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IIOT-IN-A-BOX: Applicazioni di Internet of Things per l’automazione industriale

Le piattaforme di IoT su cloud connettono in tempo (quasi) reale il mondo fisico con quello digitale con il fine di ottimizzare le operazioni.
Questo intervento si avvarrà di un kit dimostrativo di due casi d’uso, uno di telemetria industriale su cloud e uno di riprogrammazione di PLC in produzione via cloud. Entrambi i casi sono significativi per diverse applicazioni industriali, quali servopresse, termoforatura, macchine per stampaggio plastico, la lavorazione del legno, robotica e simulatori

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SAVE ottobre 2015 workshop

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Veronafiere 27-28 ottobre 2015 Gli atti dei convegni e più di 6.000 contenuti su www.verticale.net Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilità 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com 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: pm-global@eurotech.com Rev.: 2.0 IIOT ' INDUSTRY 4.0 ' SMART FACTORY '
''The integration of complex physical machinery with
networked sensors and software ' to optimize
operations
'
Industrial Internet of Things Fabbrica Intelligente Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com Rev.: 2.0 Due mondi che si avvicinano m2m IoT Machine-learning Big Data Cyber-Physical System IIOT OT IT MES ERP SCADA /PLC Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com 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: pm-global@eurotech.com Rev.: 2.0 Non solo in fabbrica: «Non abbandonerai
più il tuo prodotto
» Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com 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 nel a 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: pm-global@eurotech.com Rev.: 2.0 IIOT: ne abbiamo davvero bisogno '
Potenziale Manifatturiero = Valore produzione -------------------------------- Grado utilizzo impianto Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com Rev.: 2.0 Innovazione = Risolvere la complessità @ Business
Applications
Sensors,
Actuators,
HMI, SCADA,
PLC
Multi-
Service
Gateway
' Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com 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: pm-global@eurotech.com 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: pm-global@eurotech.com 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 model i comportamentali testati. 36 Industry Specific Solution: Predictive Maintenance & Quality Eurotech Group '' Product Management '' Contact: pm-global@eurotech.com 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: pm-global@eurotech.com 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: pm-global@eurotech.com 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: pm-global@eurotech.com Rev.: 2.0 I clienti riportano i seguenti benefici 5% '' in aircraft-on-ground events 1% '' in overal maintenance costs 97% ability to predict delays & cancellations within 12 weeks 25% '' in overal 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: pm-global@eurotech.com 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, specifical y: 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: pm-global@eurotech.com 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 chal enging 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, al owing 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: pm-global@eurotech.com 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. Specifical y 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: pm-global@eurotech.com 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: pm-global@eurotech.com Rev.: 2.0 www.eurotech.com Grazie ! www.ibm.com


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