Accelerating the
Industrial Internet of Things

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SIMILAR CASE STUDIES

Overview
ImageNo More Searching for SoftwareTRW calls for action with the help of WERMARobotStudio Case Study: Benteler AutomobiltechnikCutting-edge Predictive Analytics for HIROTEC GroupPump Cavitation DetectionRemote Condition Monitoring for London UndergroundReducing Operating Costs And Improving SafetyA.P. Plasman, Inc. Case Study HaemoCloud Global Blood Management System
Verified Vendor
SnapshotNo More Searching for SoftwareTRW calls for action with the help of WERMARobotStudio Case Study: Benteler AutomobiltechnikCutting-edge Predictive Analytics for HIROTEC GroupPump Cavitation DetectionRemote Condition Monitoring for London UndergroundReducing Operating Costs And Improving SafetyA.P. Plasman, Inc. Case Study HaemoCloud Global Blood Management System
Challenge
Tasks such as manual documentation and the fact that new software and hardware is constantly being integrated to the automation network makes the lives of maintenance staff difficult.
TRW needed a wireless monitoring system as laying cables and trunking throughout their sprawling and ageing facility would be an unimaginable task.
Benteler has a small pipe business area for which they produce fuel lines and coolant lines made of aluminum for Porsche and other car manufacturers. One of the problems in production was that when Benteler added new products, production had too much downtime.
Hirotec needed to ensure continuous operations and to minimize unplanned downtime in its manufacturing facilities. Unplanned downtime is costly and compromises Hirotec's ability to deliver its goods to customers on time.
Cavitation is a condition can occur in centrifugal pumps when there is a sudden reduction in fluid pressure. Pressure reduction lowers the boiling point of liquids, resulting in the production of vapor bubbles if boiling occurs. This is more likely to happen at the inlet of the pump where pressure is typically lowest. As the vapor bubbles move towards the outlet of the pump where pressure is higher, they rapidly collapse (return to a liquid state) resulting in shock waves that can damage pump components.
London Underground serves 1.7 billion passengers per year and the Victoria Line accounts for 213 million of those journeys. The line carries 89.1 million passengers per year in the peak service, offering the most intensive service on the underground network. Over the past eight years, a £1 billion investment programme upgraded and replaced the Victoria Line’s rolling stock and signaling and control systems to deliver a service capable of running more than 33 trains per hour. The new signalling system uses 385 Jointless Track Circuits (JTCs) to detect train position, maintain safe train separation and deliver train headways capable of meeting an extremely demanding timetable. Track circuits are the sole means of train detection and play a critical role in the safe and reliable operation of the railway; however, no provision was made for any condition monitoring during the design and installation. Because of the critical nature of the asset, a failed track circuit has a major impact on the service and constitutes the biggest cause of passenger disbenefit on the Victoria Line, amounting to £1.5 million since their introduction (London Underground CuPID database for Track Circuit failures since 2012). The Victoria Line Condition Monitoring Team, made up of six professional engineers with rail, software, electrical, mechanical, network and engineering backgrounds, delivered the solution. National Instruments Silver Alliance Partner Simplicity AI supported the project by providing additional software consulting services. We used the company’s enormous breadth of expertise to deliver the system onto an operational railway within one year of the concept design. The scope of this project consisted of designing, integrating and installing an intelligent remote condition monitoring system that could perform real-time analysis of voltage and frequency for all 385 JTCs across a 45 km of deep tube railway to predict and prevent failures and subsequent loss of passenger service. We took advantage of the accuracy, reliability and flexibility of NI hardware and software to implement an innovative system to reduce the lost customer hours experienced on the Victoria Line. The system is forecast to reduce lost customer hours by 39,000 per year—an estimated £350,000 savings per year in passenger disbenefit.
To ensure safe operation of the nuclear plant, the Institute of Nuclear Power Operations sets the performance objectives and defines the criteria (PO&C) to meet those objectives. The plant personnel manually compare each line item in the CAP report against the PO&C to evaluate the seriousness of the event. A spilled cup of coffee in the wrong place might not be too serious, while a critical pump leaking that has the potential to shut down the plant is another matter entirely. This manual process of classifying the seriousness of each item in a CAP report lies at the heart of the continuous effort to improve the safety and operation of the nuclear power plant, but requires significant time and resources. Our client needed a way to automate the classification process to increase its efficiency and to extract information from years of reported events to better understand their causes and anticipate possible adverse events.
The A.P. Plasman Corporation manages multiple facilities with multiple processes, and when they were looking for an automation solution for their paint facility in Tecumseh, they were looking for a solution that could restrict access, deploy easily, and provide the ability to modify the application quickly to suit changing needs.
