Accelerating the
Industrial Internet of Things

Integration of PLC with IoT for Bosch Rexroth

Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
Integration of PLC with IoT for Bosch Rexroth
Solair (Microsoft) Solair (Microsoft)
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SIMILAR CASE STUDIES

Overview
ImageIntegration of PLC with IoT for Bosch RexrothHaemoCloud Global Blood Management SystemFastenal Builds the Future of Manufacturing with MachineMetricsReservoir monitoring in HontominVending Machine Secure Real-time Data Using Everyware CloudMAAC Machinery Saves 50% of Support Cost Using Remote AccessUnswerving Focus Solidifies Traffic SafetyQuality compressed air for high-tech productsIndustry 4.0 and Smart Manufacturing
Verified Vendor
SnapshotIntegration of PLC with IoT for Bosch RexrothHaemoCloud Global Blood Management SystemFastenal Builds the Future of Manufacturing with MachineMetricsReservoir monitoring in HontominVending Machine Secure Real-time Data Using Everyware CloudMAAC Machinery Saves 50% of Support Cost Using Remote AccessUnswerving Focus Solidifies Traffic SafetyQuality compressed air for high-tech productsIndustry 4.0 and Smart Manufacturing
Challenge

The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.

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.

Fastenal's objective was to better understand their machine downtime, utilization, quality issues, and to embrace cutting-edge manufacturing technology/process improvement capabilities to bring their team to the next level. However, there was a lack of real-time data, visualization, and actionable insights made this transition impossible.

The Spanish Government has launched a CO2 Capture and Storage Program in Hontoman with the aim of developing this technology. This programme's approach is based on the fact that CO2 capture and storage could be an essential part of the solution to achieve substantial global CO2 emission reductions.

As vending machine technology has evolved, it has become more challenging, less reliable and costly to connect phone lines to vending machines and collect data via a modem. Manual equipment maintenance is very costly, slow and labor intensive.

MAAC is a corporate situated in Chicago and specialized in manufacturing thermoforming machinery and other companion products. MAAC found out that the automation control technology was the key to succeed in the machinery sector.

Providing machine-to-machine (M2M) wireless connectivity to deliver vital traffic information to local municipalities and their motorists to improve traffic safety.

When it came to modernisation of the existing compressed air station, the company’s management decided to opt for a compressed air contracting arrangement to ensure that the compressed air supply would always meet the latest technical standards and be capable of taking advantage of the benefits that Industry 4.0 has to offer – and not least due to the frequent fluctuations in demand in the automotive supplier industry. In this operator model, the compressed air station itself remains the property of the air system provider, whilst the customer simply uses the compressed air as needed, just like power from an electrical socket, paying only for the volume of compressed air actually used – and always at the same fixed rate. From an accounting perspective, this effectively turns fixed costs into variable costs. At Scholz, the new station was installed in a space-saving container on the roof of the company building.

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.

Solution

Bosch Rexroth has integrated its Rexroth control systems into Solair IoT platform effectively and with reduced design effort. The platform of programmable controllers Rexroth is ready for Connected Industry: it has been designed for easy integration in the supervisory systems and data management processes and for direct access through languages and systems of the IT world.

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.

MachineMetrics was the solution. The fully automated machine monitoring and manufacturing analytics solution provided visualizations of real-time manufacturing production data, instant notifications, as well as historical analytics, allowing factory workers to make faster, smarter, more confident decisions based on real-time data. Data was collected from machine controls and machine operators for the entire production floor and then used to monitor machine conditions (faults, status, tool utilization), production (OEE & Machine Utilization), work-order status, quality tracking and downtime reasons that were auto classified or indicated by the operator via the touch screens. Real-Time Dashboards were also mounted on the production floor to provide an at-a-glance indication if jobs are performing at or below expectations (against Parts Goal or OEE metrics). The real-time and historical data collected allowed managers to not only track efficiency and quickly identify production bottlenecks that are related to specific machining operations but also helped them measure the effect of process improvements.

