Accelerating the
Industrial Internet of Things

Remote Monitoring & Predictive Maintenance App for a Solar Energy System

Remote Monitoring & Predictive Maintenance App for a Solar Energy System

RapidValue RapidValue
View Full Case Study
Contact Vendor
Feature New Record
SIMILAR CASE STUDIES

Overview
ImageRemote Monitoring & Predictive Maintenance App for a Solar Energy SystemOff-Grid Demand Response Energy SolutionGPRS Mobile Network for Smart MeteringEnabling RCM & TPM for Energy SectorPower Analytics for Power PlantHaemoCloud Global Blood Management SystemIIC - Factory Automation Platform as a Service (FA-PAAS) TestbedElectric Imp Launches Cellular IoT Connection SupportReducing Unscheduled Downtime and Customer Efficiency
Verified Vendor
SnapshotRemote Monitoring & Predictive Maintenance App for a Solar Energy SystemOff-Grid Demand Response Energy SolutionGPRS Mobile Network for Smart MeteringEnabling RCM & TPM for Energy SectorPower Analytics for Power PlantHaemoCloud Global Blood Management SystemIIC - Factory Automation Platform as a Service (FA-PAAS) TestbedElectric Imp Launches Cellular IoT Connection SupportReducing Unscheduled Downtime and Customer Efficiency
Challenge

The maintenance & tracking of various modules was an overhead for the customer due to the huge labor costs involved. Being an advanced solar solutions provider, they wanted to ensure early detection of issues and provide the best-in-class customer experience. Hence they wanted to automate the whole process. 

Smart energy and next generation buildings are one of FabCity’s key topics and the Zenodys team was invited there to provide a microgrid demand response power management solution. Next generation buildings are built with a purpose to be energy sustainable and include power-generation capabilities, windmills, solar panels, self-sufficient units, etc. These buildings can generate their own power. However, when connected to a microgrid, other opportunities open up: power exchange among buildings, common storage facility, smart power management, etc. This will become an important part of the future smart cities. Microgrids are a promising concept and are expected to become one of the main energy sources in the future. In order to function as intended, microgrids must be efficiently managed with smart demand response algorithms. The aim of a microgrid is to be as self-sufficient as possible. However, this is not always the case. When the sun shines and there is plenty of wind, the participants generate their own power. But on cloudy or windless days green energy is not always available. To compensate for this, a microgrid also features a battery that stores surplus energy and provides backup power when needed.

Around the world, the electricity supply industry is turning to ‘smart’ meters to lower costs, reduce emissions and improve the management of customer supplies. Smart meters collect detailed consumption information and using this feedback consumers can better understand their energy usage which in turn enables them to modify their consumption to save money and help to cut carbon emissions. A smart meter can be defined in many ways, but generally includes an element of two-way communication between the household meter and the utility provider to efficiently collect detailed energy usage data. Some implementations include consumer feedback beyond the energy bill to include online web data, SMS text messages or an information display in consumers’ premises. Providing a cost-effective, reliable communications mechanism is one of the most challenging aspects of a smart meter implementation. In New Zealand, the utilities have embraced smart metering and designed cost effective ways for it to be implemented. The New Zealand government has encouraged such a move to smart metering by ensuring the energy legislation is consistent with the delivery of benefits to the consumer while allowing innovation in this area. On the ground, AMS is a leader in the deployment of smart metering and associated services. Several of New Zealand’s energy retailers were looking for smart metering services for their residential and small business customers which will eventually account for over 500,000 meters when the multi-year national deployment program is concluded. To respond to these requirements, AMS needed to put together a solution that included data communications between each meter and the central data collection point and the solution proposed by Vodafone satisfied that requirement.

The customer company need a centric-view of all equipment & assets, so as to enable RCM (Reliability-Centered Maintenance) and TPM (Total Productive Maintenance) process. The customer's goal is to fully utilize the life-cycle of equipment and thus improving their OEE (Overall Equipment Effectiveness).

Given low power prices maintained by stagnant demand growth, a customer’s combined cycle power plant was staffed as leanly as possible. As such, a change in operational parameters went unnoticed by engineers at the plant.

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.

In recent years, amid increasingly intense global competition in the manufacturing industry, there has been a growing demand for more rapid product development and market introduction, quality improvements and shorter lead times in order to quickly respond to the rapidly changing market environments and management environments through the introduction of new technologies and collaborations between companies. In this backdrop, there has been a growing expectation for overall optimization that uses data related to manufacturing in the increasingly global supply chain to connect the front lines of manufacturing with management, suppliers, and customers. This in turn has given rise to a need for secure connections between a variety of devices in FA environment and cutting-edge IT services (e.g., Big Data and the cloud) and for the accelerated development of applications in the field of next-generation factories connecting business-to-business (B2B) applications unleashing real economic value to effectively compete in the global marketplace.

Without continuous connectivity, real-time data is really hard to deliver for any cloud service provider. The number of IoT devices with cellular connections will nearly quadruple over the next five years with increasing LTE subscriptions and access to 5G networks, according to Ericsson’s bi-annual Mobility Report. At the same time, ensuring reliable connectivity, while being mindful of security and device management as IoT implementations scale, continues to be a challenge for industrial IoT use cases.

