Connecting machines and devices in a reliable way: What ... · Connecting machines and devices in a...

Connecting machines and devices in a reliable

way: What you need on your factory floor?June 20th , 2017

Uroš Merljak, Partner Channel Sales Director

IIoT brings benefits across the automation journey

Asset Performance

Augmented

Operator

Control Optimization

Design &

Engineering

Commissioning &

Operation

Maintenance &

Services

Cost & Time to market Efficiency Availability

What: Empower the operator with the right info

How: Mobile devices, wearable, wireless

Benefits:

• Worker productivity improvement

• Ready for millennials (knowledge work

automation)

What: Optimize asset use

How: Analytics, secondary sensing, cloud

Benefits:

• Unplanned downtime reduction

• Maintenance cost reduction

What: Bring control at the enterprise level

How: Local OT autonomy, global IT connectivity

Benefits:

• Process/Factory productivity improvement

• Energy consumption reduction

At SE, we focus on three pillars to tap into the potential of IIoT

Augmented operator Asset performance Control optimization

• Connected ProductsThe Internet of Things starts with things and it is intelligent products like

connected breakers, sensors, actuators and motor drives that serve as the

foundation of smarter operations. Digital twin.

• Edge Control: Automation & Control systemsWe enable our customers to have real time solutions for control at the

Edge of the IoT network. For mission critical scenarios, not all control

decisions can be made remotely and overridable control of devices at the

Edge of the network of things is a must.

• Applications, Analytics and ServicesOur customers come with a variety of hardware and systems.

EcoStruxure enables the most extensive breadth of agnostic Applications,

Services and Analytics working with any hardware, any systems, and any

control.

Technology Layers Explained

ANALYTICSCLOUDMOBILITY SENSING SECURITY

Open data management for seamless IT/OT convergence

Partner ecosystem

Connected

Products

Edge control

Apps,

Analytics &

services

From machine applications, such as HVAC and pumping, to process automation in F&B, WWW, MMM, and O&G

Innovation at Every Level in Industries:

Process Engineering

SimSci PES

SimSci EYESIM

Pipeline Mgmt Suite

Planning &Scheduling

SimSci Spiral Suite

Struxureware SDO

Asset Management

Avantis EAM

Avantis PRiSM

APMaaS

Operations Control

Wonderware System Platform

OASyS DNA

Citect SCADA

ClearSCADA

InformationManagement

Vijeo 360

Wonderware Online

Wonderware Historian

Wonderware SmartGlance

Industry Solutions

Line Performance Suite for F&B

APM for Power

Unit Performance for O&G

Operations Management

Wonderware MES

SimSci APC

Struxureware Operations Ampla

ResourceAdvisor

Supply Demand Sustainability

Operations Control

InTouch Machine Edition

Vijeo D, Vijeo XD

InduSoft Vijeo XL

Prometheus

Touchscreen Panel

Valve Positioners

Variable Speed Drives

MCC/PCCElectrical Panel

IndustrialSensors

Motor Starters

PowerStruxure

En

d-t

o-e

nd

Cyb

ers

ec

uri

ty

Clo

ud

i/i

lin

alo

ka

cij

i

PlantStruxure

ModiconPlantStruxure

Modicon, Foxboro, Triconex

Continuous ProcessDiscrete Process

EcoStruxure.io

Machine Automation

MachineStruxure

Altivar

Efficiency improvement as a result of convergence of IT/OT technologies

EcoStruxure for Machines

TRACK – Value proposition

Needs & Wants of Schneider Electric’s OEM customers and End Users

OEM Engineer

Maintenance

technician

End-user line manager

“I have many machines, with various purposes, ages… Handling full

history is a nightmare”

“Replacing parts on my machines interrupts production and should

be optimized”

“I would save a lot of time if I could access all machine latest

documentation and information in one place”

“I want to know if spare parts are available before I go on site”

“It is annoying when the machine logbook is not complete”

“Service to my customers would be much faster if I could have

access to machine information and location instantly”

“With standard and complete information about my customer’s

machines, I would be able to better understand what to offer them”