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.
Solution
Versiondog is an integrated data management system that can detect and document changes made to the production line network. Due to the high number of daily and weekly backups to the network, Versiondog ensures that the most recent software version is always running on every single component in the network, making maintenance work easier.
TRW began by monitoring 10 critical machines with 10 transmitters monitoring machine status. Using WIN the customer was able to get a precise overview of their status in a matter of minutes. The plug and play wireless system was quick and easy to install and up and running immediately.
ABB presented RobotStudio as the solution. Engineers can use RobotStudio for offline programming using real-time data to test alternatives without shutting down production. Using RobotStudio, engineers can simulate real-world situations to identify problems with a new robot design. If problems exist, they can be addressed before the tool is actually made of steel and iron. RobotStudio is also used to create macros and to model welding, gluing, and image processing procedures.
Hirotec decided to partner with PTC and selected its Thingworx Technology Platform and KEPServerEX agent to rapidly develop and deploy IoT software and integrate it with its manufacturing systems. PTC with its IT capabilities proved to be an ideal partner to complement Hirotec's operations technology skillset. HIROTEC also decided to use HPE Edgeline servers to support edge analytics. The ruggedized HPE Edgeline servers’ small footprint minimized the need for HIROTEC to sacrifice valuable factory floor space. In addition, the servers do not require specialized cooling to operate. To get a free demo of ThingWorx 8: http://solutions.iotone.com/thingworx
An intelligent edge solution can ingest pump sensor data in real-time and apply mathematical equations on the incoming data to identify any significant changes in pressure and alert operations personnel before damage occurs. It can also send a signal to the main system to automatically move the flow of the fluid to a different pump to prevent damage and reduce maintenance and downtime costs associated with pump cavitation.
The Victoria Line deploys variable length frequency-driven tuned electrical JTCs. The circuits energise and de-energise as trains traverse the line. Each JTC includes an electrical receiver unit matched to the frequency of the track circuit (4 to 6 kHz frequency shift keyed), which processes the incoming signal and provides a sample to a monitor point that can be used to check the health of the track circuit. Prior to the introduction of this system, we had to periodically monitor the condition of every track circuit manually on-site with a digital multimeter. Following the installation of the NI CompactRIO system, we can now simultaneously acquire the JTC monitor point samples remotely from all track circuits on the line, which means the maintenance teams can proactively predict and prevent equipment failures before they occur. We looked at various suppliers of data acquisition products and concluded that, although other products may have met the initial requirements, no other product offered the flexibility, scalability and performance of the CompactRIO platform. The diverse range of input modules and the ability to easily customise the onboard software using the NI LabVIEW platform also meant that we could deliver further condition monitoring projects using a common platform, which would reduce the time to design and develop the hardware and software for a wider range of data inputs. Due to the Safety Integrity Level (SIL4) of the track circuit system, we needed to introduce an independent isolation barrier between the receiver unit and the CompactRIO device. We collaborated with Dataforth, based in the United States, to design a SCM5B isolation module to provide galvanic isolation between the CompactRIO device and the track circuits being monitored. The SCM range of isolation modules could pass the stringent test equipment requirements of the receiver and also provide an accurate and compatible replica of the output signal for the CompactRIO acquisition. The isolation layer coupled with the low failure rates of NI hardware ensured that we could install the system without compromising the SIL4 safety integrity of the Victoria Line signalling system. We pursued an extensive engineering safety analysis on the hardware in accordance with the CENELEC railway application standards and approved by the relevant safety authorities to assure and validate the design. We split data acquisition from the CompactRIO devices across 14 geographically separate sites that were all part of a new high-bandwidth fibre optic network specifically installed for this application. The flexibility of the CompactRIO hardware, combined with NI LabVIEW software meant that we could transport data to a central condition monitoring server in real time using a lightweight transfer protocol. This was a key requirement in the design and delivery of a true remote condition monitoring system. The central condition monitoring server processes a live 10 Hz data stream from every CompactRIO device, which totals more than 7,000 data samples per second. The lightweight CompactRIO data transfer protocol ensures that the central server can rapidly analyse the data and monitor track circuits for deviations away from the ideal condition. The system compares each received frame of data to a defined standard frequency and voltage so the server can make an independent decision on the health of each track circuit connected to the CompactRIO input channels. In addition, the server stores all of the data in a near line and far line database architecture so we can analyse long-term trends on large datasets. The central server can push asset condition alerts to a human machine interface (HMI). The HMI is a large touch screen device that displays an accurate scaled replica of the Victoria Line track circuit configuration. A user can intuitively navigate the information displayed with natural touch gestures, clearly identify line-side asset condition