Leica Microsystems attributes its success to providing innovative products and superior customer service. To extend its leadership position, the company began exploring a more proactive service approach for its line of confocal microscopes and tissue processors. The Leica Microsystems project team began searching for a global software that would allow for the shift from a reactive to proactive service company. Their initiative focused on downtime avoidance and the prediction of potential problems across the globe, targeting issue prevention. As a result, customers would not only benefit from minimal product downtime, but from faster service and increased productivity. To obtain approval and funding for the initiative, the team would need to prove to management that this service strategy shift would result in optimized instrument uptime and reduced costs of service.

Solution

- Integration with inverters to collect data. - Detection of possible malfunctioning with predictive analytics. - Mobile & Cloud-based solutions with automated real-time alert notifications for field engineers. - HR scheduling solution to gather real-time details of available filed engineers & provide location information for faster issue resolution. - Integration with onsite cameras for live feeds and document management for product manuals and suggested resolution.

Three companies – Zown, Mpare and Zenodys – partnered together to design a reliable microgrid solution. Zown provided on-site connectivity, Mpare took care of power measurement and Zenodys supplied microgrid management logic. Our role is to gather and process measurements, develop efficient demand response strategies and visualize microgrid dynamics via an easy-to-understand web interface. The solution is based on the Zenodys visual IoT platform that handles most of the tasks without any programming needed: • ZenoConnect provides connectivity of various smart energy vendors (houses, windmills, PV panels, batteries, etc.) and connects them to the microgrid. It can also be easily integrated with Mpare and HelloData services. • ZenoVisual provides demand response logic and delivery of different strategies. • ZenoExperience is used for data delivery and visualization. A fine-tuned web visual interface provides easy-to-understand information for the end user. • Zenobox physically connects all the equipment and services and provides a runtime environment. In this case we chose the Linux based Raspberry PI system but for a production-ready environment we would use more robust industrial gateways. The solution is fully independent and can run off-line, but for demonstration purposes we also enabled remote solution delivery and Docker based services deployments.

AMS decided to use a communication solution based around Vodafone’s existing GPRS mobile network having considered the use of power line communications, WiMAX mobile broadband or a purpose-built RF mesh network. “There were two principal reasons why the GPRS network from Vodafone stood out for us,” said Atkins. “The infrastructure was already in place with ubiquitous coverage and a high reliability, the limitations of the other options would not have enabled us to roll out Nationwide”. Past experience of working together was also a factor, as Atkins explained: “We had used Vodafone’s GSM network technology for several years without any problems, and Vodafone had always been open to making changes we needed.” In the AMS solution, a SIM card supplied by Vodafone is installed into the modem part of the smart meter. Regular readings are taken by the meter, and sent back automatically to AMS data management system over the Vodafone GPRS network.

The customer engaged Shanghai Rockbay Information Technology and its GWG Equipment Maintenance System solution to perform plant maintenance and MRO (Maintenance, Repair, Operations) system. GWG concentrated on plant maintenance & equipment operating status management. The application visualized equipment status as well as master data including functional location, equipment’s, parts, FMEA records, maintenance bill of material etc. The application was also integrated with several customised maintenance process, which served as data warehouse for business analytics. The applications recorded every failure, incident, maintenance, status checking and other related information. System Functions: • Equipment Profile and Structure Facility & Factory • Plan & Work Order • Maintenance Processes • Parts Inventory • Analysis & Report Technology Deployed: GWG Equipment Maintenance System

Monitoring hundreds of sensors per turbine on a daily basis, GE’s Asset Performance Management detected the change in operational parameters and generated daily reports revealing the specifics of this irregularity. In turn, GE’s IPRC engineers drew upon their depth of experience with Power analytics to acknowledge the severity of the increased spread and proactively notified the customer of this issue before it triggered equipment failure. As the spread increased, GE’s IPRC engineers recommended, during a weekly status update call, that the customer perform an inspection to determine the root cause of the increased spread. The inspection uncovered a defect in the equipment, so the customer planned downtime during which they replaced the faulty piece. Upon replacement, the operational parameter returned to model-predicted values.

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.

*This is an IIC testbed currently in progress.* LEAD MEMBERS Hitachi Ltd., Mitsubishi Electric Corporation, Intel Japan MARKET SEGMENT Manufacturing: Industrial Automation for Discrete Manufacturing SOLUTION As solution for these challenges, this Testbed provides connectivity between Factory and Cloud, data analytics platform, and security resources, in order to provide facilitation of FA application development for Application Providers and FA Equipment Vendors. With this result, Application Providers and FA Equipment Vendors will be able to provide solution and services to Factory Owners and Factory Operators by just developing core logic of each application. HOW IT WORKS This Testbed provides following features to reduce application development process: • Connectivity between Factory and Cloud where architectures differ • API specialized in FA, which are re-usable for FA applications: Edge Applications, Cloud Applications, and Domain Applications • Security to protect the Factory brown field from the outside network • Integrate data from Business Systems TESTBED INTRODUCTION This testbed facilitates development of FA applications by providing a service-based platform with pre-integrated environment across factory automation (OT) and IT platform (IT). It includes IoT data processing platform that processes Big Data, IoT head end system, and IoT gateway that securely connects the service platform layer with FA environment, and FA edge device that provides functions unique to FA applications, and which also enable communications with FA devices in the field of factories. In addition, the advantage of IoT platform tested in this testbed is interoperability between FA environment, IoT gateways and IoT data processing platform and accelerates application development for next-generation factory by making available of integrated environment between FA environment and service platform layer. Tests of secure connections will be completed between FA environment and service platform layer, as well as tests of the effectiveness of testbed functions and the flow of operational data from the perspective of the front lines of manufacturing, by June 2017. After that, it will conduct “use case” tests with IIC member companies and customers.

