Industrial Internet of Things in a Box
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Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0 IIOT-IN-A-BOX: Applicazioni di Internet of Things per l’automazione industriale Andrea Ceiner, Eurotech Barbara Angelini, IBM
Transcript of Industrial Internet of Things in a Box
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IIOT-IN-A-BOX: Applicazioni di Internet of
Things per l’automazione industriale
Andrea Ceiner, Eurotech
Barbara Angelini, IBM
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IIOT ? INDUSTRY 4.0 ? SMART FACTORY ?
“The integration of complex physical machinery with
networked sensors and software … to optimize
operations”
Fabbrica Intelligente
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Due mondi che si avvicinano
IoT
IIOT OT IT
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
OT IT
LOW POWER
MILLIONS
CONNECTIONS
FEW MESSAGES x
CONNECTION
Near REAL TIME
LOW FOOTPRINT HIGH PERFORMANCE
FEW CONNECTIONS
LARGE FOOTPRINT
MANY MESSAGES
PER CONECTION
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Non solo in fabbrica: «Non abbandonerai
più il tuo prodotto»
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Perché l’IoT ha impatto sull’automazione
industriale e nel manifatturiero ?
EFFICIENZA
• Perché è un’industria MATURA che deve trovare nuove leve per fare EFFICIENZA nella PRODUZIONE
EFFICACIA
• Perché deve riconcepire i prodotti (SMART CONNECTED DEVICES)
• Perché deve trovare nuovi MODELLI di BUSINESS (dal PRODOTTO al SERVIZIO)
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IIOT: ne abbiamo davvero bisogno ?
Potenziale Manifatturiero
=
Valore produzione
--------------------------------
Grado utilizzo impianto
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Innovazione = Risolvere la complessità
@ Business
Applications
Sensors,
Actuators,
HMI, SCADA,
PLC
Multi-
Service
Gateway
?
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Incapsulare la complessità (OT & IT)
Business
Applications @
IoT Integration Platform Operational
Technologies
Cloud-side
@
Enterprise
Information
Technologies Data&Analytics Platform (PMQ,MAXIMO,…)
Sensors, Actuators,
HMI, SCADA, PLC
Multi-Service
Gateway
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IBM and Eurotech collaboration IBM Business applications
Building &
Energy
Management
Predictive
Maintenance
& Quality
Real Time
Monitoring
Enterprise
Asset
Management
Reporting &
Analytics
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IBM Predictive Maintenance and Quality è una soluzione preconfezionata cross-industry di business analytics: per monitorare indicatori di asset ed analizzare pattern storici di malfunzionamenti per anticipare, tramite analisi predittiva, malfunzionamenti di asset per indirizzare con ordini di lavoro just-in-time PMQ analizza dati provenienti da multeplici sorgenti e raccomanda azioni, agevolando decisioni, basate su modelli comportamentali testati.
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Industry Specific Solution: Predictive Maintenance & Quality
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0 © 2015 IBM Corporation
PMQ analyzes data from multiple sources and provides
recommended actions, enabling informed decisions
Manufacturing
Data
Inventory
Data
Warranty
Data Environmental
Data Financial
Data
Operations
Data
Asset Mgmt
Data
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0 © 2015 IBM Corporation
Predictive Maintenance and Quality provides several key
features
Maintenance
Analytics
Advanced Quality
Analytics
Open Architecture
Business
Intelligence
Real-time
Capabilities
Quick and Accurate
Decisioning
Maximo
Integration
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Key Business Values of Predictive Maintenance & Quality
RIDUZIONE COSTI
in Manufacturing… Reduced rework
Reduced scrap
MIGLIORAMENTO DELLA PRODUTTIVITA’
MIGLIORAMENTO DEL VALORE DEL BRAND
in Distribution… Fewer recalls
in Field Warranty… Fewer claims
in Manufacturing / Procurement... Reduced rework
Reduced scrap
Increased capacity utilization
More on-time shipments
Higher assurance of delivery of quality products from suppliers
in Development... More product coverage, more effective coverage with existing
engineering resources
Prioritization of most pressing issues
Single effective process for entire enterprise
Improved customer satisfaction
Improved brand image
Protect high-stakes, high volume product launches
Higher top-line growth and customer retention
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
I clienti riportano i seguenti benefici
5% in aircraft-on-ground events
1% in overall maintenance costs
97% ability to predict delays & cancellations within 12 weeks
25% in overall production line productivity
7 – 10% in plant maintenance costs 10% in paint yield
49% of average inventory
97% fault recognition for specific assembly operation
60% redundant service calls
87% accuracy within 48-hour warning about potential equipment failures 85% accuracy using analytical model to predict stuck pipe situations
23% in operating expenses
10%-15% in annual OPEX budget
1%-3% in annual CAPEX budget
20-30% in warranty claim processing times
45.5% in unplanned maintenance
33% anticipated in equipment and vehicle failures 34% accuracy predicting machine failures 2+ hours ahead of event
maintenance
finance
supply chain/procurement
customer service
warranty
production product design
manufacturing
quality control
maintenance
production
data scientist/statistician
maintenance
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Global automobile and motorized equipment manufacturer
demonstrates ability to accurately predict production line equipment
failures
Need Reduce unplanned downtime
on critical production lines.
