Internet of Things - Squarespace · PDF fileProcess optimization for manufacturing ......

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by The Application Developers Alliance Emerging Technology Working Group Manufacturing IoT From the Factory Floor Internet of Things

Transcript of Internet of Things - Squarespace · PDF fileProcess optimization for manufacturing ......

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by The Application Developers Alliance Emerging Technology Working Group

Manufacturing IoT From the Factory FloorInternet of Things

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EXECUTIVE SUMMARY Of all the market segments currently embracing the Internet of Things (IoT), the manufacturing space is leading the way in bridging the gap between operational and information technology (OT/IT) with data analysis and sensors. !Years of building supply chain networks and interconnecting disparate sensor systems have given manufacturing companies an advantage in transitioning toward a broader connected ecosystem where machines, products and processes are measured by sensors and programmable logic controllers (PLC), analyzed for efficiencies and monitored by decision makers. !From a developer's perspective, IoT in manufacturing is very appealing. The groundwork has been laid by manufacturing companies. Factories are more likely to adopt stable development platforms. Successful IoT deployments are often emulated in other manufacturing shops and other industries, such as retail and home, ensuring developers with IoT skills will be in high demand. !Yet manufacturers with historical supply chain strengths may suffer from what business visionary Clay Christensen calls the "Innovator's Dilemma;" where the advances of 10 and 20 years ago are no longer relevant. Massive changes in infrastructure are typically avoided as disruptions prevent production. A factory floor is the lifeblood of a company; no revenue comes in until the product ships, notes Jim Green, Senior Director and General Manager for the Data Virtualization Business Unit at Cisco. !"The rule of thumb in manufacturing is, 'Don't take any risks in the factory,'" Green says. "What you often find is 30-year-old factory equipment that companies must retrofit with new controllers. Implementing new standards that force people to make a change when it's not called for are also shunned. Developers need to be the ones to reconcile and

bridge the gateway between the older and newer equipment.” In a poetic twist, many of the manufacturing plants that use IoT technology as part of their best practices are the same organizations that produce the hardware that helps other companies take advantage of the IoT ecosystem. Therefore, developers adopting IoT into their manufacturing processes have much to teach and much to learn. !In 2014, the Application Developers Alliance and its Emerging Technologies Working Group began identifying five areas influenced by IoT to give developers insight into creating a robust IoT ecosystem. This whitepaper serves as an exploration of IoT by looking at its current state in manufacturing, best practices for creating apps and new opportunities to explore. Other investigations will cover home, retail, automotive and wearables. !INTRODUCTION It seems you can't have a conversation about manufacturing without one good mention of Henry Ford. The American industrialist best known for mass production and assembly line automation continued to streamline his assembly lines even after his workflow processes were copied by other industries. One of Ford's lesser-used quotes, "Failure is simply the opportunity to begin again, this time more intelligently," certainly rings true today when applied to deploying the Internet of Things to manufacturing. !Developers have the true potential to help automate manufacturing plants and their supply chains largely thanks to a mixture of Internet of Things technology such as embedded sensors, radio frequency identification (RFID) tags, sensor array networks, telemetric smart grids, GPS location and other sensor systems. These systems help generate incredible volumes of consumer and supply-chain data and contribute to the more than 2.5 quintillion

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bytes of data created every day, according to IBM research. One of the promises of IoT is to reduce the need for human interaction: Machines will talk with other machines and may make decisions on their own, based on analysis of gathered data, and will adjust processes as needed. It’s called “machine-to-machine,” or M2M, communications. !Process optimization for manufacturing product lines is a key application. Cameras and sensors can be used to ensure objects are in the precise location that allows for a precise build, every time. Over, say, the course of three shifts, seven days a week, they bring the potential to save significant dollars on products that don’t pass quality control — not to mention other costs, such as personnel who don’t have to spend time making corrections. !"I've seen manufacturing plants use IoT for various purposes including as a safety barrier," says Jim Haughwout, the Chief Technology Architect at Savi Technology. "If an employee crosses a line protected with a laser beam, it shuts off the assembly line, for example." !The challenge for developers, Haughwout notes, is that there are as many solutions for manufacturers as there are obstacles to overcome. "The first player that can master multiple instances that will create the optimal IoT experience will be the winner," he says.

