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Maximize profitabilitythrough actionableinsights from your data.Data Services @ FACE -23 to 24th Jun2016

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Digitalization : The future of Manufacturing

From Industry 1.0 to Industry 4.0

1800 1900 2000 Time

Degree ofcomplexity

FirstIndustrialRevolution

SecondIndustrialRevolution

ThirdIndustrialRevolution

FourthIndustrialRevolution

First mechanical loom, 1784

First conveyorbelt, Cincinnatislaughterhouse, 1870

First programmablelogic controller (PLC)Modicon 084, 1969

based on the introductionof mechanical productionequipment driven bywater and steam power

based on mass productionachieved by division oflabor concept and the useof electrical energy

based on the use ofelectronics and IT tofurther automateproduction

based on the use ofcyber-physical systems

Repair shops Standardization / Processknowledge

SoftwareUpdates

Data Driven Services


Data is the key to the future of manufacturing

Really

“Big Data”The volume of datais increasingexponentially

The datacollected canbe used tocreatevaluableinsights


Internet of Things (IoT) technology is being widely adopted

By 2020estimated

5.4 BillionDevices will beconnected toIoT.

Source: Gartner


Product Innovation

Industry 4.0 is set to revolutionize manufacturing

Main pursuits of Industry 4.0 are

Increased Collaboration

Operational Process Enhancement

Cyber-Physical Production


With data Siemens can help you to..

Data Services- Intelligent, Simple & EconomicGet a running start on the future of industry – with Siemens Plant Data Services

Enhanceindustrialsecurity

Optimizeenergy

performance

Masterasset

uptime

Maximizeprocess

efficiency

We understand:

monitoring and analytics capabilityfor critical applications plant-wide

We know:

expertise in core systems / componentsof critical industrial applications.

We integrate:

technical integration of monitoring-functionality in sub-systems and OEM-equipment.

We act:

reliability and up-time-centeredcustomer care.

We protect:

ensured industrial IT security standards.


Industrial Network validation & Analytics

Control Performance Analytics

Siemens Offers

Energy Analytics

Drive Train Analytics

Customer

Siemens


Mea

sure

men

t

Production

Line 1

Line 2

Con

sum

ptio

n

Prod

uctio

n

Wasted energy

21th14th7th 28th

MonitoringAction

Achieve transparency Realize savings Enhance efficiency

Your Benefits

Improve transparency of your energyconsumption via basic analytics anddashboard views

Improve energy efficiency and reduceenergy costs

Improve process efficiency, quality and outputby implementing measures based onadvanced data analytics

Assess energy data at yourfingertips

Identify hidden savings potential withadvanced analytics

Enhance business results by reducingoperation costs

Optimization

Energy Analytics at a glance


Siemens Answer to Industry -Energy AnalyticsSimple, intelligent & economic solution


Energy Analytics addresses all levels of metering………


Real solution -Switching from time-based to efficiency-based controls

Saving Potential%

Current

Analytic Workflow: Controls Optimization

1 | Identify current control scheme tomeet target production

2 | Identify regions of economicallyefficient operation

3 | Optimization: Identify economicaloptimal control scheme

Time of day Time of day

Aver

age

Ener

gyC

onsu

mpt

ion

Aver

age

Ener

gyC

onsu

mpt

ion

Ener

gyC

onsu

mpt

ion

Compressed Air Production

Estimatedconsumption

4 | Verify savings and identify how operations can be optimized into the future

Compressor 1 Compressor 2 Optimized Compressor 1 Compressor 2

Pastconsumption


Case Study 3 - Paint Shop Energy Management

1*

3*

3* Water1* Gas or HSD



Energy Analytics

Siemens Offers



Customer

Siemens


… only 50 % of control loops are well tuned1)

Optimized control loops save you money without newinvestments

Control Loop Monitoring of all control loops addsvalueto your PCS 7 system

Control Performance lies at the Heart of Your Process Plant

1) Source: Control Engineering


Increased Product Quality

Optimized Process EfficiencyProcess Data Analytics

Minimize Equipment Utilization

Increased Throughput Reduced Work Load

Maximized process efficiencyProcess safety - Throughput - Quality - Raw Material - Energy - Equipment Utilization

Reduced variability in processimproves product quality

Improved set point limits increasesthroughput

Reduced variability in actors forminimized equipment utilization

Reduced alarms and fewer operatorinteraction reduce operators' workload

Production start

Pro

cess

-Ala

rms

Ope

rato

rIn

put

Nom

inal

Val

ues

Production start

Pro

cess

-Var

iabl

es

Production start

Act

uatin

gV

aria

ble

Production start


Cost efficient through Managed Service ApproachProcess Data Analytics

Customer

Siemens

Visualization andrecommendations

Secureconnection

Data analytics andsimulation

Consulting andimplementation support

Secure connection

Data combinationand secure storage



Energy Analytics

Our Portfolio



Customer

Siemens


Industrial network as a critical assetWhat is your top current priority?

