KHS develops and produces machines and equipment for filling and packaging in the drinks industry. Because drinks manufacturing, filling and packaging consist of a number of highly complex processes, the user-friendly and intuitive operation of equipment is increasingly gaining in significance. In order to design these processes as simple as possible for the user, KHS decided to introduce a uniform, transparent and standardized solution to the company. The HMI interface should meet the requirement for people with different qualifications and enable them to work on a standard platform.
Moxa was asked to provide a connectivity solution for one of the world's leading cosmetics companies. This multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees, sought to improve the efficiency of their production process by migrating from manual monitoring to an automatic productivity monitoring system. The production line was being monitored by ABB Real-TPI, a factory information system that offers data collection and analysis to improve plant efficiency. Due to software limitations, the customer needed an OPC server and a corresponding I/O solution to collect data from additional sensor devices for the Real-TPI system. The goal is to enable the factory information system to more thoroughly collect data from every corner of the production line. This will improve its ability to measure Overall Equipment Effectiveness (OEE) and translate into increased production efficiencies. System Requirements • Instant status updates while still consuming minimal bandwidth to relieve strain on limited factory networks • Interoperable with ABB Real-TPI • Small form factor appropriate for deployment where space is scarce • Remote software management and configuration to simplify operations
In many automated production facilities, changes are made to SIMATIC PCS 7 projects on a daily basis, with individual processes often optimised by multiple workers due to shift changes. Documentation is key here, as this keeps workers informed about why a change was made. Furthermore, SIMATIC PCS 7 installations are generally used in locations where documentation is required for audits and certification. The ability to track changes between two software projects is not only an invaluable aid during shift changes, but also when searching for errors or optimising a PCS 7 installation. Every change made to the system is labour-intensive and time-consuming. Moreover, there is also the risk that errors may occur. If a change is saved in the project, then the old version is lost unless a backup copy was created in advance. If no backup was created, it will no longer be possible to return to the previous state if and when programming errors occur. Each backup denotes a version used by the SIMATIC PCS 7 system to operate an installation. To correctly interpret a version, information is required on WHO changed WHAT, WHERE, WHEN and WHY: - Who created the version/who is responsible for the version? - Who released the version? - What was changed in the version i.e. in which block or module of the SIMATIC PCS 7 installation were the changes made? - When was the version created? Is this the latest version or is there a more recent version? - Why were the changes made to the version? If they are part of a regular maintenance cycle, then is the aim to fix an error or to improve production processes? - Is this particular version also the version currently being used in production? The fact that SIMATIC PCS 7 projects use extremely large quantities of data complicates the situation even further, and it can take a long time to load and save information as a result. Without a sustainable strategy for operating a SIMATIC PCS 7 installation, searching for the right software version can become extremely time-consuming and the installation may run inefficiently as a result.
1) Deliver a connected digital product system to protect and increase the differentiated value of Haemonetics blood and plasma solutions. 2) Improve patient outcomes by increasing the efficiency of blood supply flows. 3) Navigate and satisfy a complex web of global regulatory compliance requirements. 4) Reduce costly and labor-intensive maintenance procedures.
Before working with Ayla Networks, Ozner was already using cloud connectivity to identify and solve water-filtration system malfunctions as well as to monitor filter cartridges for replacements.
But, in June 2015, Ozner executives talked with Ayla about how the company might further improve its water systems with IoT technology. They liked what they heard from Ayla, but the executives needed to be sure that Ayla’s Agile IoT Platform provided the security and reliability Ozner required.
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.
Most of the customer's warehouses run on utility and generator power. Since these warehouses are in remote locations, power outages are a very common scenario. Diesel fuel, thereby, becomes a significant cost for these warehouses. Energy consumption was also very high due to the lack of a consistent temperature throughout the facility. This lack of a consistent temperature in all areas and no way to control it, resulted in the customer losing a significant amount of their temperature sensitive goods due to spoilage.
The researchers know from past experience that some banks do take security of their mobile applications seriously. These are the banks the researchers work with on a daily basis. Given no application in the sample set achieved an A or B rating, it emphasises how much in the minority these banks are.