BUILDING THE ‘BRILLIANT FACTORY’ Smartphones, smart homes and smart cars have nothing on the next generation of the industrial Internet in manufacturing. Innovative leaders in this space adopt common standards, support R&D best practices, share infrastructure and promote the overall computerization of manufacturing. !

Companies like General Electric (GE) are among those defining this movement towards automated and efficient communication with a mix of new technologies and traditional machines to create what they term as a "Brilliant Factory." !"The ability to put intelligence in the network was limited because historically the capabilities were not there," says Joseph Salvo, Director at GE Global Research. "Intelligence at the edge was expensive those days and the drivers over the last 20 years. But because computers are less expensive than in the past, we are seeing the exponential amount of compute power come to manufacturing in the factory and everywhere it touches." !In Schenectady, New York, for example, GE installed tens of thousands of tiny sensors in a factory that collects data about each step in the manufacturing of a battery. !"The sensors know, for instance, how humid the factory floor was on a certain production day, and exactly how much pressure a machine applied to a particular battery component," the Washington Post reported. "If polymer parts come out slightly thicker one day compared with another, sensors communicate this to the operator, who can examine stats from the two days." !Not all IoT deployments in manufacturing are addressing legacy issues. This past summer, GE announced it would build a new “brilliant factory” in Greenville, South Carolina. The $400 million investment will include some of the latest IoT processes to help monitor manufacturing processes that test the effectiveness of new manufacturing methods such as replacing nickel alloys with a hardier ceramic component in gas turbines. !

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To get developers thinking about different ways to change the manufacturing landscape, GE sponsors a series of developer events. A recent crowdsourcing event asked developers to redesign an engine bracket for a turbine. GE received 700 entries from around the world with the winner of best design doing so to integrate in a brilliant factory. !"As we are installing industrial equipment — things like wind turbine farms, power plants, health care systems — developers have the ability now to integrate all these individual objects, the objects that GE makes as well as other objects, into incredibly complex systems.” Joseph Salvo notes. “And manufacturers can use that computing power at the edge; in the cloud; and at central presences to make real time decisions that you could not make 20 years ago."

HOW WILL IoT WORK FOR MANUFACTURING? There are levels of complexities that manufacturers need to address that other verticals do not have to tangle with. !Let's say you need to embed a sensor in a tractor or a refrigerator. The developer needs to find the right device to fit in the right shape of the space to control that tractor or withstand the cold temperatures of that refrigerator. These challenges tend to require custom sensors and non-standard-based interfaces. So it's up to the developer to make sure they can talk to the sensor. They can control it, they can read data from it, they can normalize data from it, says Mobeen Khan an M2M executive with AT&T Business Solutions. !"The goal for the solution providers like us is to make it as easy as possible for developers to do this," Khan says. "We are putting together these devices - or agents - so that the developer does not need to talk all the way down to the device but it does have the capabilities to work with these devices."

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Don't Know Your Past - Don't Know Your Future While we often talk about contemporary influences on IoT, it is important to acknowledge the shoulders of the giants of technology that have helped modern Web evolve to the state that it is in. 1969: ARPANET served as a testbed for new

networking technologies, linking many universities and research centers

1974: Beginnings of TCP/IP thanks to the U.S. government

1989: Tim Berners-Lee proposes the World Wide Web

1990: John Romkey creates the first Internet ‘device’, a toaster that could be turned on and off over the Internet.

1993: Quentin Stafford-Fraser and Paul Jardetzky create the Trojan Room Coffee Pot, which measured the level of coffee three times every minute and was later monitored online using a web camera.

1998: Scott Brave, Andrew Dahley, and Professor Hiroshi Ishii developed inTouch, a project at MIT.

1999: The Internet of Things term is coined by Kevin Ashton executive director of the Auto-ID Center.

1999: Auto-ID Labs opens which is the research-oriented successor to the MIT Auto-ID Center. The Labs develop the Electronic Product Code or EPC, a global RFID-based item identification system intended to replace the UPC bar code.

2003: RFID is deployed on a massive scale by the US Department of Defense in their Savi program.

2004: RFID is deployed on a massive scale by Walmart.

2008: A group of companies launched the IPSO Alliance to promote the use of Internet Protocol (IP) in networks of "smart objects" and to enable the Internet of Things.