Worldsensing provided 5 Spidernano surface seismic recording units SRU and borehole instrumentation to obtain a clear picture of reservoir behaviour. Monitoring equipment includes temperature and pressure gauges and a U-tube fluid sampling system. Hardware Components - Geophysical instrumentation - In-well pressure gauge - U-tube fluid sampling system

Eurotech solutions integrate the latest in vending technology including touchscreen display, cashless payment options, and vending industry standard protocols to simplify development for OEMs. Eurotech products such as the ReliaGATE 20-11 multi-service gateway can enable M2M communications in different environments whether connected through a LAN, over WiFi or over a cellular network. Software Components - Eurotech Everyware Software Framework (ESF) - Everyware Cloud

eWON VPN router is the chosen solution for connecting machines. The secure VPN connection that eWON technology provides, offers full integration of IT security standards. eWON’s unique remote access solution allows MAAC to connect to machines in the field with the same ease and flexibility as a machine in their shop.

Web-based, wirelessly enabled, intelligent traffic signs — including radar speed display signs and variable message signs powered by KORE Global Connect. With multi-national customers using web-based interfaces, All Traffic Solutions delivers global access to local traffic data in real-time. The data and statistics collected by these devices are what helps customers determine safety benchmarks, traffic pattern flows and ultimately change the flow of traffic in a city for the better. And by coordinating with KORE, All Traffic Solutions is able to manufacture every device they deploy with wireless connectivity, knowing that global services are available and can be implemented quickly and easily when requested by their customers. This single source solution allows municipalities to take advantage of the wireless connectivity without having to order different equipment. Since every device is installed with this capability, they have the opportunity to decide to use it or not.

Following a detailed compressed air audit to identify the company’s exact compressed air needs, Scholz’s compressed air station was designed to incorporate the very latest technology, including all of the features that today’s advanced stations should offer. Of course, first and foremost, this includes outstanding reliability, quality and efficiency, as well as impressive energy savings. In addition, ease of maintenance together with networking and integrated control features consistent with the Industry 4.0 environment also play a key role, not least in laying the foundation for predictive maintenance. A safety concept was also devised. The data gathered during the analysis were input into the new system's controller – a SIGMA AIR MANAGER 4.0 (SAM 4.0) in this case – and therefore provide the foundation for highly-efficient operation of the entire system. Since the compressors and compressed air treatment components are equipped with integrated industrial PC technology, they are able to forward their data to a master controller. This master controller monitors all components, as well as the environmental and production conditions. is also able to precisely adapt compressed air production to match the company’s actual compressed air requirement. Furthermore, amongst many other key benefits, the SAM 2 optimises pressure values, automatically adjusts compressor system air delivery to accommodate fluctuating air demand and optimises system efficiency through constant analysis of the relationship between control losses, switching losses and pressure flexibility. This advanced controller also enables the compressed air station to benefit from future services, such as predictive maintenance. The controller also allows remote diagnostics capability. If requested by the customer, this option means that performance data are constantly sent to a data centre operated by the compressed air system provider for monitoring. The master controller independently analyses the situation at all times and, if appropriate, sends a message to the service team, or directly to the local installation technician or the central data centre. The air system provider’s central data centre then acts as the dispatching point for all further activities – worldwide.

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.

Customer

Bosch Rexroth provides worldwide integrated technologies for operations and control of industrial plants and mobile equipment and technologies related to renewable energy in 80 countries for over 200 years.

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.

Fastenal is an American industrial supply company based in Winona, Minnesota. They provide companies with the fasteners, tools, and supplies needed to manufacture products, build structures, protect personnel, and maintain facilities and equipment.

Spanish Government

Vending machine manufacturing companies.

MAAC is a corporate situated in Chicago and specialized in manufacturing thermoforming machinery and other companion products.

Located in State College, Pa., All Traffic Solutions is consistently recognized as a leading innovator in the traffic safety market for speed displays, message signs and imaging products, delivering groundbreaking levels of service and product capability. By integrating cloud technology into all of its products, All Traffic Solutions allows customers to manage all their equipment and data remotely, through a browser.

Horst Scholz GmbH & Co. KG is a manufacturer of precision plastic parts. These include products used in medical technology and precision engineering parts, destined primarily for the automotive industry. The medical sector in particular insists on stringent requirements to ensure high product quality – and it’s no different when it comes to the quality standards for the compressed air the company relies on for control and process air.

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.