TRACK is a repository service for OEMs that enables online

access to documentation and history of all their machines

Bill of material, technical documentation, localization, service log,

warranty info, spare part availability, and more

TRACK is a cloud repository service

To access key information

about my machine

Machine info trackingWeb application Spare part management

Architecture

Machine and components

documentation

Localization of Installed Base

Spare part availability

information

Easy order placement

(For SE components)

Lifecycle management

Maintenance / service

logbook

Warranty status of

machine and components

0 1 2 3

Life cycle management

Asset registration

Warranty and maintenance log

Spare parts management

Spare parts availability and order options

Machine info tracking

Machine architecture

Machine documentation

TRACK: wireframe examples of user interface


MONITOR – Value proposition

Needs & Wants of Schneider Electric’s OEM customers and End Users

OEM Engineer

Maintenance

technician

End-user line manager

“I want to make my producing line more stable and efficient”

“Health, performance and efficiency are key aspects I need to

control on my machines”

“Real-time data from my machines is very valuable”

“I would save a lot of time if I could diagnose the issue remotely and

travel on site only if necessary”

“It is annoying when I can not find the root cause of a machine issue”

“After I ship the machine, I would love to have some info on how it is

performing, what the issues are, …”

“I value all services that can help me support my customers”

“I need to reassure my customer about privacy and security to get

connected to its data”

MONITOR is a cloud based service for End Users to remotely

monitor and analyze machine health and performance

Customizable dashboards for live KPIs, notifications & alerts,

predictive maintenance, performance optimization, expert reports, and more

TRACK is a remote monitoring and analytics service for End Users

To access machine

insights through a

dashboard

Machine Raw DataWeb application Remote expertise

Live KPIs in visual form

Programmed notifications

(threshold breach)

Advanced analysis to

interpret data and

provide

recommendations

Analytics on machine

Machine condition analysis

(health, performance,

efficiency)

0 1 2 3

Pain points to be addressed by analytics

Health

Monitoring

Utilization

Monitoring

Efficiency &

Optimization

• Monitor efficiency

energy, utilization efficiency,

• Optimize

taking into account several

conditions / parameters

• Anticipate ageing

through use monitoring

• Predict failures

based on collected variables

(internal or external), for different

types of failures

• Monitor utilization

working time and statistics on

past usage, on-off time, stand-

by time etc.

Analytics

Level 2

Advanced monitoring

Level 3

Expert monitoring

Level 1

Basic monitoring

MONITOR: wireframe examples of user interface

Notification & Alerts to be programmed Automatic Report

Analytics processed data

Fault, Ageing, Use optimization…

Link with expertise

(OEM – SE) for - Diagnostic

- Data interpretation

- Expert reports

- …

Dashboard with Raw data and

Notifications


FIX – Value proposition

Needs and wants of Schneider Electric’s OEM customers and End Users

OEM Engineer

Maintenance

technician

End User line

Manager

“I cannot afford downtimes on my line, problems must be solved for good, and fast”

“My machines are complex and very different; yet, I want my people on site (including my

operators) to be able to troubleshoot”

“I want to provide best maintenance quality and solve issues fast”

“I have to be as efficient for new products as for those I am used to.”

“In case I need it, I should have immediate access to expert assistance.”

“I don’t want to take a long flight to solve something basic”

“Whenever possible, I want technicians on the line to solve problems by themselves”

“But when necessary, I want to take remote control over the machine for faster and better

maintenance, wherever the machine is”

“I don’t want to send technicians on site when I don’t need to”

“When something goes wrong, I want to be able to keep my machine running without

having to wait for someone to come”

End User

Operator

FIX is a service to facilitate maintenance operations with the

help of step-by-step procedures and remote experts leveraging

augmented reality

What do I get with FIX?