2014: The Industrial Internet Consortium (IIC) was formed to bring together organizations and technologies to accelerate growth of the industrial internet.

(References: Postscapes.com, IIC)

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In the next phase of IT automation, according to TechRepublic author, Mary Shacklett, "multiple factories, logistics providers, etc., will interconnect with each other in a system of people-originated and IoT big data automation - all controlled by a central system 'back plane' that is capable of synchronizing and orchestrating all events throughout the supply chain and giving everyone involved full visibility of what is going on." !Developers must also consider that not everything they need to measure, monitor and control comes with its own IP or a MAC address; that there is another layer involved. !Programmable logic controllers (PLC) are used in automation systems from as complex as nanometer injection mold manufacturing to as simple as an amusement park ride. In these cases, the network is attached to the PLC, not to the hardware itself. The device may be a paint gun or a punch press, but it's the PLC that has the address. !In a very simple sense, a machine would be connected by a PCL through a data transmitter such as a Modbus/RS485 and processed through protocol mapping on a CPU outside the machine. Then the message is delivered through a PubSub (publish-subscription message system) to a separate broker such as MQTT (formerly known as Message Queue Telemetry Transport) which then sends and receives messages to a separate analysis software chain either on premise or in the cloud. !The challenge for developers may come in making sure that the right PLC is connected to the right piece of hardware without having to physically see the connection in the factory. !"If you are building an application for the controller number 35 on Port 5 through a PLC, how do you address that? What happens when somebody plugs it into Port 4 or you need to reprogram the controller?" says Cisco’s Jim Green.

The CIP or common industrial protocol is getting a lot of attention for this reason. The specification is sponsored by Cisco and others as part of ODVA. The international consortium also supports network technologies for the Internet of Things including EtherNet/IP, DeviceNet, CompoNet and ControlNet. !Another common approach involves the use of APIs and the use of web services such as JSON, REST and Ajax-type interfaces. With the standardization of interfaces and being able to absolutely assume that the functionality of that API will be as defined, developers won't have to worry what’s behind it in order to use a service. !While the development can take place at the sensor level, the middleware stack or the analytics platform in the cloud, an emerging practice is to turn to all-in-one solutions so that development is seamless and not cobbled together from different providers. !"We have a tracking platform called Cargo View that is a device that developers can program to use if you are shipping pharmaceuticals or other high-value or sensitive materials," AT&T's Khan says. "With this device, you can read off location, temperature, humidity and other markers whether your package is on land, sea or air and you can track the cargo and all the things around it." !CAUTION AHEAD While it may seem like full-steam ahead for deploying IoT-related technologies in factories, there are other obstacles for manufacturing adoption beyond rudimentary security and privacy. !Deploying IoT solutions in factories may take several weeks to several months depending on the complexities of the manufacturing plant and the needs of the enterprise. Developers need to !

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schedule additional time for integration issues and may be required to redesign user interfaces to make sure the systems are easy to understand and operate. !Because of the ad-hoc nature of manufacturing development within IoT, companies that build custom solutions run the risk of not being able to scale effectively, according to Dan Murphy, Vice President of Marketing at ThingWorx. !"It's fairly common for manufacturers to build IoT solutions themselves," Murphy says. "The first thing they try to do is to use their internal engineering teams to build out their core infrastructure. With that, they are able to start with their 'generation 1' or 'Hello World' type of proof of concepts and build a simple application with a simple repository. However, they often run into trouble when they try to scale this application, apply security models or privacy models against the app in the form of user roles or logins. That's where companies like ours come in and help."

FROM RFID TO SENSOR ARRAYS In an industrial capacity, sensors using Radio Frequency Identification (RFID) are a tried and true technology that are gaining favor with developers with the added value of new IoT technologies. !Tags can be placed on products moving through the supply chain. Inventory and maintenance needs can be tracked, monitored and communicated (if sensors include communications chips) remotely, thus reducing logistics and personnel costs. !Like retail consumer tracking, fleet tracking also had a pre-Internet iteration, using satellites to track vehicle locations. Now, companies can use sensors to measure a multitude of variables, and real-time analytics help to optimize maintenance and route planning, among other things.