Solution TypeIOTIOTIOTIOTM2MIOTM2MIOTIOT
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)Cutting Edge (technology has been on the market for < 2 years)Cutting Edge (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)Emerging (technology has been on the market for > 2 years)
Data Collected
Status of machine, distance between parcels, movement of objects
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Cycle times, setup time, expected setup time, total setup time, machine utilization, machine utilization rate, downtime, planned downtime, unplanned downtime, OEE, OOE, TEEP, availability, performance, quality, rejection rate, scrap rate, total parts, good parts, bad parts, parts rejected, parts scrapped, expected parts, production efficiency, average pph, ideal pph, expected pph, expected part time, ideal part time.
Real-time data on CO2 injection, microseismicity, stress, electromagnetic reservoir change
Vending machine data, including sales, key functionality
Traffic flow trends and patterns.
Pressure values, performance data
Asset manufacturing and performance data, temperature, fluid pressure, viscosity, contamination levels
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 CasesMachine Condition MonitoringProcess Control & Optimization (PCO)Machine Condition MonitoringMachine Condition MonitoringProcess Control & Optimization (PCO)Factory Operations Visibility & Intelligence Smart City OperationsProcess Control & Optimization (PCO)

Operational Impact
Impact #1
Real-time status reports enable maintenance personnel to do predictive maintenance and problem detection before interruption in production processes.
Integrated across multiple information systems to share information with hospital and IT staff.
Increase in machine utilization.
Cloud solutions enable aggregation of real-time data critical for monitoring the progress of the CO2 injection to enable more robust analysis and lower costs.
Touchscreens feature allows manufacturers and operators to offer advertising, caloric information, updated inventory and a more attractive user experience.
The flux of information is delivered in real time and can help troubleshooting the issue or provide a fast solution to customers.
Municipalities around the world can receive vital traffic and safety information to better manage traffic flow, implement new DOT programs, improve driver and pedestrian safety as well as the reduce traffic congestion.
System servicing and maintenance is possible; compliance with fixed intervals is no longer necessary
Data from embedded sensors provides insights into fluid loop health with custom intelligent algorithms running in the cloud and at the edge.
Impact #2
Total cost of ownership is lowered due to reduction in unexpected maintenance costs.
A smart system of devices providing critical operational data for service and support.
Improved workforce productivity.
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Real-time visibility, monitoring, and control of equipment improves asset and resource efficiency.
Increasing information flow through a variety of sensors available for data collection (tampering, cameras, speed, traffic patterns, etc.)
Enhance operational reliability and efficiency
Total lifecycle management from manufacturing, through the sales chain, installation and performance, and eventual decommissioning of each unit.
Impact #3
The location of individuals and assets can be identified in near real-time.
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Data transparency and reliability.
Real-time status reports enable maintenance personnel to remotely diagnose the status of vending machine inventory and functionality.
eWON router solve the problem of phone modem delay time.
Reduce both energy and total life-cycle costs

Quantitative Benefit
Benefit #1

The solution provides 24/7 monitoring which enables access to real-time information about machines.

Enable increased number of procedures per facility per day.

Achieved ROI in 25 days.

The system is able to retrieve high volume samples (>10L sample volume) providing an accurate compositional window on subsurface geochemical conditions.

With eWON, MAAC eliminate 50-70% of support cost, in addition to significantly reducing hours of machine downtime.

Reduction of some 50 percent in oil consumption in the first year alone

Fewer contamination events due to real-time monitoring of filter health to detect issues before they cause damage.

Benefit #2

Reduced downtime and unexpected maintenance calls.

Experienced a 20% increase in machine utilization.

Reduced insurance/compliance disputes through complete audit trails of asset authenticity and performance.

Benefit #3

Increased customer satisfaction.

Produced 150,000 more parts than the previous year.

Increased customer loyalty and satisfaction.