and receive predicted equipment failure warnings. We plan to deploy two HMIs for faster response times—one in the Victoria Line control center and another in the maintenance control center. Both can be used by signaling maintenance staff. We can remotely interrogate each track circuit on the railway with a single touch, presenting the user with a live graphical representation of the root mean square (RMS) voltage, frequency and track state information using the data streamed from the line-side CompactRIO devices. Alongside the HMI, a suite of touch screen devices can display the CompactRIO data in the line-side equipment rooms and through a smartphone or tablet. This means the data from the CompactRIO devices is available anywhere on the Victoria Line through a connection to the new condition monitoring network. We selected Simplicity AI to develop the CompactRIO FPGA and real-time software. Although London Underground has internal LabVIEW developers, we used Simplicity AI on this project because of the company’s high level of FPGA and real-time experience. The company provided full documentation, source code, and results from long-term stability and stress tests within three months to ensure that the CompactRIO system could be assured to a level suitable for use in a safety-critical environment on London Underground’s infrastructure. For each deployed unit, we paired an NI cRIO-9025 controller with an 8-slot NI cRIO-9118 chassis. We could use up to eight NI 9220 analog input modules to provide a maximum of 128 physical inputs per CompactRIO system. We selected this configuration because it offered the required processing power and provided dual network ports for redundant network operation to maximize system uptime. The CompactRIO platform helped the team take a bottom-up approach in developing the system because the ever-evolving specifications were unknown until we acquired early asset data. This flexible platform accommodated rapid iterations in the development of application functionality, which saved a significant amount of time in project delivery. Early on we faced the challenge of calculating frequency and RMS voltage simultaneously over all 128 channels on the FPGA. Simplicity AI addressed this by delivering a serial process architecture that uses the high clock rate of the FPGA to process data for each channel sequentially. The software builds up a 10 ms buffer for each channel then iterates through each buffer and calculates the frequency and RMS voltage. A key feature for the deployment on London Underground was for the system to be installed, commissioned and maintained by rail technicians unfamiliar with NI software and the CompactRIO platform. Simplicity AI provided a common software package configured for each location via a simple external text file in the standard XML file format. We developed an application using the Replication and Deployment (RAD) utility, which automated the process of installing the system and application software to the CompactRIO device along with the correct configuration file. The CompactRIO deployment tool simplified the rollout of the system, delivered installation efficiencies and allowed for CompactRIO devices to be remotely deployed, configured and updated from a centrally managed location. This remote one-click configuration also proved extremely beneficial during the development phase when London Underground and Simplicity AI engineers worked in parallel as a joint team on different sections of the project.
As operators create each CAP report, Saffron automatically applies the attributes of all PO&C objectives to each line item within the CAP report and then suggests an appropriate classification. An experienced operator reviews each Saffron recommendation to confirm the recommendation or to change it. The validated report then becomes part of Saffron’s memory base, providing the input for Saffron to continuously improve by learning and remembering the specific variables upon which the classification decision is made. Not only does Saffron continuously learn from new cap reports, Saffron also implements this learning to prior cap report classifications to ensure that the most advanced knowledge is applied retrospectively.
B-Scada's product suite comprising an IoT platform, wireless sensors and SCADA software were employed in various means to come up with solutions to address the aforementioned challenge.
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.
Customer
The customer manufactures automobile filters which are subsequently distributed to spare parts businesses.
TRW Automotive GmbH in Blumberg, Germany is part of a globally active group that mainly manufacturers components for engines and automobiles in every conceivable configuration. Around the world, TRW has more than 65,000 employees and 186 branches in 26 countries, in-cluding 13 test tracks and 22 technology centres. The TRW Blumberg site began operation in 1945 and today still produces valves of all dimensions and in various materials.
Benteler International AG is active in business divisions Automotive, Steel Pipes and Distribution and employs 28,000 people at 170 locations in 38 countries.
HIROTEC Group is a $1.6B Japanese corporation that is globally recognized as a premier automotive manufacturing equipment and parts supplier. With over 85 years of mass production experience and engineering discipline and 26 facilities in nine countries around the world, HIROTEC Group designs and builds roughly 7 million doors and 1.5 million exhaust systems a year, making it one of the largest private production companies in today’s global automotive market.
London Underground Limited
A service company managing US plant operations
A.P. Plasman is a highly integrated, full service plastics supplier with over 900,000 square feet of plant space. They have production facilities in Windsor, Ontario and Fort Payne, Alabama and maintain a sales presence in Canada, Michigan and Japan. The company takes great pride in their status as a leading provider of Class ‘A’ exterior products to the North American automotive industry. They are a full service provider with dedicated plants for tooling, molding, paint and assembly.