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A New Way to Talk to Systems - MQTT The connections between IoT devices or controllers and the backend systems that will read and analyze them have been around for about a decade. One of the more well known is that of MQTT (Message Queue Telemetry Transport). Created by Andy Stanford-Clark and Arlen Nipper back in 1999, the idea was to build a lightweight messaging transport protocol suitable for communication in M2M or IoT. The protocol is currently under OASIS standards review. !In a recent interview, Stanford-Clark says its time to value for a very simple MQTT subscriber going through a transformation to web services HTTP POSTer somewhere is in minutes, maybe even seconds. "It’s very, very quick," Stanford-Clark says. "So, that’s a great tool for developers to be looking at now, and it’s node.js runtime." !MQTT's most significant endorsement came from Facebook, which used the protocol for its Facebook Messenger program. The stand-alone app lets people to send messages 1-on-1 or to groups of friends. Facebook software developer Lucy Zhang noted that the choice to use MQTT helped augment an internal group messaging application called Beluga.  !"With just a few weeks until launch, we ended up building a new mechanism that maintains a persistent connection to our servers," Zhang wrote in a Facebook blog. "To do this without killing battery life, we used a protocol called MQTT that we had experimented with in Beluga. MQTT is specifically designed for applications like sending telemetry data to and from space probes, so it is designed to use bandwidth and batteries sparingly. By maintaining an MQTT connection and routing messages through our chat pipeline, we were able to often achieve phone-to-phone delivery in the hundreds of milliseconds, rather than multiple seconds." !Alternatives to MQTT include XMPP, OneM2M, OMG’s DDS, the AMPQ standard, and the IETF

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Sensors embedded in infrastructure or otherwise located for environmental reports can provide increased situational awareness for companies using tracking techniques — for example, real-time weather reports and traffic updates. But these sensors are also useful in security applications, as for security systems that combine audio and visual monitors with vibration sensors to detect when someone is someplace he or she shouldn’t be. !

The electric utility industry is already employing this type of security system to prevent theft at substations. The vibration sensors, along with infrared sensors, help personnel monitoring the system to distinguish whether it’s an animal intruder or a person attempting to steal copper wire. !Another area of opportunity is in the oil and gas industries. Sensors embedded in the earth could allow resource development companies a more accurate depiction of areas they’re exploring for extraction. Again, in theory, the cost of an elaborate network of sensors would be offset by decreased development costs and increased resource recovery. !IoT IN ACTION AROUND THE GLOBE Developers have many opportunities to automate manufacturing systems with Internet of Things technologies outside of North America. !Spending on IoT technologies in Asia-Pacific alone is expected to reach nearly $10 billion in 2014 and increase to nearly $58 billion by 2020, according to a 2014 Frost & Sullivan report. China, for instance, is planning to invest five billion renminbi yuan (RMB: about $753 million) in the IoT industry by 2015, says Siemens. !China’s largest furniture manufacturer, QuanU Furniture has four large-scale manufacturing bases with more than 20 overseas sales offices and more than 3,000 stores. The company’s export market includes Europe, the U.S. and South East Asia. QuanU Furniture operates discrete manufacturing, meaning its production runs are often high volume and highly complex. !The company worked with Hewlett-Packard to establish full implementation of component level identification and tracking of QuanU Furniture’s products by means of the Internet of Things, barcodes and Radio Frequency Identification (RFID)

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What Part Will Wireless Sensor Networks Play? While it appears that wireless sensor networks (WSNs) are key to allowing objects to “participate” in IoT, thus far there have been delays in widespread deployment because of the disparate and sometimes proprietary nature of the technology. !The Institute of Electrical and Electronics Engineers (IEEE) reports that WSNs seem to be trending away from the proprietary in favor of those based on IPs, using the emerging standard 6LoWPAN/IPv6. While it would be difficult to build an all-IP infrastructure because of the many existing sensors already in place, IEEE believes it’s possible to blend the old and the new and move to an all-IP basis in the future. !In addition, the introduction of low-cost, low-power wireless technology is opening up new avenues for WSNs - and, by extensions, IoT. When sensors consume less power, app developers are no longer inhibited by the need to locate sensors near power sources. And as WSNs become more efficient in power use, possibilities open for “harvesting” energy from sources traditionally thought of as waste heat or light, which is then used to power WSNs. These advancements solve three critical issues that previously had proved to be barriers for WSNs: reliability, power, and cost.