Technology
HardwareSolair GatewaySpidernano Passive Seismic Recording UnitMulti Service IoT GatewayseWON Cosy - Industrial VPN Router
SoftwareSolair IoT PlatformAmazon 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 CloudBright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud
Tech PartnersAmazon Web ServicesMachineMetricsAmazon Web Services

IoT Snapshot: Hardware
Processors & Boards
Transceivers
Sensors & Actuators
Network Equipment
Devices
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
ImageIntegration of PLC with IoT for Bosch RexrothHaemoCloud Global Blood Management SystemFastenal Builds the Future of Manufacturing with MachineMetricsReservoir monitoring in HontominVending Machine Secure Real-time Data Using Everyware CloudMAAC Machinery Saves 50% of Support Cost Using Remote AccessUnswerving Focus Solidifies Traffic SafetyQuality compressed air for high-tech productsIndustry 4.0 and Smart Manufacturing
Verified Vendor
SnapshotIntegration of PLC with IoT for Bosch RexrothHaemoCloud Global Blood Management SystemFastenal Builds the Future of Manufacturing with MachineMetricsReservoir monitoring in HontominVending Machine Secure Real-time Data Using Everyware CloudMAAC Machinery Saves 50% of Support Cost Using Remote AccessUnswerving Focus Solidifies Traffic SafetyQuality compressed air for high-tech productsIndustry 4.0 and Smart Manufacturing
Challenge

The application arises from the need to monitor and anticipate the problems of one or more machines managed by a PLC. These problems, often resulting from the accumulation over time of small discrepancies, require, when they occur, ex post technical operations maintenance.

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.

Fastenal's objective was to better understand their machine downtime, utilization, quality issues, and to embrace cutting-edge manufacturing technology/process improvement capabilities to bring their team to the next level. However, there was a lack of real-time data, visualization, and actionable insights made this transition impossible.

The Spanish Government has launched a CO2 Capture and Storage Program in Hontoman with the aim of developing this technology. This programme's approach is based on the fact that CO2 capture and storage could be an essential part of the solution to achieve substantial global CO2 emission reductions.

As vending machine technology has evolved, it has become more challenging, less reliable and costly to connect phone lines to vending machines and collect data via a modem. Manual equipment maintenance is very costly, slow and labor intensive.

MAAC is a corporate situated in Chicago and specialized in manufacturing thermoforming machinery and other companion products. MAAC found out that the automation control technology was the key to succeed in the machinery sector.

Providing machine-to-machine (M2M) wireless connectivity to deliver vital traffic information to local municipalities and their motorists to improve traffic safety.

When it came to modernisation of the existing compressed air station, the company’s management decided to opt for a compressed air contracting arrangement to ensure that the compressed air supply would always meet the latest technical standards and be capable of taking advantage of the benefits that Industry 4.0 has to offer – and not least due to the frequent fluctuations in demand in the automotive supplier industry. In this operator model, the compressed air station itself remains the property of the air system provider, whilst the customer simply uses the compressed air as needed, just like power from an electrical socket, paying only for the volume of compressed air actually used – and always at the same fixed rate. From an accounting perspective, this effectively turns fixed costs into variable costs. At Scholz, the new station was installed in a space-saving container on the roof of the company building.

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.

Solution

Bosch Rexroth has integrated its Rexroth control systems into Solair IoT platform effectively and with reduced design effort. The platform of programmable controllers Rexroth is ready for Connected Industry: it has been designed for easy integration in the supervisory systems and data management processes and for direct access through languages and systems of the IT world.

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.

MachineMetrics was the solution. The fully automated machine monitoring and manufacturing analytics solution provided visualizations of real-time manufacturing production data, instant notifications, as well as historical analytics, allowing factory workers to make faster, smarter, more confident decisions based on real-time data. Data was collected from machine controls and machine operators for the entire production floor and then used to monitor machine conditions (faults, status, tool utilization), production (OEE & Machine Utilization), work-order status, quality tracking and downtime reasons that were auto classified or indicated by the operator via the touch screens. Real-Time Dashboards were also mounted on the production floor to provide an at-a-glance indication if jobs are performing at or below expectations (against Parts Goal or OEE metrics). The real-time and historical data collected allowed managers to not only track efficiency and quickly identify production bottlenecks that are related to specific machining operations but also helped them measure the effect of process improvements.