To access insights about a machine

and maintenance help

Maintenance insightsMobile App in Augmented

Reality

Remote Maintenance

Services

Step-by-step procedures

(displayed via the app)

Over-the-shoulder expert assistance

Remote troubleshooting

1 2 3

Level 1

Self-troubleshooting with

digital procedures

Level 3

Remote troubleshooting

Level 2

Remote expert assistance

Level 0

Visualization of machine

Point of Interest

Show me how this looks like: focus on the mobile App

Step-by-step digital

maintenance procedures

Step-by-step AR maintenance

procedures

Advanced access to experts

(screen sharing)

Simple access to experts Remote Troubleshooting

service (ticketing system)

Machine PoI

Real time information Tunneling to machine

Customer Success Stories

Customer Challenge• Automate maintenance data collection

• Improve availability & utilization of production

assets

• Developing standardized solution for 9 separate

production facilities

The Solution• Avantis EAM®

• Avantis PRO®

• Avantis VIP Advanced Scheduling

Customer Benefits

• Inventory reduction via better asset utilization

• Minimize potential loss when kiln is offline

• Advanced planning and scheduling software

resulted in more planned maintenance activities

The Results: Life is On with...

$2M reduction in first year inventory

“By closely monitoring and managing what we use, reorder

activities, and parts and materials pricing, we have reduced

inventory by at least $2 million in the last few years. This is a

significant contribution to keeping our prices competitive in the

marketplace”.

Mike Ralls,

Plant Systems Administrator,

Ash Grove Cement

5th largest cement manufacturer

in the USA with annual production

capacity of >8M tonnes

Ash Grove

Cement, USAEnterprise Planning, Scheduling &

Compliance Management

Edge

control

Connected

products

Apps,

analytics,

and services

Edge

Control

Connected

Products

Avantis

EAM®Avantis

PRO®

Avantis VIP

Advanced Sched.

Industry

Customer Challenge• Improve asset utilization across 5 mines

• Flexible solution for local operating conditions

• Ensure new system drives continuous

improvement through the business

• Capture of real-time data and root-cause analysis

of ‘less than perfect’ utilization

The Solution• Ampla operations management system

• Schneider Electric consulting services, project

design, implementation, training and support

Customer Benefits

• Significant productivity improvements

• Provide clear root cause analysis

• Provides clarity on how to achieve optimum

productivity

• Drives improvements to assets, resources &

processes


Asset utilization improved by 10-20%

“The asset utilization project is already delivering significant

results. We have achieved around 10-20% capacity

improvement globally”.Dan Curry,

Group Manager, Processing Operations,

MMG

Diversified base metals company

which operates & develops base

metal projects across Australia,

DR Congo, Laos & Peru

MMG Limited,

AustraliaStandardization of asset utilization

Edge

control

Connected

products

Apps,

analytics,

and services

Connected

Products

Ampla Operations

Management System

Industry

Edge

Control Schneider Electric Project

Management

Customer Challenge• Outdated analog SCADA system

• Nuisance alarms

• Dependence on external support

The Solution• StruxureWare SCADA Expert – ClearSCADA

• ClearSCADA Mobile System

• Trio Digital radios

Customer Benefits • Simplified troubleshooting

• Reduced maintenance costs

• Integrated diagnostics


80% reduction in external support costs

Number of faults reduced by 66%

Provider of water & sewerage

services to 1.7 million people

and 50,000 business over

4,000 km2

“We used to average 150 SCADA incidents per month.

Within 4 months this had reduced to less than 50”.

Roger Brown,

Yarra Valley Water

Yarra Valley Water Powerful SCADA alarm capability and mobile data

access

Apps,

analytics,

and services

Edge

control

Connected

products

Industry

Asset Management

StruxureWare

Trio Digital Radios

Customer Challenge• Expand daily capacity of water supply

• Provide safe drinking water

• Integrate existing pumping station with new plant

The Solution• Wonderware InTouch® HMI

• Wonderware ActiveFactory™ Software

• Wonderware Historian Software

• Wonderware SCADAlarm

Customer Benefits • Real time reporting has enabled more effective

maintenance during downtime

• Increased water supply capacity

• Historical reporting enabling greater visibility


Increase daily water supply by 75% &

Project ROI of 2 years

Thunder Bay, CanadaCommissioning new water treatment plant in city

Major city in Canada with

population of more than

120,000

“It’s very easy to use. I am able to pull whatever parameters

I need into one trend and see how they’re related and make

better-informed decisions”.