How can I maintain reliabilityand still be flexible?

How can I be more effectivein my network maintenance?

How do I identify network healthand anticipate network behavior?

How do I preventnetwork failures?


Main failure scenarios within industrial networks

Failed robustness

Device misbehaviorat high load

Bad network communicationsquality

• Traffic overload

• Cycle time, jitter

Incorrect Planning andparameterization

Design problems of controller ordevice

Loss of transparency, loss of production and asset malfunctionConsequential losses

Ramp-up phase Operational phase

Sporadic failures

Sudden abnormalityin the network

Firmware problems

Increasing device mal-functions andsecurity incidents

Network changes(topology and use)

Increasing network load


Services across the lifecycle of industrial networks

Check and certify roboustness ofPROFINET/PROFIBUS networksThrough hardware check, physicalnetwork build, data communicationcheck, compliance with PNOregulations

Supervise & diagnosestability in PROFINET/PROFIBUS networksContinuous, remote monitoringof status, KPIs (cycle time,network- load, events etc.)

Industrial Network Validation Industrial Network Analytics

Your Benefit – Smooth production ramp-upIdentify defects in planning – Rogue planning and parameterization defects in networksIdentify defects in HW – Such as cables, active and passive networks componentsCompare to PNO standards – Know to what extent approval standards of PNO are met

Your Benefit – Increase network availabilityCentralized monitoring – For quicker and efficient reaction by maintenance staffHighest transparency – Identifying bottlenecks in network communication beforehandImmediate expert support – For faster localization of root causes in networks


Network Validation @ Saint Gobain Gyproc India Ltd, Bangalore

Challenge

Customerbenefit

• No shutdown time available.

• Having a failure-free network was still achallenge.

• Siemens provided answers to Saint Gobain’sproblems with Profibus Network validationservice.

• Network architecture - 7 different networkshaving 140 slaves.

• Improve network stability, availability &reliability, thereby avoiding production loss dueto network failures.

• Increase the signal strength throughout thenetwork by up to 100%.

Solution

Situation • SOx and NOx emissions reduced by more than 90%

• Availability and reliability of networkinfrastructure.

• Network installations done by differentvendors

• To achieve network stability, speed wasreduced in key areas


Transforming data into actionable insights – from field equipment to userIndustrial Network Analytics

Siemensoperationcenter

Systemintegrator/OEM

Private cloud

OfficePlant

Internet

PlanningMaintenance

Network service station

SINEMA server

Bus analyzer agentsAsset


Sample dashboards – Instant advice based on historic data and onlineanalyticsIndustrial Network Analytics

Overview of more plants andnetworks

Status about all sub-networks of onesite

Exact identificationof all notifications

Easy access to all current and historicaldevice data (switch load, port load…),trend views

Übersicht über Teilnetzwerke


Industrial Network Validation and AnalyticsUSPs

Validation

Siemens is the only provider of simulated stress tests forindustrial networks

Analytics

Simple depiction of network diagnostic information

Proactive context feedback provided by Siemens experts

Reactive (on-demand) cRSP feedback provided by Siemensexperts (ad-hoc )

Decision-making support at all levels (from users to management)

Expertise in hardware, software and cloud-based services

Simple integration into existing automation systems

Exceeds requirements of PNO regulations regardingPROFINET telegram transmissions under stress loads

Field devices checked for availability under stress loadsonline



Energy Analytics

Our Portfolio



Customer

Siemens


A Managed Condition Monitoring Servicebased on Online Data Collection and Analytics


Reduce forced outage downtimesDrive Train Analytics

• Reduce unplanned production losses• Accelerate issue resolution• Improve availability centered operation and maintenance

planning

Customer drivers and goals

• Accurate operation history for better root cause analysisenables reduced forced outage downtime

• Increasing operational efficiency in maintenance planning &execution through immediate asset transparency

• Optimize maintenance planning by early detection of patternsthat may cause anomalous behavior

Why it is worthwhile!

Siemens offering

• Trend-setting Managed Service Platform• Siemens Expert Network for fast problem analysis and

solving• Vast industry knowledge directly from the manufacturer

of drive train components up to whole plants• State-of-the-art IT security

Why Siemens?

Onlinedashboards

+ + +ReportsNotifications

and warningsData

assessment


Sandeep BardeData ServicesSiemens LtdKalwa Works,Thane-Belapur Road,Airoli NodeNavi MumbaiPhone: +91 (22) 39663023Mobile: +91 9930765543

E-mail:[email protected]

Thank You!!

www.siemens.com/plantdataservices

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