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.
Solution TypeITIOTITIOTIOTIOTITIOTIOT
Solution MaturityMature (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)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)
Data Collected
- Quantity of parts produced. - Quantity of parts scrapped. - Detailed breakdown of downtime.
Real-time location of robots
Pump pressure and condition data
The CAP reports are semi-structured PDF documents in that they include meta-data fields with structured and unstructured text. Each CAP report may be only one page; others have gone to 69 pages.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Supporting Files
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Use Cases
Use CasesProcess Control & Optimization (PCO)Machine Condition MonitoringDigital TwinPredictive Maintenance (PdM)Predictive Maintenance (PdM)Asset Health Management (AHM)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Process Control & Optimization (PCO)

Operational Impact
Impact #1
Since Versiondog always ensures that the most recent software version is always running on every single component in the network, maintenance work is not only easier, but also generally takes less time. In addition, the disaster recovery process is also much faster minimizing downtime.
The WIN wireless system allows TRW to scale their operations easily. Additional WIN slave units can be added to the network without the need for additional cabling.
Real-time Tracking - The location of individuals and assets can be identified in near real-time and integrated into process simulations.
Through the Thingworx platform, HIROTEC gained real-time visibility into its business operations, which in turn allows the company to address issues that impact its efficiency and throughput. The solution also enables HIROTEC to perform sophisticated analysis of historical data so that it can better understand production facility performance and ways to drive improvements.
Real-time Alert System - An intelligent edge solution can ingest pump sensor data in real-time and apply mathematical equations on the incoming data to identify any significant changes in pressure and alert operations personnel before damage occurs.
The system provided a solid architecture utilising an array of FPGA and real-time features to provide a versatile platform for deployment on the London Underground network.
Data Analytics - Saffron enables plant operators to see causal relationships between events and root causes and have immediate access to converging, trending or repeating patterns.
Using B-Scada’s Status software, A.P. Plasman was able to create and implement a versatile, highly functional solution for monitoring a large paint facility in Tecumseh. Their solution allowed them to quickly and easily display process information from multiple locations using a web-based interface created to their exact requirements.
Institutional System Integration - Integrated across multiple information systems to share information with hospital and IT staff.
Impact #2
Versiondog 4.0 with its ability to allow small, customised sub-programs to be added to it has enabled to firm to obtain more accurate information of their spare parts inventory.
TRW has gained an overview of costly processes and hidden capacity.
Offline Programming - Simulation and debugging of production processes related to new tools are possible without shutting down production.
HIROTEC will be able to build on the solution to enable augmented reality applications to further advance its manufacturing capabilities and efficiencies — completing its transformation from smart factory to smart enterprise.
FogHorn's solution enables customer to reduce maintenance and downtime costs.
Delivered a reliable remote condition monitoring system that empowers maintainers to proactively respond to failures before they occur and provides management with a better insight into the asset lifecycle.
High ROI - Operators can now easily identify and eliminate causes of adverse events. No models are required, saving time to insight and driving high Return-On-Investment.
They were able to develop their custom solution very quickly, and with minimal input from B-Scada.
Edge-based Intelligence - A smart system of devices providing critical operational data for service and support.
Impact #3
Versiondog is also used as a training tool and has hence improved the education and training standards of employees.
Installation Efficiency - Technicians are able to query instruments remotely during commissioning to confirm device functionality.
The need to invest in new Computer Numerical Control (CNC) machine via analysis that supported improved efficiencies and elimination of process bottlenecks was eliminated.
Complete Business Transformation - Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.

Quantitative Benefit
Benefit #1
Reduced downtime due to access to better equipment data. This has reduced costs and saved time for TRW.
There was a 100% reduction in time to manually inspect production systems, enabling technicians to re-invest that time in tasks that drive more value to production workflows.
We completed the project on schedule with one year of development time, including all design, assurance, procurement and installation. We also delivered under the allocated budget.
Saffron automatically classified 18,000 CAP items (sample dataset), with 92% accurate and 18 false positives and 15 false negatives against this data set.
Enable increased number of procedures per facility per day.
Benefit #2
Reduced downtime and unexpected maintenance calls.
Benefit #3
Increased customer satisfaction.