Tata Power's power generation equipment OEMs (M/s BHEL) is required to provide all of the instrumentation and measurement devices for conducting performance guarantee and performance evaluation tests. M/s BHEL faced a number of specific challenges in conducting PG tests: employing high-accuracy digital communications for instrumentation, shortening setup and dismantling time, reducing hardware required, making portable instrument setup, avoiding temporary cabling work and the material waste costs
KHS decided to use Zenon from COPA-DATA for the implementation of the new ClearLine HMI. The Zenon HMI/SCADA platform offers precisely what we need for our machines and production lines. The zenon software has well-developed graphical display possibilities and numerous HMI elements already included as standard. Software Components - Zenon: the HMI/SCADA software from COPA-DATA - Everywhere App
Moxa's ioLogik E2212 with included Active OPC Server software perfectly met the customer’s requirements. Part of Moxa's Ethernet Micro RTU Controller family, the ioLogik E2122 continues of Moxa's tradition of offering intelligent I/O solutions with active communications architecture. With active "push" architecture, the ioLogik will proactively communicate with the central Real-TPI system instead of waiting for slower and bandwidth-consuming poll-and-response messaging. Moxa's support for active "push" communications helps the customer conserve the limited available bandwidth in factory networks and maintain a constant up-to-date stream of data from connected devices. The other unique component of Moxa's solution is Active OPC Server, which is included with Moxa's I/O products. Moxa's Active OPC Server supports push architecture and allows seamless connections with most SCADA software, including ABB Real-TPI. Compared to third-party OPC servers, the Active OPC Server is a convenient solution designed to work with Moxa's I/O devices that can be freely downloaded from the Moxa website. After evaluating these features, the customer installed ioLogik E2212 units on their production line to interface with optical sensors that maintain a count of how many units are produced. The ioLogik is configured to proactively transmit the counter value to the Active OPC Server every time the value hits a certain threshold, which ensures that an up-to-date count is available to the ABB Real-TPI system. Product Solutions: 1. Active OPC Server Seamlessly connect ioLogik/ioPAC to your SCADA system 2. ioLogik E2212 Smart Ethernet Remote I/O with 8 DIs, 8 DOs, 4 DIOs
The Siemens Solutions Partner AUVESY (Automated Versioning Systems) has developed a major PCS 7 add-on for its versiondog software that can be integrated seamlessly into any SIMATIC PCS 7 setup while meeting all data management requirements. The versiondog software allows users to back up, version and document not only SIMATIC PCS 7 projects, but also software versions of all other automation devices involved in production. The data management system is usually installed on a virtual machine in the local network and is available to all users who have been granted the necessary authorisation. The versiondog PCS 7 add-on is installed with full functionality in the production network of a SIMATIC PCS 7 installation and is able to: - Carry out all data backups and version management throughout the entire lifecycle of a SIMATIC PCS 7 installation. - Ensure that only the valid version is used in production due to automated backups of the automation systems and cyclical comparisons with the version released on the server. This can also help to detect cyber-attacks. - Plan and map out the entire lifecycle of a SIMATIC PCS 7 system, from commission to operation, with a complete change history. - Compare SFC and CFC blocks of a SIMATIC PCS 7 project without the need for any additional drivers. Blocks can be compared graphically or in text form using versiondog’s proprietary SmartCompare technology. All differences are highlighted in colour and can be individually selected, thus removing the need for manual searches. - Fully document changes within a SIMATIC PCS 7 project for audits, validation or certification. - Provide version control of software versions for immediate device restoration when errors occur (disaster recovery) The versiondog software is the key to providing optimum data management support for process control systems. Siemens knows this, too, which is why versiondog is listed as an official PCS 7 add-on in the Siemens Industrial Mall at www.mall.industry.siemens.com. For additional details view: https://mall.industry.siemens.com/mall/en/WW/Catalog/Products/10048340
Built on Bright Wolf’s Strandz platform and leveraging Amazon Web Services (AWS) cloud storage, Haemonetics won IoT Evolution App of the Year in 2015. Through their partnership with Bright Wolf, Haemonetics released HaemoCloud, connecting the blood supply chain from donation to transfusion. The new system works directly with their existing HaemoCommunicator suite – connecting all Haemonetics sensors and devices in order to format and transfer device information, as well as collect and manage operational data, and send it to the AWS cloud. HaemoCloud also integrates with hospital and other institutional information systems to store and share information with relevant hospital and IT staff, creating a seamless data experience for customers. Data collected in HaemoCloud will allow Haemonetics to build preventative maintenance algorithms and provide customers industry-leading device performance. The system’s flexible architecture also enables Haemonetics to take advantage of new market opportunities and grow with new offerings from Amazon Web Services (AWS) in the future.
