependence on installed physical infrastructure and allows the user to safely take information with them, providing exponential improvements in process flexibility.
A complete connected product system from device to edge to cloud, incorporating custom algorithms, and enterprise systems integration.
AWS Cloud infrastructure and services for a secure, scalable system to support digital transformation.
After deploying the iTank solution, which runs on a secure, scalable, and robust IoT Platform, Retif personnel and customers can now view tank levels and alerts in the iTank Management Portal.
“The application is color-coded, so they simply look at the customers approaching the 25% full mark. This makes deliveries easy because they can pull up all of the deliveries in a designated area and just service those customers that meet a certain threshold in a geographic region, saving time, money and increasing efficiencies.”
The deployment expanded across more tanks in Retif’s seven state coverage region. To date, Retif has deployed thousands of tank monitors, many of which were installed by Retif personnel.
Infomobility.it set out its requirements to three companies, including Vodafone. The formal tender specified three key criteria: high network reliability and coverage, Quality of Service (QoS) and cost-effective network charges for data traffic.
The Group chose Vodafone for its ability to deliver on all three criteria. During the testing phase of proposed solutions, Vodafone provided technical support to Infomobility.it’s engineering department and helped its staff to configure an appropriate SIM for a cost-effective M2M communications solution.
“One important aspect of the QoS we offer is the updating frequency of the data transmitted by our box. Consequently, we needed a good billing solution and a proprietary encryption protocol to lower data exchange costs,” says Gianluigi Brasili, Chief Technical Officer, Infomobility.it Group.
With the Vodafone M2M communications solution in place, Infomobility.it has so far provided Italian insurance companies with around 7,500 InfoBoxes. Tests indicate that network coverage is very good.
“The vast majority of vehicles have reported excellent coverage which is especially encouraging considering the terrain in certain parts of Italy,” says Franco.
To demonstrate our solutions’ features, IoT Systems created a serverless infrastructure and dashboard to remotely monitor vacuum pumps on-site at semiconductor customer and deliver that valuable data and alerts to equipment owners. Our SenseQ gateway and SenseQ cloud infrastructure were integrated with InControl’s Smart Sensors to securely and reliably transfer data from behind an enterprise firewall to the cloud via Amazon Web Services (see Figure 1). Additionally, SenseQ provides quick, secure device provisioning, and scales easily for new equipment. The solution also includes dynamic thresholds for sensor and alarm types, defined by the SenseQ Engine, to differentiate routine warnings from critical failures. Finally, to meet changing customer needs, we built a configurable dashboard template with visualized equipment data. Equipment owners and operators can use the dashboard from their smartphone, tablet, or PC and receive alarms via in-dashboard notifications, email, or SMS.
Mercedes-Benz Russia and GAZ
The customer is a major US emergency service provider controlling the 9-1-1 service to US as well as global citizens for more than 30 years. The end customers include US wire-line, wireless, VoIP carriers, municipalities, and over 3000 public agencies.
Lordan manufactures thermal-engineering heating and cooling systems with a global reputation for delivering high-quality custom-made designs and supply flexibility.
KSP Steel, the first Kazakhstan Company producing steel seamless pipes for oil and gas sector, was founded in early 2007. Republic of Kazakhstan President Nursultan Nazarbayev attended the official opening of KSP Steel’s plant in the city of Pavlodar in December 2007. The total area of the company production facilities amounts to approximately 133 ha. Over 7,500 well-trained specialists work there. The company’s head office in Almaty coordinates the operation of the plant.
Despite billions in yearly global revenue, this maker of industrial filtration and fluid management equipment faced losing everything to more nimble competitors in a rapidly changing, more connected world. In order to deliver on the promise of digital transformation, the company needed a partner with deep industrial IoT development and deployment experience to help them realize their vision.
Retif Oil & Fuel
Based in the Italian province of Teramo, the Infomobility.it Group provides telematic solutions for its haulage and insurance customers. The Group began by providing remote sensing devices
and its portfolio now also includes geographic information and satellite navigation systems and, more recently, driving monitoring products.
InControl Engineering is an innovative solutions company specializing in the design and integration of smart sensors for manufacturing in numerous industries.
|Solution Maturity||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)||Cutting Edge (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)||Cutting Edge (technology has been on the market for < 2 years)|
Plant availability and per-unit maintenance costs.
Asset manufacturing and performance data, temperature, fluid pressure, viscosity, contamination levels
|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||Predictive Maintenance (PdM)||Process Control & Optimization (PCO)||Asset Lifecycle Management (ALM)||Manufacturing System Automation||Factory Operations Visibility & Intelligence ||Structural Health Monitoring (SHM)||Fleet Management (FM)||Machine Condition Monitoring|
A single point of contact for service activities for the customer that secures the optimal performance of their equipment and systems for years to come.
Regular notifications with shipment information to rail carriers, departments in charge, and county officials
Direct cost savings within weeks of the system’s deployment
Increased Worker Productivity - 40% Increase
Data from embedded sensors provides insights into fluid loop health with custom intelligent algorithms running in the cloud and at the edge.
Improved situational awareness of predictive maintenance requirements
A precise adaptation of maintenance activities to the plant’s processes ensures a comprehensive collaboration between the maintenance team and all levels of customer’s organization.
Effective prevention of derailment
Immediate identification of material-flow bottlenecks with mid shift change management to rectify issues
Reduction in Factory Downtime - 50% Decrease
Total lifecycle management from manufacturing, through the sales chain, installation and performance, and eventual decommissioning of each unit.
Lowered costs for all parties
Maximum availability of the customer’s production equipment, the ability to optimally schedule production, and the means to calculate costs over the long term.
Full-fledged dashboard with infrastructure, weather, and shipment information with GIS data
Mobile and web-based administrative consoles provide the company and customers full control over their systems and workforce.
Securely and reliably transmit data between equipment, sensors, and owners' devices
Workforce optimization savings of more than 600 labor hours a month
Fewer contamination events due to real-time monitoring of filter health to detect issues before they cause damage.
Retif has reduced the number of unnecessary deliveries by 48%, resulting in a net total in return-on-investment of over $10,000 per month in delivery expenses alone.
Some insurance companies have reduced individual premiums by between 10 and 25% and large fleet operators have seen premiums fall by as much as 60%.
Increased production visibility and real-time measurement increased production floor productivity more than 10%
Reduced insurance/compliance disputes through complete audit trails of asset authenticity and performance.
Over one year, the company forecasts turnover will increase from €4.8 million to €6.4 million, with approximately 15,000 InfoBox devices installed in vehicles.
Increased customer loyalty and satisfaction.
|Software||Bright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud|
|Tech Partners||BoschGeneral Electric (GE)IBMIntelKUKA AGNational InstrumentsPTC||LeaderMES (Emerald Information Systems LTD)||Amazon Web Services|
IoT Snapshot: Hardware
|Processors & Boards|
|Sensors & Actuators|
|Devices & Equipment|
IoT Snapshot: Software
|Software as a Service|
|Platform as a Service|
|Infrastructure as a Service|
IoT Snapshot: Service
|Construction & Buildings|
|Equipment & Machinery|
|Logistics & Warehousing|