It stands to reason then that GoodMeasure, a long-time customer of Electric Imp, is quite excited about the recent debut of the vendor’s cellular connectivity functionality. Electric Imp products – which enable and manage secure connectivity – are woven into every fiber of GoodMeasure’s platform, according to co-founder and CTO Regan Ryan.

After quickly dismissing the idea of building a smart solution internally, the Leica Microsystems project team evaluated several vendors, hiring a third-party research firm to conduct a benchmark study. “There were many players in the market, but price and performance were the key drivers during our evaluation,” explained Frank Bunge, Director of Technical Services Europe at Leica Microsystems. “PTC®Axeda® software came out on top in all categories and provided the professional support that we needed—that is very important for us.” Leica Microsystems chose PTC Axeda software to remotely monitor and support its TCS confocal microscopes and ASP300 S tissue processor equipment. With PTC Axeda software, Leica Microsystems has the ability to control software releases and upgrades to systems, enabling the company to test and approve any software updates when necessary. As a result, the company can meet its established verification and validation processes for regulated environments. “We wanted a model where we could focus on users and our equipment, and PTC Axeda software provided us with the agents and the applications,” Bunge said. “Our experience with the software has been quite positive. In the event that something goes wrong, we get immediate feedback and quality support.” Registered users log into the Leica RemoteCare™ site to view the devices in the regions for which they are responsible. Using PTC Axeda software, users can compare current parameters with the products’ specifications, including hardware and calibration changes, software and PC system status, laser errors/uptime, galvanometer settings, critical temperatures, and cooling system health. Critical events become predictable with the information provided. “With Leica RemoteCare, we now monitor the performance of our tissue processors,” Bunge explained. “As soon as the temperature is out of range, an alarm and email are sent to both the customer and to Leica. The customer then makes the necessary adjustments before a specimen is potentially lost. That is a major benefit of the system.” The company also monitors cleaning sequences. If systems need to be cleaned, the customer is alerted so that they don’t lose specimens. They also use RemoteCare to adjust the microscope prior to any issues in situations where power is diminishing, ensuring uninterrupted research. The Leica Microsystems project team has enabled a number of RemoteCare customer successes in a short timeframe. For example, a research institution in Germany was experiencing system crashes of its Leica Microsystems microscopes during long-term experiments. With RemoteCare, Leica Service could diagnose the problems by examining saved error logs. Using this information, it was discovered that the memory sizes at the time of the crash fell below 500 MB. From here, instead of dispatching an engineer onsite to replace what would appear to be a defective detector board, a service representative could remotely diagnose and resolve the issue. As a result, diagnosis and repair took one hour instead of three days of downtime and the potential unnecessary use of spare parts. Another customer success took place at a U.S. based university. When Leica Service received an error message explaining a failing tissue processor program, the service representative contacted the customer who was unaware that a failure had even occurred. After further inspection, the customer removed debris under the seal, restoring the original state of the tissue processor. As a result of this proactive service call, the university avoided potential system downtime and protected their specimen from damage. “Each department within Leica Microsystems benefits from RemoteCare, so this is not just a service product,” Bunge emphasized. “For example, R&D benefits from obtaining more information from the field on the reliability and use of our products. The sales department is convinced that RemoteCare will help them win more deals since service is now a competitive differentiator with even better product reliability.” RemoteCare is available to all customers with Silver and Gold service contracts at no cost and benefits can also be received by customers with equipment under warranty or those with extended Bronze service contracts. Bunge reports that RemoteCare has customers realizing more value from their service contracts: “As soon as customers realize the benefits of RemoteCare, there is a higher probability that they will continue with their service contracts.” When paired with PTC Axeda, RemoteCare’s safety features also aid in customer adoption and implementation. By Leica educating their customers on RemoteCare, they understand that it does not allow Leica Microsystems to access any customer or hospital data. The only access Leica will have is to the system information outlined to the customer. RemoteCare is promoted by sales as a standard feature for microscopes and tissue processors. In conversations with customers, benefits of RemoteCare are discussed, and once a customer is ready for implementation, a service technician installs PTC Axeda software on the computer of the microscope or tissue processor and provides training to all necessary teams. With roughly 300 systems connected, the company plans to increase that number to 1,000 microscopes and tissue processors by the end of 2009, with a long-term goal of 5,000 connected by 2012 . “Smart services will become standard for almost every piece of Leica equipment, especially high-end and medium products,” said Bunge.

Customer

A leading manufacturer and distributor of solar panels and solar energy based out of the U.S. They provide complete and fully integrated solar system, including modules, trackers, inverters, ISIS energy management software, networking, AC & DC disconnects, and all DC wiring.

FabCity, an off-grid Smart Energy Campus, is taking place on Java-eiland in Amsterdam. The purpose of the event is to carry out research on the future of smart cities in Europe in search of new social, economical, sustainable, logistic and political systems.