Technology
Hardware
SoftwareversiondogKepware KEPServerEXThingworx 8Status EnterpriseStatus Device CloudAmazon 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
Tech PartnersHewlett Packard Enterprise (HPE)Amazon Web Services

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
ImageNo More Searching for SoftwareTRW calls for action with the help of WERMARobotStudio Case Study: Benteler AutomobiltechnikCutting-edge Predictive Analytics for HIROTEC GroupPump Cavitation DetectionRemote Condition Monitoring for London UndergroundReducing Operating Costs And Improving SafetyA.P. Plasman, Inc. Case Study HaemoCloud Global Blood Management System
Verified Vendor
SnapshotNo More Searching for SoftwareTRW calls for action with the help of WERMARobotStudio Case Study: Benteler AutomobiltechnikCutting-edge Predictive Analytics for HIROTEC GroupPump Cavitation DetectionRemote Condition Monitoring for London UndergroundReducing Operating Costs And Improving SafetyA.P. Plasman, Inc. Case Study HaemoCloud Global Blood Management System
Challenge
Tasks such as manual documentation and the fact that new software and hardware is constantly being integrated to the automation network makes the lives of maintenance staff difficult.
TRW needed a wireless monitoring system as laying cables and trunking throughout their sprawling and ageing facility would be an unimaginable task.
Benteler has a small pipe business area for which they produce fuel lines and coolant lines made of aluminum for Porsche and other car manufacturers. One of the problems in production was that when Benteler added new products, production had too much downtime.
Hirotec needed to ensure continuous operations and to minimize unplanned downtime in its manufacturing facilities. Unplanned downtime is costly and compromises Hirotec's ability to deliver its goods to customers on time.
Cavitation is a condition can occur in centrifugal pumps when there is a sudden reduction in fluid pressure. Pressure reduction lowers the boiling point of liquids, resulting in the production of vapor bubbles if boiling occurs. This is more likely to happen at the inlet of the pump where pressure is typically lowest. As the vapor bubbles move towards the outlet of the pump where pressure is higher, they rapidly collapse (return to a liquid state) resulting in shock waves that can damage pump components.
London Underground serves 1.7 billion passengers per year and the Victoria Line accounts for 213 million of those journeys. The line carries 89.1 million passengers per year in the peak service, offering the most intensive service on the underground network. Over the past eight years, a £1 billion investment programme upgraded and replaced the Victoria Line’s rolling stock and signaling and control systems to deliver a service capable of running more than 33 trains per hour. The new signalling system uses 385 Jointless Track Circuits (JTCs) to detect train position, maintain safe train separation and deliver train headways capable of meeting an extremely demanding timetable. Track circuits are the sole means of train detection and play a critical role in the safe and reliable operation of the railway; however, no provision was made for any condition monitoring during the design and installation. Because of the critical nature of the asset, a failed track circuit has a major impact on the service and constitutes the biggest cause of passenger disbenefit on the Victoria Line, amounting to £1.5 million since their introduction (London Underground CuPID database for Track Circuit failures since 2012). The Victoria Line Condition Monitoring Team, made up of six professional engineers with rail, software, electrical, mechanical, network and engineering backgrounds, delivered the solution. National Instruments Silver Alliance Partner Simplicity AI supported the project by providing additional software consulting services. We used the company’s enormous breadth of expertise to deliver the system onto an operational railway within one year of the concept design. The scope of this project consisted of designing, integrating and installing an intelligent remote condition monitoring system that could perform real-time analysis of voltage and frequency for all 385 JTCs across a 45 km of deep tube railway to predict and prevent failures and subsequent loss of passenger service. We took advantage of the accuracy, reliability and flexibility of NI hardware and software to implement an innovative system to reduce the lost customer hours experienced on the Victoria Line. The system is forecast to reduce lost customer hours by 39,000 per year—an estimated £350,000 savings per year in passenger disbenefit.
To ensure safe operation of the nuclear plant, the Institute of Nuclear Power Operations sets the performance objectives and defines the criteria (PO&C) to meet those objectives. The plant personnel manually compare each line item in the CAP report against the PO&C to evaluate the seriousness of the event. A spilled cup of coffee in the wrong place might not be too serious, while a critical pump leaking that has the potential to shut down the plant is another matter entirely. This manual process of classifying the seriousness of each item in a CAP report lies at the heart of the continuous effort to improve the safety and operation of the nuclear power plant, but requires significant time and resources. Our client needed a way to automate the classification process to increase its efficiency and to extract information from years of reported events to better understand their causes and anticipate possible adverse events.
The A.P. Plasman Corporation manages multiple facilities with multiple processes, and when they were looking for an automation solution for their paint facility in Tecumseh, they were looking for a solution that could restrict access, deploy easily, and provide the ability to modify the application quickly to suit changing needs.
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.
Solution
Versiondog is an integrated data management system that can detect and document changes made to the production line network. Due to the high number of daily and weekly backups to the network, Versiondog ensures that the most recent software version is always running on every single component in the network, making maintenance work easier.