Michelle Warywoda,

Process Engineer,

Bare Point (Partner)

Industry

Edge

control

Connected

products

Apps,

analytics,

and services

Wonderware InTouch

HMI, Historian, Active

Factory, SCADAlarm

Customer Challenge• Harmonize multiple systems over 5 regions

• Reduce operating costs

• Maintain reliability per governmental standards

The Solution• PlantStruxure

• Vijeo Citect SCADA

Customer Benefits • Modular approach lowers TCO

• Reliability ensured through robust TVDA

• Greater operational insight with scalable SCADA


Deployment time reduced by 65%

25% lower engineering costs

Largest Dutch drinking water

company serves 5.4 millioncustomers

“We have a high-performance automation platform with high

reliability and maintainability”.

Doeke Schippers,

Vitens

Vitens, NetherlandsStandardized , cost-effective process automation

Industry

Connected

products

Apps,

analytics,

and services

Edge

control

PlantStruxure

Vijeo Citect

SCADA

Sydney desalination plant with

a 250 million litres per day

capacity supplies water to up to

1.5 million people

Customer Challenge• Integrate renewable energies

• Achieve energy efficiency

• Ensure interoperability of 8,500 devices

• Streamlined project execution

The Solution• EcoStruxure

Customer Benefits • Real-time visibility of operational performance

• Seamless integration of motor control centers

and instrumentation

• 100% of energy consumption offset by

wind power


Energy savings of 1500 MWh per month

Sydney Water Holistic electrical, automation & energy

management

“Solutions to problems were developed within hours rather

than days. Schneider Electric had a sense of urgency, and a

willingness to work with you to get the job done, that you

rarely find with other partners”.

Peter Jones,

Project Director,

Aecom

Industry

Apps,

analytics,

and services

Edge

control

Connected

productsVariable Speed Drives

IP cameras for Security

Switchgear, Transformers

Quantum Unity PLC’s

CitectSCADA

Customer Challenge• Ensure far-flung sites are safe and reliable

• Accurately monitor critical indicators

• Maximise value and time of field operators

• Limit production downtimes

The Solution• Wonderware® IntelaTrac

Customer Benefits • Improve plant availability factor

• Visual inspection of equipment optimized and

standardised

• Identify and anticipate potential problems,

avoiding need for emergency intervention


Plant availability factor of >90%

Infenium, ItalyMaximising plant availability with preventive

maintenance & operational management

Leading company in field of

petroleum additives for lubricant

and fuels, JV between ExxonMobil

& Shell

“Using IntelaTrac has made a major contribution to reaching

a plant availability factor above 90%, since it has integrated

perfectly with the other innovations added to our equipment”.

Mauro Tassistro,

Applications Team Leader,

Infenium International Limited.

Apps,

analytics,

and services

Industry

Wonderware

IntelaTrac

Edge

control

Connected

products

Customer Challenge• Address growing demands in biomedical field

• Integrating complex technology with ultra high levels of

functionality

The Solution• Wonderware System Platform

• Wonderware InTouch HMI

• Wonderware InBatch

• Wonderware Historian

Customer Benefits • Significant cost savings

• Reduced deployment time of products

• Reduction in development time, shortening time to market


60% reduction in capital investment

Xcellerex, USA Achieving cost reductions & accelerating time to market

Leading supplier of innovative

manufacturing technologies for the

fast-growing biopharmaceutical

industry

“Integration of Wonderware’s software has resulted in an

overall reduction in development time of nearly 60%. This

directly impacts customers with reduced costs and shorter

time to market. In fact, we’ve been able to reduce deployment

time from 3-5 years to an amazing 12-18 months. This

results in huge implementation

savings”.

John A. Chickosky,

Chief Commercial Officer & President, Biosystems,

Xcellerex

Apps,

analytics,

and services

Industry

Wonderware

System Platform,

InTouch HMI,

InBatch, Historian

Edge

control

Connected

products

Customer Challenge• Ensure energy efficiency & centralized control

• Reduce costs

• Ensure open platform allowing products from

different vendors to work together

The Solution• Wonderware InTouch® HMI

Customer Benefits • Reduced energy consumption & cost savings

• Energy & money savings

• Solution brought software & development costs to

an affordable level


Total annual savings of $30,000 &

40% savings in energy

Echelon Corp., USANew Building Automation software for HQ

building

Worldwide leader in automation

systems provider for buildings

“Wonderware makes system design much easier and saves

both time and money for our customers”.