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technology. Hand-held data terminals combined with wireless networks replace the existing manual identification, collation and recording methods. This change increased delivery speed by 25 percent. Error rates declined 95 percent and inventory data accuracy has reached nearly 100 percent. !European manufacturing is also heavily invested in IoT. German industry leaders, researchers, industry association and unions have established what they call Industry 4.0 as the region's mandate for intelligent automation and standardizing machine safety and production. !For example, Bosch Rexroth business in Lohr am Main, Germany supports a Cyber-Physical Production System (CPPS). The automation independently controls required maintenance and repair services of eight machines in the Bosch Feuerbach plant from Berlin or somewhere else in the world. If necessary the Remote Condition Monitoring (RCM) may trigger actions such as ordering spare parts or informing technicians about further actions that have to be taken. Separately, the Bosch Plant in Homburg - Southeast of Luxembourg - connects multiple partners in the logistic value chain with an RFID-based Automotive Network. !IIC has also launched a two-year project creating a track and trace test bed. The goal is to manage handheld power tools in manufacturing and maintenance environments.  !IoT DEVELOPERS GET INVOLVED Conventional wisdom suggests the best way for developers to get involved in IoT development for manufacturing is just to pick up a Raspberry Pi or an Arduino starter kit and do something. !"I think it’s really important for developers to get their hands dirty," IBM's Stanford-Clark says. "Write some code one weekend or one evening; try it out. Get your device

publishing an MQTT stream back to some broker somewhere, and just understand the implications of when connectivity goes away, when battery life runs out, when the amount of memory on a device is genuinely restricted rather than assuming gigabytes of storage and gigabytes of disk spinning in a device when it’s just a little chip the size of your thumbnail that’s hanging on the end of a bit of wet string, and send a transactional message over that, to say that something important happened."

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Intel Inside Your IoT: The company that powered nearly every desktop and server on the planet is at it again with the development community. This time, they are proving a modular system-on-a-chip and software for those building Internet of Things products. !The Intel® Edison development board is about the size of a stamp with a reduced power package for building small devices - including wearables, robotics, and IoT. The board includes a dual-core, dual-threaded Intel® Atom™ SoC at 500MHz and a 32-bit Intel® Quark™ microcontroller at 100 MHz. It supports 40 GPIOs and includes 1GB LPDDR3, 4 GB EMMC, and dual-band Wi-Fi and Bluetooth LTE. !The Intel® Galileo development board is Arduino Uno R3 Shields compatible and connects with a host of industry standard I/O interfaces, including a full-sized mini-PCI Express slot, 100 Mb Ethernet port, microSD slot, USB host port, and USB client port. The processor board includes an Intel® Quark™ SoC X1000, a 32 bit single-core, single thread Pentium® processor instruction set architecture (ISA)-compatible, operating at speeds up to 400 MHz. !The product span includes soil moisture sensors, interactive light fixtures, and even the wearable 'Synapse' Dress. !Intel, the Intel logo, Pentium, Atom, and Quark are trademarks of Intel Corporation in the U.S. and/or other countries.

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!Various government agencies and standards consortiums are also putting out the big call to developers to help out the manufacturing industry. !This past June, the U.S. National Science Foundation (NSF) announced its support of a CPS-centered research project called RoseLine. The goal is to develop new clocking technologies, synchronization protocols, operating system methods, as well as control and sensing algorithms. !The non-profit trade association IPC (a.k.a. “the Association Connecting the Electronics Industries”) recently initiated CAMEST (the Coalition for the Advancement of MicroElectronic Systems Technology) as a way to identify critical technology for furthering development in the electronics manufacturing industry. The standards-developing organization is adopting IoT standards for items such as design, printed board manufacturing, electronics assembly and testing. !The Industrial Internet Consortium hosts a series of meetings and started reaching out to developers at the Internet of Things West Conference, in Las Vegas this past November. The Digital Manufacturing and Design Innovation Institute launched this year to create a model simulation environment that connects to the real world in Chicago. The collaborative effort includes more than 500 supporting companies and organizations, 40 industry partners and upwards of 30 academia, government and community partners. The initiative includes using IoT technologies to measure wind turbines, heath care machinery and transportation manufacturing such as measuring the effectiveness of wind speed and fuel efficiency using different angles of the blades.