TRW began by monitoring 10 critical machines with 10 transmitters monitoring machine status. Using WIN the customer was able to get a precise overview of their status in a matter of minutes. The plug and play wireless system was quick and easy to install and up and running immediately.
ABB presented RobotStudio as the solution. Engineers can use RobotStudio for offline programming using real-time data to test alternatives without shutting down production. Using RobotStudio, engineers can simulate real-world situations to identify problems with a new robot design. If problems exist, they can be addressed before the tool is actually made of steel and iron. RobotStudio is also used to create macros and to model welding, gluing, and image processing procedures.
Hirotec decided to partner with PTC and selected its Thingworx Technology Platform and KEPServerEX agent to rapidly develop and deploy IoT software and integrate it with its manufacturing systems. PTC with its IT capabilities proved to be an ideal partner to complement Hirotec's operations technology skillset. HIROTEC also decided to use HPE Edgeline servers to support edge analytics. The ruggedized HPE Edgeline servers’ small footprint minimized the need for HIROTEC to sacrifice valuable factory floor space. In addition, the servers do not require specialized cooling to operate. To get a free demo of ThingWorx 8: http://solutions.iotone.com/thingworx
An intelligent edge solution can ingest pump sensor data in real-time and apply mathematical equations on the incoming data to identify any significant changes in pressure and alert operations personnel before damage occurs. It can also send a signal to the main system to automatically move the flow of the fluid to a different pump to prevent damage and reduce maintenance and downtime costs associated with pump cavitation.
The Victoria Line deploys variable length frequency-driven tuned electrical JTCs. The circuits energise and de-energise as trains traverse the line. Each JTC includes an electrical receiver unit matched to the frequency of the track circuit (4 to 6 kHz frequency shift keyed), which processes the incoming signal and provides a sample to a monitor point that can be used to check the health of the track circuit. Prior to the introduction of this system, we had to periodically monitor the condition of every track circuit manually on-site with a digital multimeter. Following the installation of the NI CompactRIO system, we can now simultaneously acquire the JTC monitor point samples remotely from all track circuits on the line, which means the maintenance teams can proactively predict and prevent equipment failures before they occur. We looked at various suppliers of data acquisition products and concluded that, although other products may have met the initial requirements, no other product offered the flexibility, scalability and performance of the CompactRIO platform. The diverse range of input modules and the ability to easily customise the onboard software using the NI LabVIEW platform also meant that we could deliver further condition monitoring projects using a common platform, which would reduce the time to design and develop the hardware and software for a wider range of data inputs. Due to the Safety Integrity Level (SIL4) of the track circuit system, we needed to introduce an independent isolation barrier between the receiver unit and the CompactRIO device. We collaborated with Dataforth, based in the United States, to design a SCM5B isolation module to provide galvanic isolation between the CompactRIO device and the track circuits being monitored. The SCM range of isolation modules could pass the stringent test equipment requirements of the receiver and also provide an accurate and compatible replica of the output signal for the CompactRIO acquisition. The isolation layer coupled with the low failure rates of NI hardware ensured that we could install the system without compromising the SIL4 safety integrity of the Victoria Line signalling system. We pursued an extensive engineering safety analysis on the hardware in accordance with the CENELEC railway application standards and approved by the relevant safety authorities to assure and validate the design. We split data acquisition from the CompactRIO devices across 14 geographically separate sites that were all part of a new high-bandwidth fibre optic network specifically installed for this application. The flexibility of the CompactRIO hardware, combined with NI LabVIEW software meant that we could transport data to a central condition monitoring server in real time using a lightweight transfer protocol. This was a key requirement in the design and delivery of a true remote condition monitoring system. The central condition monitoring server processes a live 10 Hz data stream from every CompactRIO device, which totals more than 7,000 data samples per second. The lightweight CompactRIO data transfer protocol ensures that the central server can rapidly analyse the data and monitor track circuits for deviations away from the ideal condition. The system compares each received frame of data to a defined standard frequency and voltage so the server can make an independent decision on the health of each track circuit connected to the CompactRIO input channels. In addition, the server stores all of the data in a near line and far line database architecture so we can analyse long-term trends on large datasets. The central server can push asset condition alerts to a human machine interface (HMI). The HMI is a large touch screen device that displays an accurate scaled replica of the Victoria Line track circuit configuration. A user can intuitively navigate the information displayed with natural touch gestures, clearly identify line-side asset condition and receive predicted equipment failure warnings. We plan to deploy two HMIs for faster response times—one in the Victoria Line control center and another in the maintenance control center. Both can be used by signaling maintenance