Ozner is leveraging Ayla’s IoT cloud platform to better manage and maintain its connected filtration systems and to help expand its sales into international markets.
The Ayla Insights business intelligence and analytics tool was employed to obtain real-world customer data from the Ozner Water connected smart-filtration systems in use. The customer data collected through Ayla insights included additional maintenance and service checkpoints from the deployed systems.
Meanwhile, Ayla engineers built Ozner a mobile app that lets Chinese customers remotely control their own filtration systems using popular social networks, such as Weixin (aka WeChat).
*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.
Working with their partner LogicLadder, SenseGrow installed wireless temperature sensors in temperature-controlled environments. Hardware and software was installed for both generator fuel management and energy meters on utility supply Using SenseGrow’s ioEYE Platform, our partner LogicLadderTM delivered their EnergyLogicIQ product. This solution ultimately helped lower the spoilage rate of temperature sensitive goods while lowering their energy and fuel costs.
New European regulations are putting more requirements on organisations to keep their customers’ data safe. The basis of the requirement is that the customer owns their data and an organisation “borrowing” that data has a duty of care over the information and needs to use “state of the art” security to keep customer data from fallings into unauthorised hands. Any lapses in that duty can result in large fines (up to €20m or 4% of turnover, whichever is higher).
Honeywell XYR 6000 wireless temperature, pressure and flow transmitters were installed at various process points to measure key process parameters. Multinodes were installed at vantage points within the power generation unit, and all data was made available for real-time visualization, trending/historization reports and data export to Microsoft Excel. The Experion platform was used for data logging, analysis and reporting to support the PG test procedure. Hardware Components - Honeywell XYR 6000 transmitter - MultiNode - WSG Software Components - Honeywell Experion platform
KHS GmbH is a supplier of filling and packaging systems based in Dortmund, Germany, with more than 4,600 employees. The company offers filling lines for glass and PET bottles, kegs, and cans for the beverage, food, and non-food industries, and is a wholly owned subsidiary of Salzgitter Klöckner-Werke GmbH, a member of Salzgitter AG.
A France-based multinational corporation, with retail presence in 130 countries, 23 global braches, and over 66,000 employees.
Auvesy's process control system support with Versiondog has been used by many pharmaceutical companies, including: Amgen, Boehringer, Saxonia Medical, Fresenius, GlaxoSmithKline, KVP (Bayer Health Care), Lohmann & Rauscher, Lundbeck Pharma A/S, Rentschler, Roche Diagnostics, Sun Chemical, Vetter Pharma, and Xellia Pharmaceuticals.
Haemonetics Corporation is the leading global provider of blood and plasma supplies and services. Our comprehensive portfolio of devices, information management, and consulting services offers blood management solutions for each facet of the blood supply chain — from plasma and blood collectors to hospitals.
Ozner Water International Holding is part of a large Chinese company that develops, manufactures and sells water-purification systems.
Parekh Integrated Services Private Limited (PISPL) is a pioneer in the field of warehousing, distribution and supply chain solutions. It provides customized warehouse management systems, flexible point-to-point distribution solutions, complex end-to-end integrated logistics solutions and supply chain management.
Mobile financial payment providers.
Tata Power is India's second largest private power producer and is part of the Tata Group with more than 4,100 employees. The core business of the company is to generate, transmit and distribute electricity.
|Solution Maturity||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)||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)||Mature (technology has been on the market for > 5 years)|
Real-time operation data
CNC machine data (positioning, production rate, temperature, vibration).
Field devices, PLC data, SCADA systems, robots, and other automation devices. Full data is collected consistently from all devices linked to the solution. Data can be used for disaster recovery. CFC and SFC plans are also stored and can be compared in detail.
Machine maintenance data, anonymized procedure data, detailed maintenance logs.