Worldsensing provided 5 Spidernano surface seismic recording units SRU and borehole instrumentation to obtain a clear picture of reservoir behaviour. Monitoring equipment includes temperature and pressure gauges and a U-tube fluid sampling system. Hardware Components - Geophysical instrumentation - In-well pressure gauge - U-tube fluid sampling system

Eurotech solutions integrate the latest in vending technology including touchscreen display, cashless payment options, and vending industry standard protocols to simplify development for OEMs. Eurotech products such as the ReliaGATE 20-11 multi-service gateway can enable M2M communications in different environments whether connected through a LAN, over WiFi or over a cellular network. Software Components - Eurotech Everyware Software Framework (ESF) - Everyware Cloud

eWON VPN router is the chosen solution for connecting machines. The secure VPN connection that eWON technology provides, offers full integration of IT security standards. eWON’s unique remote access solution allows MAAC to connect to machines in the field with the same ease and flexibility as a machine in their shop.

Web-based, wirelessly enabled, intelligent traffic signs — including radar speed display signs and variable message signs powered by KORE Global Connect. With multi-national customers using web-based interfaces, All Traffic Solutions delivers global access to local traffic data in real-time. The data and statistics collected by these devices are what helps customers determine safety benchmarks, traffic pattern flows and ultimately change the flow of traffic in a city for the better. And by coordinating with KORE, All Traffic Solutions is able to manufacture every device they deploy with wireless connectivity, knowing that global services are available and can be implemented quickly and easily when requested by their customers. This single source solution allows municipalities to take advantage of the wireless connectivity without having to order different equipment. Since every device is installed with this capability, they have the opportunity to decide to use it or not.

Following a detailed compressed air audit to identify the company’s exact compressed air needs, Scholz’s compressed air station was designed to incorporate the very latest technology, including all of the features that today’s advanced stations should offer. Of course, first and foremost, this includes outstanding reliability, quality and efficiency, as well as impressive energy savings. In addition, ease of maintenance together with networking and integrated control features consistent with the Industry 4.0 environment also play a key role, not least in laying the foundation for predictive maintenance. A safety concept was also devised. The data gathered during the analysis were input into the new system's controller – a SIGMA AIR MANAGER 4.0 (SAM 4.0) in this case – and therefore provide the foundation for highly-efficient operation of the entire system. Since the compressors and compressed air treatment components are equipped with integrated industrial PC technology, they are able to forward their data to a master controller. This master controller monitors all components, as well as the environmental and production conditions. is also able to precisely adapt compressed air production to match the company’s actual compressed air requirement. Furthermore, amongst many other key benefits, the SAM 2 optimises pressure values, automatically adjusts compressor system air delivery to accommodate fluctuating air demand and optimises system efficiency through constant analysis of the relationship between control losses, switching losses and pressure flexibility. This advanced controller also enables the compressed air station to benefit from future services, such as predictive maintenance. The controller also allows remote diagnostics capability. If requested by the customer, this option means that performance data are constantly sent to a data centre operated by the compressed air system provider for monitoring. The master controller independently analyses the situation at all times and, if appropriate, sends a message to the service team, or directly to the local installation technician or the central data centre. The air system provider’s central data centre then acts as the dispatching point for all further activities – worldwide.

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.

Customer

Bosch Rexroth provides worldwide integrated technologies for operations and control of industrial plants and mobile equipment and technologies related to renewable energy in 80 countries for over 200 years.

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.

Fastenal is an American industrial supply company based in Winona, Minnesota. They provide companies with the fasteners, tools, and supplies needed to manufacture products, build structures, protect personnel, and maintain facilities and equipment.

Spanish Government

Vending machine manufacturing companies.

MAAC is a corporate situated in Chicago and specialized in manufacturing thermoforming machinery and other companion products.

Located in State College, Pa., All Traffic Solutions is consistently recognized as a leading innovator in the traffic safety market for speed displays, message signs and imaging products, delivering groundbreaking levels of service and product capability. By integrating cloud technology into all of its products, All Traffic Solutions allows customers to manage all their equipment and data remotely, through a browser.

Horst Scholz GmbH & Co. KG is a manufacturer of precision plastic parts. These include products used in medical technology and precision engineering parts, destined primarily for the automotive industry. The medical sector in particular insists on stringent requirements to ensure high product quality – and it’s no different when it comes to the quality standards for the compressed air the company relies on for control and process air.

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.