staff. We can remotely interrogate each track circuit on the railway with a single touch, presenting the user with a live graphical representation of the root mean square (RMS) voltage, frequency and track state information using the data streamed from the line-side CompactRIO devices. Alongside the HMI, a suite of touch screen devices can display the CompactRIO data in the line-side equipment rooms and through a smartphone or tablet. This means the data from the CompactRIO devices is available anywhere on the Victoria Line through a connection to the new condition monitoring network. We selected Simplicity AI to develop the CompactRIO FPGA and real-time software. Although London Underground has internal LabVIEW developers, we used Simplicity AI on this project because of the company’s high level of FPGA and real-time experience. The company provided full documentation, source code, and results from long-term stability and stress tests within three months to ensure that the CompactRIO system could be assured to a level suitable for use in a safety-critical environment on London Underground’s infrastructure. For each deployed unit, we paired an NI cRIO-9025 controller with an 8-slot NI cRIO-9118 chassis. We could use up to eight NI 9220 analog input modules to provide a maximum of 128 physical inputs per CompactRIO system. We selected this configuration because it offered the required processing power and provided dual network ports for redundant network operation to maximize system uptime. The CompactRIO platform helped the team take a bottom-up approach in developing the system because the ever-evolving specifications were unknown until we acquired early asset data. This flexible platform accommodated rapid iterations in the development of application functionality, which saved a significant amount of time in project delivery. Early on we faced the challenge of calculating frequency and RMS voltage simultaneously over all 128 channels on the FPGA. Simplicity AI addressed this by delivering a serial process architecture that uses the high clock rate of the FPGA to process data for each channel sequentially. The software builds up a 10 ms buffer for each channel then iterates through each buffer and calculates the frequency and RMS voltage. A key feature for the deployment on London Underground was for the system to be installed, commissioned and maintained by rail technicians unfamiliar with NI software and the CompactRIO platform. Simplicity AI provided a common software package configured for each location via a simple external text file in the standard XML file format. We developed an application using the Replication and Deployment (RAD) utility, which automated the process of installing the system and application software to the CompactRIO device along with the correct configuration file. The CompactRIO deployment tool simplified the rollout of the system, delivered installation efficiencies and allowed for CompactRIO devices to be remotely deployed, configured and updated from a centrally managed location. This remote one-click configuration also proved extremely beneficial during the development phase when London Underground and Simplicity AI engineers worked in parallel as a joint team on different sections of the project.
As operators create each CAP report, Saffron automatically applies the attributes of all PO&C objectives to each line item within the CAP report and then suggests an appropriate classification. An experienced operator reviews each Saffron recommendation to confirm the recommendation or to change it. The validated report then becomes part of Saffron’s memory base, providing the input for Saffron to continuously improve by learning and remembering the specific variables upon which the classification decision is made. Not only does Saffron continuously learn from new cap reports, Saffron also implements this learning to prior cap report classifications to ensure that the most advanced knowledge is applied retrospectively.
B-Scada's product suite comprising an IoT platform, wireless sensors and SCADA software were employed in various means to come up with solutions to address the aforementioned challenge.
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.
Customer
The customer manufactures automobile filters which are subsequently distributed to spare parts businesses.
TRW Automotive GmbH in Blumberg, Germany is part of a globally active group that mainly manufacturers components for engines and automobiles in every conceivable configuration. Around the world, TRW has more than 65,000 employees and 186 branches in 26 countries, in-cluding 13 test tracks and 22 technology centres. The TRW Blumberg site began operation in 1945 and today still produces valves of all dimensions and in various materials.
Benteler International AG is active in business divisions Automotive, Steel Pipes and Distribution and employs 28,000 people at 170 locations in 38 countries.
HIROTEC Group is a $1.6B Japanese corporation that is globally recognized as a premier automotive manufacturing equipment and parts supplier. With over 85 years of mass production experience and engineering discipline and 26 facilities in nine countries around the world, HIROTEC Group designs and builds roughly 7 million doors and 1.5 million exhaust systems a year, making it one of the largest private production companies in today’s global automotive market.
London Underground Limited
A service company managing US plant operations
A.P. Plasman is a highly integrated, full service plastics supplier with over 900,000 square feet of plant space. They have production facilities in Windsor, Ontario and Fort Payne, Alabama and maintain a sales presence in Canada, Michigan and Japan. The company takes great pride in their status as a leading provider of Class ‘A’ exterior products to the North American automotive industry. They are a full service provider with dedicated plants for tooling, molding, paint and assembly.
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.