Challenge: Big Data and Analytics is part of the company’s enterprise-wide
initiative to improve corporate decision making by transforming data into
actionable information. For one of the manufacturing divisions their goal was to
reduce, if not eliminate, unplanned downtime of critical production equipment.
Solution: Analyzed 16 months of production line data to develop predictive
models for machine failures. The company knew the causes of some of the
failures, but was eager to uncover additional patterns to identify causal factors of
failure. Pilot project was able to develop models to accurately predict 34% of
machine failures, specifically: 27% of machine failures occurring during production
time more than 8 hours in advance of the event and 7% of machine failures
occurring during production within 2 to 8 hours in advance of the event
Approach Pilot project analyzing 16 months
of production data develop
predictive models for machine
failures
Results accurately predict 34% of machine
failures 2 or more hours in
advance of the event
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
A major global steel producer based in Asia uses predictive analytics
to maximize productivity with preventive maintenance
45.5% reduction in unplanned maintenance
Challenge: client theorized that 65 % of facility failures and product defects during the previous
three years could have been prevented with systematic preventive maintenance and early
warning and diagnosis of problems. However, given the lack of interconnectivity of and visibility
into production, quality and facilities data, the company found it challenging to anticipate
machine or facility failures and product defects.
Solution: Predict and prevent problems by applying analytics to a vast volume and variety of
near-real-time and historical production data. Detect and alert facilities managers to impending
machine malfunctions, allowing them to change production conditions or implement preventive
maintenance to avoid machine failure. The solution can also determine the root cause of quality
issues, helping the company manage conditions to avoid costly product defects.
Higher-quality steel and on-time delivery are helping this steel producer stay ahead of the
competition in a cutthroat market.
100s of millions in opportunity cost savings by
delivering high-quality products
on time
Increases productivity with near-real-time
monitoring and accurate alerts
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
Large Utility (Asia): helps electric power providers reduce
maintenance costs and optimize parts inventory.
Reduce expensive damage resulting
resulting from unexpected
breakdown
Optimize procurement model of major
equipment and warehouse
management of spare parts
Save approximately 400M ¥ Yuan
(US$65M) of maintenance costs in
5 years
Challenge: Provider of information services and systems to the
equipment-intensive enterprises electric power industry sought
more effective management of clients’ capital equipment and
production assets. Specifically wanted to reduce unplanned
shutdown time, control and lower the operating costs, optimize
operating plans, and improve poorly integrated maintenance
systems.
Solution: IBM PMQ Predictive Maintenance and Quality to
accurately predict the equipment failure, optimize the warehouse
management of spare parts, lower procurement costs, and
improve efficiency of equipment utilization.
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
IIOT-IN-A-BOX
• telemetry for live data monitoring of ElectroMechanic Cylinder
• ElectroMechaninc Cylinder re-programming for an unexpected
urgent change in production schedule
Maximo
MQTT MQTT
Eurotech Group – Product Management – Contact: [email protected] Rev.: 2.0
www.eurotech.com
Grazie ! www.ibm.com