Vector in partnership with Advanced Metering Services (AMS) are providers of smart metering solutions in New Zealand. AMS chose Vodafone to provide a reliable, cost-effective mobile communications network to transmit the metering data. Vodafone worked closely with AMS to provide a bespoke technical solution and to develop new price plans that ensured the smart metering solution met the requirements of New Zealand’s energy retailers, consumers and distribution companies.

A Solar Cell Manufacturer with 2 factories, more than 40 engineers, integrated with OA (Office Automation) & ERP(Enterprise Resources Planning) Purchasing Process.

A Power & Utility Generation Company

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.

Out-of-box cellular connectivity users.

Leica Microsystems, Inc. is a world leader in microscopes and scientific instruments. The company manufactures a broad range of products for numerous applications that require microscopic imaging, measurement, and analysis. The company also offers system solutions for life science, including biotechnology and medicine, research and development of raw materials, and industrial quality assurance. Leica Microsystems brings histopathology labs and researchers the most comprehensive product portfolio. The range includes the ideal product for each histology step and high-productivity workflow solutions for the entire lab.

Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIT
Solution MaturityCutting 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)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Cutting Edge (technology has been on the market for < 2 years)Emerging (technology has been on the market for > 2 years)
Data Collected
Weather data Live video feeds Solar panel alignment data Field staff location Breakdown data
Mobility and the expected specific measurements
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
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 CasesBuilding Energy Management System (BEMS)MicrogridAdvanced Metering Infrastructure (AMI)Factory Operations Visibility & Intelligence Asset Health Management (AHM)Process Control & Optimization (PCO)Factory Operations Visibility & Intelligence Edge Computing | Edge IntelligenceTrack and Trace for Industrial Tools & AssetsPredictive Maintenance

Operational Impact
Impact #1
Achieved maximum utilization of solar energy through remote controlling of solar panel directions.
Visual environment enables participants and other providers to set up their solutions fast and without any programming. This enables engineering teams to directly work on their internet of things solutions.
Detailed smart meter data allows energy suppliers to use tiered pricing to encourage off-peak energy usage.
RCM setup enables all engineering staffs from different factory sites to access on one single platform.
Given GE IPRC’s inspection recommendation and the customer’s ability to proactively plan downtime for maintenance, the customer was able to eliminate the risk of a component failure which would have triggered catastrophic failure.
Integrated across multiple information systems to share information with hospital and IT staff.
Facilitate development of high value-added applications for manufacturing industry
Electric Imp’s products aim to ease all of that. An imp-authorized hardware module embedded in a device connects to the so-called Electric Imp Cloud. That cloud authenticates and manages all devices at scale, establishes secure connectivity, and handles the necessary processing and integrations as the data flows between the device and a third-party public or private cloud.
Impact #2
Reduced time spent in monitoring locations and downtime through predictive maintenance.
The solution for the FabCity was delivered fast and they managed to overcome Internet of Things and smart energy challenges, hardware interoperability, infrastructure gap between the edge and cloud, and on-the-edge challenges – in a really short time.
AMS’s smart metering solution provides a cost-effective mechanism for environmentally minded consumers to recover a fee for power they feed back into the network.
By leveraging on system knowledge, the breakdown time is expected to reduce through the enabled service-level maintenance.
A smart system of devices providing critical operational data for service and support.
For FA equipment vendors: Facilitate integration of value-added applications, such as remote operations and predictive maintenance
The new solution supports hybrid operation modes, allowing devices to securely use lower-cost networks when available, according to a press release. For example, telematics applications can send high volumes of buffered sensor data via Wi-Fi when a truck is at a loading bay, but only transmit location data and alerts via a cellular connection when the vehicle is moving, according to the press release.
Impact #3
Improved efficiency through process automation
Zenodys offers an off-the-shelf demand response solution that is highly flexible and efficient, has been tested in real cases, can be easily integrated into buildings, factories, cities and other microgrid environments, and managed via a fully visual environment.
Generate MRO Purchase request & integrated with company’s OA system, it could find alternative spare parts & utilize spare parts inventory
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
For Factory owners and operators: • Facilitate deployment of applications as to improve productivity, quality, and factory-operation uptime; and reduce lead time of production. • Facilitate deployment of applications as to optimize value chain and supply chain by coordinating between manufacturing and other departments such as procurement, distribution, and sales.
This added service builds out a portfolio to help customers scale connected solutions, boosting the benefits of buying an out-of-the-box connectivity solution versus developing it in-house, according to Fiennes.

Quantitative Benefit
Benefit #1

Reduced operational cost by 25-30%

Increased OEE by 20%

Enable increased number of procedures per facility per day.

The company has fixed 30% of detected problems remotely on connected systems and improved time to repair fulfillment from 75% to 87%. Optimized instrument uptime by reducing unscheduled downtime by 40%

Benefit #2

Reduced software purchasing investment by 60%

Reduced downtime and unexpected maintenance calls.

Reduced service costs by cutting field service visits by 33%. Improvement of service productivity by 5%.

Benefit #3

Reduced spare parts inventory by 30%

Increased customer satisfaction.

They have reduced 50 onsite visits in the first half of 2009 with an expected 400 visits saved at the end of 2009. That translates into a savings of more than $500,000 U.S. dollars.