Solution TypeITIOTITIOTIOTIOTITIOTIOT
Solution MaturityMature (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)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)
Data Collected
- Quantity of parts produced. - Quantity of parts scrapped. - Detailed breakdown of downtime.
Real-time location of robots
Pump pressure and condition data
The CAP reports are semi-structured PDF documents in that they include meta-data fields with structured and unstructured text. Each CAP report may be only one page; others have gone to 69 pages.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Supporting Files
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Youtube Video IDv-VZwI2GwW8v-VZwI2GwW8v-VZwI2GwW8v-VZwI2GwW8v-VZwI2GwW8v-VZwI2GwW8v-VZwI2GwW8

Use Cases
Use CasesProcess Control & Optimization (PCO)Machine Condition MonitoringDigital TwinPredictive Maintenance (PdM)Predictive Maintenance (PdM)Asset Health Management (AHM)Process Control & Optimization (PCO)Process Control & Optimization (PCO)Process Control & Optimization (PCO)

Operational Impact
Impact #1
Since Versiondog always ensures that the most recent software version is always running on every single component in the network, maintenance work is not only easier, but also generally takes less time. In addition, the disaster recovery process is also much faster minimizing downtime.
The WIN wireless system allows TRW to scale their operations easily. Additional WIN slave units can be added to the network without the need for additional cabling.
Real-time Tracking - The location of individuals and assets can be identified in near real-time and integrated into process simulations.
Through the Thingworx platform, HIROTEC gained real-time visibility into its business operations, which in turn allows the company to address issues that impact its efficiency and throughput. The solution also enables HIROTEC to perform sophisticated analysis of historical data so that it can better understand production facility performance and ways to drive improvements.
Real-time Alert System - An intelligent edge solution can ingest pump sensor data in real-time and apply mathematical equations on the incoming data to identify any significant changes in pressure and alert operations personnel before damage occurs.
The system provided a solid architecture utilising an array of FPGA and real-time features to provide a versatile platform for deployment on the London Underground network.
Data Analytics - Saffron enables plant operators to see causal relationships between events and root causes and have immediate access to converging, trending or repeating patterns.
Using B-Scada’s Status software, A.P. Plasman was able to create and implement a versatile, highly functional solution for monitoring a large paint facility in Tecumseh. Their solution allowed them to quickly and easily display process information from multiple locations using a web-based interface created to their exact requirements.
Institutional System Integration - Integrated across multiple information systems to share information with hospital and IT staff.
Impact #2
Versiondog 4.0 with its ability to allow small, customised sub-programs to be added to it has enabled to firm to obtain more accurate information of their spare parts inventory.
TRW has gained an overview of costly processes and hidden capacity.
Offline Programming - Simulation and debugging of production processes related to new tools are possible without shutting down production.
HIROTEC will be able to build on the solution to enable augmented reality applications to further advance its manufacturing capabilities and efficiencies — completing its transformation from smart factory to smart enterprise.
FogHorn's solution enables customer to reduce maintenance and downtime costs.
Delivered a reliable remote condition monitoring system that empowers maintainers to proactively respond to failures before they occur and provides management with a better insight into the asset lifecycle.
High ROI - Operators can now easily identify and eliminate causes of adverse events. No models are required, saving time to insight and driving high Return-On-Investment.
They were able to develop their custom solution very quickly, and with minimal input from B-Scada.
Edge-based Intelligence - A smart system of devices providing critical operational data for service and support.
Impact #3
Versiondog is also used as a training tool and has hence improved the education and training standards of employees.
Installation Efficiency - Technicians are able to query instruments remotely during commissioning to confirm device functionality.
The need to invest in new Computer Numerical Control (CNC) machine via analysis that supported improved efficiencies and elimination of process bottlenecks was eliminated.
Complete Business Transformation - Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.

Quantitative Benefit
Benefit #1
Reduced downtime due to access to better equipment data. This has reduced costs and saved time for TRW.
There was a 100% reduction in time to manually inspect production systems, enabling technicians to re-invest that time in tasks that drive more value to production workflows.
We completed the project on schedule with one year of development time, including all design, assurance, procurement and installation. We also delivered under the allocated budget.
Saffron automatically classified 18,000 CAP items (sample dataset), with 92% accurate and 18 false positives and 15 false negatives against this data set.
Enable increased number of procedures per facility per day.
Benefit #2
Reduced downtime and unexpected maintenance calls.
Benefit #3
Increased customer satisfaction.

Technology
Hardware
SoftwareversiondogKepware KEPServerEXThingworx 8Status EnterpriseStatus Device CloudAmazon 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
Tech PartnersHewlett Packard Enterprise (HPE)Amazon Web Services

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