TIME FOR ACTION The time for developers to get involved could not be better. Companies in Asia-Pacific are expected to invest $9.96 billion in the Industrial Internet of Things in 2014,

according to Frost & Sullivan. As previously noted, that number is expected to rise to $57.96 billion by 2020. !"The Internet of Things for manufacturing is a wide open field and it depends on what part of the ecosystem you want to play in," says Alec Saunders, Technology Ecosystem, Platform and Developer Relations Leader. “In factory automation systems there is a lot of innovation that can be done on factory floor, but there is also room for innovation in supply chain and inventory management, and many other areas. There is really no one-size fits all solution." !In one instance, Caterpillar’s mining division Aquila has installed more than 35 surface mine control systems in more than 20 different coal, iron, copper, and gold mines in Canada, the U.S., Australia, South Africa, and Russia. Aquila’s managers used the QNX Neutrino RTOS to be an extremely robust and stable platform and credit it with being a significant factor in the success of their product. !Elevator manufacturer ThyssenKrupp has leveraged IoT to dramatically change the game in elevator reliability through predictive and even preemptive service. !Chipmaker Intel used IoT technology to save $9 million. At one of its Malaysian plants, Intel's CPU-based tester models in semiconductor manufacturing line were redesigned with sensors. The data was then sent to Mitsubishi Electric C Controller gateway devices all powered by Intel Atom chips. !These examples of IoT in manufacturing illustrate how, "the cycle of production can be analyzed and made more efficient. At any scale the end value is making more money from improving processes and saving people’s time," says Mike Maas, a Technical Evangelist at Cisco. !As factories are optimized, the beautiful design of IoT interoperability will allow developers to link factories with energy providers, cities and ultimately consumers. !

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"It's great to know where your delivery trucks are, but if your factory is really tied to energy and smart city systems, you can use telematics to prevent workers from standing around, leaving the lights on and waiting for a truck that is running late. As connected systems come together, analytics from a previously isolated system will influence efficiency of the others in new and useful ways," Maas says.

CONCLUSION Analyst firm Gartner placed Internet of Things at the apex of its hype cycle for emerging technologies in 2014. But don't let that stop you. !"The 'gee wow' factor or daily factor of IoT can really play up the hype around IoT," says Savi Technology’s Jim Haughwout." As developers, it's important to create not just a set of standards but a markup language so you can share information; sharing information from server to devices and devices to other devices. Contribute to the overall picture so can we build a common lingua franca." !When it comes down to the rational for building systems that tap into the Internet of Things for the manufacturing marketplace, developers should always ignore the news and focus on the pain points of the customer. !“IoT is still in the early days and there isn’t a set of universal standards yet. Therefore, finding specific customers and specific customer problems becomes even more critical,” says Alec Saunders. !As for the future of the Internet of Things, more standards and best practices are expected. “We are seeing many framework attempts and as a result, coming to common use cases, feature sets and needs that any massively deployed device set would require,” says Corey Plender, Director of Solution Sales & Architecture at Bosch Software Innovations. !

Innovations that are built today will surely pave the way for more efficient manufacturing. !"Adding IoT to manufacturing makes sense because you can pull data from the M2M asset just as another source of input. When that is put into a central point and you have all your data in one place, it is extremely valuable for manufacturers and stakeholders across the value chain," says Plender. !ONE IN A SERIES This whitepaper is one of a series of documents designed to help developers understand the many facets of the Internet of Things that are connecting to the Internet. The series begins with an introduction and each of the papers focuses on a vertical marketplace such as automotive, manufacturing, wearables, home, and retail. The papers include a review of available standards, opportunities for exploration and individual growth, as well as specific calls-to-action that developers can immediately use. !ABOUT THE APPLICATION DEVELOPERS ALLIANCE The Application Developers Alliance is a non-profit global membership organization that supports developers as creators, innovators, and entrepreneurs. We promote the continued growth of the industry and advocate on behalf of our members on public policy and industry issues. The Apps Alliance serves a growing membership of tens of thousands of developers and hundreds of companies including: mobile app publishers, platforms, wireless carriers, hardware manufacturers, ad networks, enterprise tools and service providers.

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