Technology
Hardware
SoftwareZenodys PlatformAsset Performance ManagementAmazon 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 CloudAxeda Machine Cloud
Tech PartnersAmazon Web ServicesIndustrial Internet Consortium (IIC)IntelMitsubishi Electric AutomationElectric Imp

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
ImageRemote Monitoring & Predictive Maintenance App for a Solar Energy SystemOff-Grid Demand Response Energy SolutionGPRS Mobile Network for Smart MeteringEnabling RCM & TPM for Energy SectorPower Analytics for Power PlantHaemoCloud Global Blood Management SystemIIC - Factory Automation Platform as a Service (FA-PAAS) TestbedElectric Imp Launches Cellular IoT Connection SupportReducing Unscheduled Downtime and Customer Efficiency
Verified Vendor
SnapshotRemote Monitoring & Predictive Maintenance App for a Solar Energy SystemOff-Grid Demand Response Energy SolutionGPRS Mobile Network for Smart MeteringEnabling RCM & TPM for Energy SectorPower Analytics for Power PlantHaemoCloud Global Blood Management SystemIIC - Factory Automation Platform as a Service (FA-PAAS) TestbedElectric Imp Launches Cellular IoT Connection SupportReducing Unscheduled Downtime and Customer Efficiency
Challenge

The maintenance & tracking of various modules was an overhead for the customer due to the huge labor costs involved. Being an advanced solar solutions provider, they wanted to ensure early detection of issues and provide the best-in-class customer experience. Hence they wanted to automate the whole process. 

Smart energy and next generation buildings are one of FabCity’s key topics and the Zenodys team was invited there to provide a microgrid demand response power management solution. Next generation buildings are built with a purpose to be energy sustainable and include power-generation capabilities, windmills, solar panels, self-sufficient units, etc. These buildings can generate their own power. However, when connected to a microgrid, other opportunities open up: power exchange among buildings, common storage facility, smart power management, etc. This will become an important part of the future smart cities. Microgrids are a promising concept and are expected to become one of the main energy sources in the future. In order to function as intended, microgrids must be efficiently managed with smart demand response algorithms. The aim of a microgrid is to be as self-sufficient as possible. However, this is not always the case. When the sun shines and there is plenty of wind, the participants generate their own power. But on cloudy or windless days green energy is not always available. To compensate for this, a microgrid also features a battery that stores surplus energy and provides backup power when needed.

Around the world, the electricity supply industry is turning to ‘smart’ meters to lower costs, reduce emissions and improve the management of customer supplies. Smart meters collect detailed consumption information and using this feedback consumers can better understand their energy usage which in turn enables them to modify their consumption to save money and help to cut carbon emissions. A smart meter can be defined in many ways, but generally includes an element of two-way communication between the household meter and the utility provider to efficiently collect detailed energy usage data. Some implementations include consumer feedback beyond the energy bill to include online web data, SMS text messages or an information display in consumers’ premises. Providing a cost-effective, reliable communications mechanism is one of the most challenging aspects of a smart meter implementation. In New Zealand, the utilities have embraced smart metering and designed cost effective ways for it to be implemented. The New Zealand government has encouraged such a move to smart metering by ensuring the energy legislation is consistent with the delivery of benefits to the consumer while allowing innovation in this area. On the ground, AMS is a leader in the deployment of smart metering and associated services. Several of New Zealand’s energy retailers were looking for smart metering services for their residential and small business customers which will eventually account for over 500,000 meters when the multi-year national deployment program is concluded. To respond to these requirements, AMS needed to put together a solution that included data communications between each meter and the central data collection point and the solution proposed by Vodafone satisfied that requirement.

The customer company need a centric-view of all equipment & assets, so as to enable RCM (Reliability-Centered Maintenance) and TPM (Total Productive Maintenance) process. The customer's goal is to fully utilize the life-cycle of equipment and thus improving their OEE (Overall Equipment Effectiveness).

Given low power prices maintained by stagnant demand growth, a customer’s combined cycle power plant was staffed as leanly as possible. As such, a change in operational parameters went unnoticed by engineers at the plant.

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.

In recent years, amid increasingly intense global competition in the manufacturing industry, there has been a growing demand for more rapid product development and market introduction, quality improvements and shorter lead times in order to quickly respond to the rapidly changing market environments and management environments through the introduction of new technologies and collaborations between companies. In this backdrop, there has been a growing expectation for overall optimization that uses data related to manufacturing in the increasingly global supply chain to connect the front lines of manufacturing with management, suppliers, and customers. This in turn has given rise to a need for secure connections between a variety of devices in FA environment and cutting-edge IT services (e.g., Big Data and the cloud) and for the accelerated development of applications in the field of next-generation factories connecting business-to-business (B2B) applications unleashing real economic value to effectively compete in the global marketplace.

Without continuous connectivity, real-time data is really hard to deliver for any cloud service provider. The number of IoT devices with cellular connections will nearly quadruple over the next five years with increasing LTE subscriptions and access to 5G networks, according to Ericsson’s bi-annual Mobility Report. At the same time, ensuring reliable connectivity, while being mindful of security and device management as IoT implementations scale, continues to be a challenge for industrial IoT use cases.

Leica Microsystems attributes its success to providing innovative products and superior customer service. To extend its leadership position, the company began exploring a more proactive service approach for its line of confocal microscopes and tissue processors. The Leica Microsystems project team began searching for a global software that would allow for the shift from a reactive to proactive service company. Their initiative focused on downtime avoidance and the prediction of potential problems across the globe, targeting issue prevention. As a result, customers would not only benefit from minimal product downtime, but from faster service and increased productivity. To obtain approval and funding for the initiative, the team would need to prove to management that this service strategy shift would result in optimized instrument uptime and reduced costs of service.