Solution TypeIOTIOTIOTIOTM2MIOTM2MIOTIOT
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)Cutting Edge (technology has been on the market for < 2 years)Cutting Edge (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)Emerging (technology has been on the market for > 2 years)
Data Collected
Status of machine, distance between parcels, movement of objects
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Cycle times, setup time, expected setup time, total setup time, machine utilization, machine utilization rate, downtime, planned downtime, unplanned downtime, OEE, OOE, TEEP, availability, performance, quality, rejection rate, scrap rate, total parts, good parts, bad parts, parts rejected, parts scrapped, expected parts, production efficiency, average pph, ideal pph, expected pph, expected part time, ideal part time.
Real-time data on CO2 injection, microseismicity, stress, electromagnetic reservoir change
Vending machine data, including sales, key functionality
Traffic flow trends and patterns.
Pressure values, performance data
Asset manufacturing and performance data, temperature, fluid pressure, viscosity, contamination levels
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 CasesMachine Condition MonitoringProcess Control & Optimization (PCO)Machine Condition MonitoringMachine Condition MonitoringProcess Control & Optimization (PCO)Factory Operations Visibility & Intelligence Smart City OperationsProcess Control & Optimization (PCO)

Operational Impact
Impact #1
Real-time status reports enable maintenance personnel to do predictive maintenance and problem detection before interruption in production processes.
Integrated across multiple information systems to share information with hospital and IT staff.
Increase in machine utilization.
Cloud solutions enable aggregation of real-time data critical for monitoring the progress of the CO2 injection to enable more robust analysis and lower costs.
Touchscreens feature allows manufacturers and operators to offer advertising, caloric information, updated inventory and a more attractive user experience.
The flux of information is delivered in real time and can help troubleshooting the issue or provide a fast solution to customers.
Municipalities around the world can receive vital traffic and safety information to better manage traffic flow, implement new DOT programs, improve driver and pedestrian safety as well as the reduce traffic congestion.
System servicing and maintenance is possible; compliance with fixed intervals is no longer necessary
Data from embedded sensors provides insights into fluid loop health with custom intelligent algorithms running in the cloud and at the edge.
Impact #2
Total cost of ownership is lowered due to reduction in unexpected maintenance costs.
A smart system of devices providing critical operational data for service and support.
Improved workforce productivity.
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device.
Cloud solutions enable aggregation of 'big data' to enable more robust analysis and lower costs.
Real-time visibility, monitoring, and control of equipment improves asset and resource efficiency.
Increasing information flow through a variety of sensors available for data collection (tampering, cameras, speed, traffic patterns, etc.)
Enhance operational reliability and efficiency
Total lifecycle management from manufacturing, through the sales chain, installation and performance, and eventual decommissioning of each unit.
Impact #3
The location of individuals and assets can be identified in near real-time.
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Data transparency and reliability.
Real-time status reports enable maintenance personnel to remotely diagnose the status of vending machine inventory and functionality.
eWON router solve the problem of phone modem delay time.
Reduce both energy and total life-cycle costs

Quantitative Benefit
Benefit #1

The solution provides 24/7 monitoring which enables access to real-time information about machines.

Enable increased number of procedures per facility per day.

Achieved ROI in 25 days.

The system is able to retrieve high volume samples (>10L sample volume) providing an accurate compositional window on subsurface geochemical conditions.

With eWON, MAAC eliminate 50-70% of support cost, in addition to significantly reducing hours of machine downtime.

Reduction of some 50 percent in oil consumption in the first year alone

Fewer contamination events due to real-time monitoring of filter health to detect issues before they cause damage.

Benefit #2

Reduced downtime and unexpected maintenance calls.

Experienced a 20% increase in machine utilization.

Reduced insurance/compliance disputes through complete audit trails of asset authenticity and performance.

Benefit #3

Increased customer satisfaction.

Produced 150,000 more parts than the previous year.

Increased customer loyalty and satisfaction.


Technology
HardwareSolair GatewaySpidernano Passive Seismic Recording UnitMulti Service IoT GatewayseWON Cosy - Industrial VPN Router
SoftwareSolair IoT PlatformAmazon 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 CloudBright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud
Tech PartnersAmazon Web ServicesMachineMetricsAmazon Web Services

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