Steve Nguyen,

Director, Corporate Marketing,

Echelon Corporation

Building

Apps,

analytics,

and services

Edge

control

Connected

products

Wonderware

InTouch HMI

Customer Challenge• Ensure maintenance planning application is in pace with

growing business

• Ensure the migration to new system is within prescribed

budget

The Solution• Avantis PRO®

• Avantis DSS®

Customer Benefits • Significant cost savings

• Reduced inventory management and purchasing costs

• New system automates maintenance planning and

tracking activities


Approx. cost savings of $2M

CF Industries, USA Upgrading existing system software to improve

structured maintenance

One of the largest manufacturers

and distributors of nitrogen and

phosphate fertilizer products in

North America

“We’ve installed the Avantis DSS solution and it paid for itself

almost immediately. It turns raw data into business

intelligence and that improves our performance”.

Dave Wiedenfeld,

Group Project Leader, IT,

CF Industries

Apps,

analytics,

and services

Industry

Edge

control

Connected

products

Avantis PRO® Avantis DSS®

USA based foam producing

company producing packaged

materials for meats, baked items &

deli foods

Customer Challenge• Maximize speed & efficiency in foam production

• Overhaul outdated and obsolete control

component used in thermoformers

• Invest in new machinery that would be more

capable, more cost-effective & fast to build

The Solution• Magelis G5U HMI

• Lexium LXM52 servo drives

• BMH motors

• PacDrive Controllers

Customer Benefits • Increased productivity

• Easy to use interface

• Integrated and end-to-end solution enables quick

and easy identification of issues

• Access to real-time diagnostics and WW support


70% increase in productivity & 15% cost

savings on machine setup

Commodore Sols., USAIncreasing productivity & reducing overhead costs

“It makes much more sense to have an integrated solution,

which is why we chose Schneider Electric for all the

control components”.

Kurt Bartosch,

Engineering Manager,

Commodore Technology Solutions

Connected

products

Industry

BMH Motors

Apps,

analytics,

and services

Edge

control

Lexium

Servo Drives

PacDrive

Controllers

Magelis G5U

HMI

Zahtjev kupca• Povećati transparentnost proizvodnje

• Upravljati rasporedom operacija u proizvodnji

• Iskoristiti postojeće kapacitete proizvodnje

Rješenje• Wonderware MES performance softver

Postignuto• Ukupna efikasnost proizvodnje(OEE) povećana s

45% na 65% u 2 godine

• Smanjeni prekidi proizvodnje za više od 50%

• Efikasnost proizvodnje povećana za 25%-30%

Rezultat: Life is On sa...

$400,000 u godišnjim uštedama

“Energetska efikasnost je naš

prioritet, ne samo zbog

ekonomskih razloga već i zbog

našeg opredjeljenja zaštite

okoliša”.

Joe Herrick,

Packaging System Manager,

New Belgium Brewing

New Belgium BreweryOdgovor na zahtjev za povećanjem proizvodnje piva

Povećanje kapaciteta pakirnice na

oko 1.3 milijuna barela

godišnje

Customer Challenge• Develop a sustainable environment

• Reduce energy consumption

• Reduce water consumption

The Solution• PlantStruxure solution

• Modicon Premium

• Vijeo Citect SCADA

Customer Benefits • Reduced engineering time for fine-tuning process control

• Decreased production costs


20% in energy savings 38% water savings

700 million bags of Lays,

Ruffles, Doritos, Fritos snacks,

2,700 employees in the plant

“Energy efficiency is a priority for us, not only for economic

savings but because of our commitment to the

environment”.

Matutano Snack Ventures,

S.A., Spain

Matutano, SpainSnack food company reduces energy consumption

Edge

control

Connected

products

Industry

Vijeo Citect

Modicon

Premium PlanstruXure

PowerLogic Meters

Apps,

analytics,

and services

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