Solution

- Integration with inverters to collect data. - Detection of possible malfunctioning with predictive analytics. - Mobile & Cloud-based solutions with automated real-time alert notifications for field engineers. - HR scheduling solution to gather real-time details of available filed engineers & provide location information for faster issue resolution. - Integration with onsite cameras for live feeds and document management for product manuals and suggested resolution.

Three companies – Zown, Mpare and Zenodys – partnered together to design a reliable microgrid solution. Zown provided on-site connectivity, Mpare took care of power measurement and Zenodys supplied microgrid management logic. Our role is to gather and process measurements, develop efficient demand response strategies and visualize microgrid dynamics via an easy-to-understand web interface. The solution is based on the Zenodys visual IoT platform that handles most of the tasks without any programming needed: • ZenoConnect provides connectivity of various smart energy vendors (houses, windmills, PV panels, batteries, etc.) and connects them to the microgrid. It can also be easily integrated with Mpare and HelloData services. • ZenoVisual provides demand response logic and delivery of different strategies. • ZenoExperience is used for data delivery and visualization. A fine-tuned web visual interface provides easy-to-understand information for the end user. • Zenobox physically connects all the equipment and services and provides a runtime environment. In this case we chose the Linux based Raspberry PI system but for a production-ready environment we would use more robust industrial gateways. The solution is fully independent and can run off-line, but for demonstration purposes we also enabled remote solution delivery and Docker based services deployments.

AMS decided to use a communication solution based around Vodafone’s existing GPRS mobile network having considered the use of power line communications, WiMAX mobile broadband or a purpose-built RF mesh network. “There were two principal reasons why the GPRS network from Vodafone stood out for us,” said Atkins. “The infrastructure was already in place with ubiquitous coverage and a high reliability, the limitations of the other options would not have enabled us to roll out Nationwide”. Past experience of working together was also a factor, as Atkins explained: “We had used Vodafone’s GSM network technology for several years without any problems, and Vodafone had always been open to making changes we needed.” In the AMS solution, a SIM card supplied by Vodafone is installed into the modem part of the smart meter. Regular readings are taken by the meter, and sent back automatically to AMS data management system over the Vodafone GPRS network.

The customer engaged Shanghai Rockbay Information Technology and its GWG Equipment Maintenance System solution to perform plant maintenance and MRO (Maintenance, Repair, Operations) system. GWG concentrated on plant maintenance & equipment operating status management. The application visualized equipment status as well as master data including functional location, equipment’s, parts, FMEA records, maintenance bill of material etc. The application was also integrated with several customised maintenance process, which served as data warehouse for business analytics. The applications recorded every failure, incident, maintenance, status checking and other related information. System Functions: • Equipment Profile and Structure Facility & Factory • Plan & Work Order • Maintenance Processes • Parts Inventory • Analysis & Report Technology Deployed: GWG Equipment Maintenance System

Monitoring hundreds of sensors per turbine on a daily basis, GE’s Asset Performance Management detected the change in operational parameters and generated daily reports revealing the specifics of this irregularity. In turn, GE’s IPRC engineers drew upon their depth of experience with Power analytics to acknowledge the severity of the increased spread and proactively notified the customer of this issue before it triggered equipment failure. As the spread increased, GE’s IPRC engineers recommended, during a weekly status update call, that the customer perform an inspection to determine the root cause of the increased spread. The inspection uncovered a defect in the equipment, so the customer planned downtime during which they replaced the faulty piece. Upon replacement, the operational parameter returned to model-predicted values.

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.

*This is an IIC testbed currently in progress.* LEAD MEMBERS Hitachi Ltd., Mitsubishi Electric Corporation, Intel Japan MARKET SEGMENT Manufacturing: Industrial Automation for Discrete Manufacturing SOLUTION As solution for these challenges, this Testbed provides connectivity between Factory and Cloud, data analytics platform, and security resources, in order to provide facilitation of FA application development for Application Providers and FA Equipment Vendors. With this result, Application Providers and FA Equipment Vendors will be able to provide solution and services to Factory Owners and Factory Operators by just developing core logic of each application. HOW IT WORKS This Testbed provides following features to reduce application development process: • Connectivity between Factory and Cloud where architectures differ • API specialized in FA, which are re-usable for FA applications: Edge Applications, Cloud Applications, and Domain Applications • Security to protect the Factory brown field from the outside network • Integrate data from Business Systems TESTBED INTRODUCTION This testbed facilitates development of FA applications by providing a service-based platform with pre-integrated environment across factory automation (OT) and IT platform (IT). It includes IoT data processing platform that processes Big Data, IoT head end system, and IoT gateway that securely connects the service platform layer with FA environment, and FA edge device that provides functions unique to FA applications, and which also enable communications with FA devices in the field of factories. In addition, the advantage of IoT platform tested in this testbed is interoperability between FA environment, IoT gateways and IoT data processing platform and accelerates application development for next-generation factory by making available of integrated environment between FA environment and service platform layer. Tests of secure connections will be completed between FA environment and service platform layer, as well as tests of the effectiveness of testbed functions and the flow of operational data from the perspective of the front lines of manufacturing, by June 2017. After that, it will conduct “use case” tests with IIC member companies and customers.