Process parameters, including temperature, pressure, flow
|Original Full Case Study|| Open in new tab|| Open in new tab|| Open in new tab|| Open in new tab|| Open in new tab|| Open in new tab|| Open in new tab|
|Youtube Video ID|
|Use Cases||Factory Operations Visibility & Intelligence ||Manufacturing System Automation||Process Control & Optimization (PCO)||Process Control & Optimization (PCO)||Predictive Maintenance||Factory Operations Visibility & Intelligence ||Building Energy Management System (BEMS)||Perimeter Security & Access Control ||Process Control & Optimization (PCO)|
Ongoing application development and improvements are relatively quick and inexpensive to implement due to the system's flexibility.
Seamless integration between the ioLogik I/O device and ABB Real-TPI with Moxa's Active OPC server. Effortless, One-Click method to generate I/O tags on the Active OPC Server simplifies initial system setup.
Improved safety and security through improved management of data. Cyber-security is greatly improved through the ability to identify and prevent cyber attacks.
Integrated across multiple information systems to share information with hospital and IT staff.
Expand its knowledge of customer requirements and use the information for future product improvements. Anticipate many more of its customers’ needs before they became service problems or system malfunctions
Facilitate development of high value-added applications for manufacturing industry
Reduced energy consumption by not unnecessarily cooling below the required limit.
It is not recommended to build security solutions in-house; rely on a proven solution that gets exposed via their broad install base, and has teams dedicated to securing mobile applications.
Real-time status reports enable maintenance personnel to remotely diagnose the status of a device which reduced CAPEX and OPEX required for conducting PG tests.
Better user interface with a universal platform and less training were needed for employees.
Reduce network traffic with Active communications architecture
Automated audit trail protocol.
A smart system of devices providing critical operational data for service and support.
Allow customers to control and monitor their filtration systems anytime, anywhere—and communicate with Ozner customer service—via smartphone and their favorite social network.
For FA equipment vendors:
Facilitate integration of value-added applications, such as remote operations and predictive maintenance
It is important to plan ahead so that the risk is reduced and a remediation plan is in place to minimise any fallout both in terms of image and PR but also technically.
High-accuracy measurements from instruments with a digital communications capability by the solution.
Real-time status reports enable production engineers to remotely monitor the status of a device on a production line.
Active OPC Server included free, to save deployment costs
Time-savings for engineers due to the easy comparison of CFC and SFC project data.
Delivers an improved level of care, reduced costs, and traceability across the entire blood value chain.
Conquer long-distance maintenance and service concerns as the company expands beyond China into international markets
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.
Device binding is a technique to lock an instance of the mobile application to a particular phone. This stops the application being cloned. It also helps control access to back-end servers as user credentials can be locked to a given device.
Programming time, production time, and installation time are shortened which reduced indirect costs.
Labor costs reduced by 13% due to remote access.
Return on investment is generally achieved within six to twelve months.
Enable increased number of procedures per facility per day.
90% reduction in spoilage of goods
Wireless technology would help save a total of $4.7M.
Capital equipment lifeline increased by 8%.
Increases of quality and quantity of 20-30% are experienced by most customers.
Reduced downtime and unexpected maintenance calls.
28% fewer breakdowns in Diesel Generator and HVAC sets.
The entire OneWireless infrastructure was installed and commissioned in just 2 days.
Customers report an average 25% reduction in downtime.
Increased customer satisfaction.
25% reduction in energy costs.
Indirect cost caused by the end-customer can be reduced by 50% due to reduction in cycle time and increase in test efficiency.
|Hardware||Smart Ethernet I/O Solutions|
|Software||MX-AOPC UA SuiteSystem 800xA||SIMATIC PCS 7versiondog||Amazon Virtual Private Cloud (VPC)Amazon Elastic Compute Cloud (Amazon EC2)Amazon Route 53Amazon Simple Storage Service (Amazon S3)Bright Wolf Strandz Enterprise IoT Application PlatformAWS Cloud||Ayla Networks IoT Platform||SenseGrow ioEYE|
|Tech Partners||ABB||SiemensDigital Factory (Siemens)||Amazon Web Services||Industrial Internet Consortium (IIC)IntelMitsubishi Electric Automation||INSIDE Secure|
IoT Snapshot: Hardware
|Processors & Boards|
|Sensors & Actuators|
IoT Snapshot: Software
|Software as a Service|
|Platform as a Service|
|Infrastructure as a Service|
IoT Snapshot: Service
|Construction & Buildings|
|Equipment & Machinery|
|Logistics & Warehousing|