It stands to reason then that GoodMeasure, a long-time customer of Electric Imp, is quite excited about the recent debut of the vendor’s cellular connectivity functionality. Electric Imp products – which enable and manage secure connectivity – are woven into every fiber of GoodMeasure’s platform, according to co-founder and CTO Regan Ryan.

After quickly dismissing the idea of building a smart solution internally, the Leica Microsystems project team evaluated several vendors, hiring a third-party research firm to conduct a benchmark study. “There were many players in the market, but price and performance were the key drivers during our evaluation,” explained Frank Bunge, Director of Technical Services Europe at Leica Microsystems. “PTC®Axeda® software came out on top in all categories and provided the professional support that we needed—that is very important for us.” Leica Microsystems chose PTC Axeda software to remotely monitor and support its TCS confocal microscopes and ASP300 S tissue processor equipment. With PTC Axeda software, Leica Microsystems has the ability to control software releases and upgrades to systems, enabling the company to test and approve any software updates when necessary. As a result, the company can meet its established verification and validation processes for regulated environments. “We wanted a model where we could focus on users and our equipment, and PTC Axeda software provided us with the agents and the applications,” Bunge said. “Our experience with the software has been quite positive. In the event that something goes wrong, we get immediate feedback and quality support.” Registered users log into the Leica RemoteCare™ site to view the devices in the regions for which they are responsible. Using PTC Axeda software, users can compare current parameters with the products’ specifications, including hardware and calibration changes, software and PC system status, laser errors/uptime, galvanometer settings, critical temperatures, and cooling system health. Critical events become predictable with the information provided. “With Leica RemoteCare, we now monitor the performance of our tissue processors,” Bunge explained. “As soon as the temperature is out of range, an alarm and email are sent to both the customer and to Leica. The customer then makes the necessary adjustments before a specimen is potentially lost. That is a major benefit of the system.” The company also monitors cleaning sequences. If systems need to be cleaned, the customer is alerted so that they don’t lose specimens. They also use RemoteCare to adjust the microscope prior to any issues in situations where power is diminishing, ensuring uninterrupted research. The Leica Microsystems project team has enabled a number of RemoteCare customer successes in a short timeframe. For example, a research institution in Germany was experiencing system crashes of its Leica Microsystems microscopes during long-term experiments. With RemoteCare, Leica Service could diagnose the problems by examining saved error logs. Using this information, it was discovered that the memory sizes at the time of the crash fell below 500 MB. From here, instead of dispatching an engineer onsite to replace what would appear to be a defective detector board, a service representative could remotely diagnose and resolve the issue. As a result, diagnosis and repair took one hour instead of three days of downtime and the potential unnecessary use of spare parts. Another customer success took place at a U.S. based university. When Leica Service received an error message explaining a failing tissue processor program, the service representative contacted the customer who was unaware that a failure had even occurred. After further inspection, the customer removed debris under the seal, restoring the original state of the tissue processor. As a result of this proactive service call, the university avoided potential system downtime and protected their specimen from damage. “Each department within Leica Microsystems benefits from RemoteCare, so this is not just a service product,” Bunge emphasized. “For example, R&D benefits from obtaining more information from the field on the reliability and use of our products. The sales department is convinced that RemoteCare will help them win more deals since service is now a competitive differentiator with even better product reliability.” RemoteCare is available to all customers with Silver and Gold service contracts at no cost and benefits can also be received by customers with equipment under warranty or those with extended Bronze service contracts. Bunge reports that RemoteCare has customers realizing more value from their service contracts: “As soon as customers realize the benefits of RemoteCare, there is a higher probability that they will continue with their service contracts.” When paired with PTC Axeda, RemoteCare’s safety features also aid in customer adoption and implementation. By Leica educating their customers on RemoteCare, they understand that it does not allow Leica Microsystems to access any customer or hospital data. The only access Leica will have is to the system information outlined to the customer. RemoteCare is promoted by sales as a standard feature for microscopes and tissue processors. In conversations with customers, benefits of RemoteCare are discussed, and once a customer is ready for implementation, a service technician installs PTC Axeda software on the computer of the microscope or tissue processor and provides training to all necessary teams. With roughly 300 systems connected, the company plans to increase that number to 1,000 microscopes and tissue processors by the end of 2009, with a long-term goal of 5,000 connected by 2012 . “Smart services will become standard for almost every piece of Leica equipment, especially high-end and medium products,” said Bunge.

Customer

A leading manufacturer and distributor of solar panels and solar energy based out of the U.S. They provide complete and fully integrated solar system, including modules, trackers, inverters, ISIS energy management software, networking, AC & DC disconnects, and all DC wiring.

FabCity, an off-grid Smart Energy Campus, is taking place on Java-eiland in Amsterdam. The purpose of the event is to carry out research on the future of smart cities in Europe in search of new social, economical, sustainable, logistic and political systems.

Vector in partnership with Advanced Metering Services (AMS) are providers of smart metering solutions in New Zealand. AMS chose Vodafone to provide a reliable, cost-effective mobile communications network to transmit the metering data. Vodafone worked closely with AMS to provide a bespoke technical solution and to develop new price plans that ensured the smart metering solution met the requirements of New Zealand’s energy retailers, consumers and distribution companies.

A Solar Cell Manufacturer with 2 factories, more than 40 engineers, integrated with OA (Office Automation) & ERP(Enterprise Resources Planning) Purchasing Process.

A Power & Utility Generation Company

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.

Out-of-box cellular connectivity users.

Leica Microsystems, Inc. is a world leader in microscopes and scientific instruments. The company manufactures a broad range of products for numerous applications that require microscopic imaging, measurement, and analysis. The company also offers system solutions for life science, including biotechnology and medicine, research and development of raw materials, and industrial quality assurance. Leica Microsystems brings histopathology labs and researchers the most comprehensive product portfolio. The range includes the ideal product for each histology step and high-productivity workflow solutions for the entire lab.

Solution TypeIOTIOTIOTIOTIOTIOTIOTIOTIT
Solution MaturityCutting 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)Mature (technology has been on the market for > 5 years)Emerging (technology has been on the market for > 2 years)Emerging (technology has been on the market for > 2 years)Cutting Edge (technology has been on the market for < 2 years)Emerging (technology has been on the market for > 2 years)
Data Collected
Weather data Live video feeds Solar panel alignment data Field staff location Breakdown data
Mobility and the expected specific measurements
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
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 CasesBuilding Energy Management System (BEMS)MicrogridAdvanced Metering Infrastructure (AMI)Factory Operations Visibility & Intelligence Asset Health Management (AHM)Process Control & Optimization (PCO)Factory Operations Visibility & Intelligence Edge Computing | Edge IntelligenceTrack and Trace for Industrial Tools & AssetsPredictive Maintenance

Operational Impact
Impact #1
Achieved maximum utilization of solar energy through remote controlling of solar panel directions.
Visual environment enables participants and other providers to set up their solutions fast and without any programming. This enables engineering teams to directly work on their internet of things solutions.
Detailed smart meter data allows energy suppliers to use tiered pricing to encourage off-peak energy usage.
RCM setup enables all engineering staffs from different factory sites to access on one single platform.
Given GE IPRC’s inspection recommendation and the customer’s ability to proactively plan downtime for maintenance, the customer was able to eliminate the risk of a component failure which would have triggered catastrophic failure.
Integrated across multiple information systems to share information with hospital and IT staff.
Facilitate development of high value-added applications for manufacturing industry
Electric Imp’s products aim to ease all of that. An imp-authorized hardware module embedded in a device connects to the so-called Electric Imp Cloud. That cloud authenticates and manages all devices at scale, establishes secure connectivity, and handles the necessary processing and integrations as the data flows between the device and a third-party public or private cloud.
Impact #2
Reduced time spent in monitoring locations and downtime through predictive maintenance.
The solution for the FabCity was delivered fast and they managed to overcome Internet of Things and smart energy challenges, hardware interoperability, infrastructure gap between the edge and cloud, and on-the-edge challenges – in a really short time.
AMS’s smart metering solution provides a cost-effective mechanism for environmentally minded consumers to recover a fee for power they feed back into the network.
By leveraging on system knowledge, the breakdown time is expected to reduce through the enabled service-level maintenance.
A smart system of devices providing critical operational data for service and support.
For FA equipment vendors: Facilitate integration of value-added applications, such as remote operations and predictive maintenance
The new solution supports hybrid operation modes, allowing devices to securely use lower-cost networks when available, according to a press release. For example, telematics applications can send high volumes of buffered sensor data via Wi-Fi when a truck is at a loading bay, but only transmit location data and alerts via a cellular connection when the vehicle is moving, according to the press release.
Impact #3
Improved efficiency through process automation
Zenodys offers an off-the-shelf demand response solution that is highly flexible and efficient, has been tested in real cases, can be easily integrated into buildings, factories, cities and other microgrid environments, and managed via a fully visual environment.
Generate MRO Purchase request & integrated with company’s OA system, it could find alternative spare parts & utilize spare parts inventory
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
For Factory owners and operators: • Facilitate deployment of applications as to improve productivity, quality, and factory-operation uptime; and reduce lead time of production. • Facilitate deployment of applications as to optimize value chain and supply chain by coordinating between manufacturing and other departments such as procurement, distribution, and sales.
This added service builds out a portfolio to help customers scale connected solutions, boosting the benefits of buying an out-of-the-box connectivity solution versus developing it in-house, according to Fiennes.

Quantitative Benefit
Benefit #1

Reduced operational cost by 25-30%

Increased OEE by 20%

Enable increased number of procedures per facility per day.

The company has fixed 30% of detected problems remotely on connected systems and improved time to repair fulfillment from 75% to 87%. Optimized instrument uptime by reducing unscheduled downtime by 40%

Benefit #2

Reduced software purchasing investment by 60%

Reduced downtime and unexpected maintenance calls.

Reduced service costs by cutting field service visits by 33%. Improvement of service productivity by 5%.

Benefit #3

Reduced spare parts inventory by 30%

Increased customer satisfaction.

They have reduced 50 onsite visits in the first half of 2009 with an expected 400 visits saved at the end of 2009. That translates into a savings of more than $500,000 U.S. dollars.


Technology
Hardware
SoftwareZenodys PlatformAsset Performance ManagementAmazon 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 CloudAxeda Machine Cloud
Tech PartnersAmazon Web ServicesIndustrial Internet Consortium (IIC)IntelMitsubishi Electric AutomationElectric Imp

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