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
Cost & Time to market
Augmented
Operator
Control Optimization
Asset Performance
Design &
Engineering
Efficiency
Commissioning &
Operation
Availability
Maintenance &
Services
At SE, we focus on three pillars to tap into the potential of IIoT
Augmented operator
Asset performance
Control optimization
What: Empower the operator with the right info
What: Optimize asset use
What: Bring control at the enterprise level
How: Mobile devices, wearable, wireless
How: Analytics, secondary sensing, cloud
How: Local OT autonomy, global IT connectivity
Benefits:
• Worker productivity improvement
• Ready for millennials (knowledge work
automation)
Benefits:
• Unplanned downtime reduction
• Maintenance cost reduction
Benefits:
• Process/Factory productivity improvement
• Energy consumption reduction
Technology Layers Explained
•
Connected Products
The 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 systems
We 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 Services
Our 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.
MOBILITY
CLOUD
SENSING
ANALYTICS
SECURITY
Open data management for seamless IT/OT convergence
Partner ecosystem
Innovation at Every Level in Industries:
EcoStruxure.io
Connected
Products
Cloud i/ili na lokaciji
Edge control
Resource
Advisor
End-to-end Cybersecurity
Apps,
Analytics &
services
Supply Demand
Sustainability
Process
Engineering
SimSci PES
SimSci EYESIM
Pipeline Mgmt Suite
Planning &
Scheduling
Operations
Management
Information
Management
Asset
Management
Operations
Control
Industry
Solutions
SimSci Spiral Suite
Struxureware SDO
Wonderware MES
SimSci APC
Struxureware Operations Ampla
Vijeo 360
Wonderware Online
Wonderware Historian
Wonderware SmartGlance
Avantis EAM
Avantis PRiSM
APMaaS
Wonderware System Platform
OASyS DNA
Citect SCADA
ClearSCADA
Line Performance Suite for F&B
APM for Power
Unit Performance for O&G
Operations Control
Machine Automation
Discrete Process
InTouch Machine Edition
Vijeo D, Vijeo XD
InduSoft Vijeo XL
Prometheus
MachineStruxure
PlantStruxure
Modicon
Touchscreen
Panel
Valve
Positioners
Motor
Starters
Continuous Process
PlantStruxure
Industrial
Sensors
Variable Speed
Drives
Altivar
From machine applications, such as HVAC and pumping, to process automation in F&B, WWW, MMM, and O&G
PowerStruxure
Modicon, Foxboro, Triconex
MCC/PCC
Electrical Panel
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
“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”
OEM Engineer
“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”
“I have many machines, with various purposes, ages… Handling full
history is a nightmare”
End-user line manager
“Replacing parts on my machines interrupts production and should
be optimized”
Maintenance
technician
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
0
1
Web application
Machine info tracking
Lifecycle management
Spare part management
To access key information
about my machine
Architecture
Maintenance / service
logbook
Spare part availability
information
Warranty status of
machine and components
Easy order placement
Machine and components
documentation
Localization of Installed Base
2
3
(For SE components)
TRACK: wireframe examples of user interface
Machine info tracking
Life cycle management
Machine architecture
Asset registration
Spare parts management
Spare parts availability and order options
Machine documentation
Warranty and maintenance log
EcoStruxure for Machines
MONITOR – Value proposition
Needs & Wants of Schneider Electric’s OEM customers and End Users
“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”
OEM Engineer
“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”
Maintenance
technician
“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”
End-user line manager
“Real-time data from my machines is very valuable”
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
0
1
Web application
Machine Raw Data
Analytics on machine
Remote expertise
To access machine
insights through a
dashboard
Live KPIs in visual form
Machine condition analysis
(health, performance,
efficiency)
Advanced analysis to
interpret data and
provide
recommendations
Programmed notifications
(threshold breach)
2
3
Pain points to be addressed by analytics
Analytics
Health
Monitoring
Utilization
Monitoring
Efficiency &
Optimization
•
Anticipate ageing
through use monitoring
•
•
Monitor efficiency
energy, utilization efficiency,
•
Predict failures
based on collected variables
(internal or external), for different
types of failures
•
Optimize
taking into account several
conditions / parameters
Monitor utilization
working time and statistics on
past usage, on-off time, standby time etc.
MONITOR: wireframe examples of user interface
Level 1
Basic monitoring
Level 2
Advanced monitoring
Level 3
Expert monitoring
Dashboard with Raw data and
Notifications
Analytics processed data
Fault, Ageing, Use optimization…
Link with expertise
(OEM – SE) for
-
Notification & Alerts to be programmed
Automatic Report
Diagnostic
Data interpretation
Expert reports
…
EcoStruxure for Machines
FIX – Value proposition
Needs and wants of Schneider Electric’s OEM customers and End Users
“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”
OEM Engineer
“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”
Maintenance
technician
“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”
End User line
Manager
“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?
1
2
3
Mobile App in Augmented
Reality
Maintenance insights
Remote Maintenance
Services
To access insights about a machine
and maintenance help
Step-by-step procedures
(displayed via the app)
Over-the-shoulder expert assistance
Remote troubleshooting
Show me how this looks like: focus on the mobile App
Level 0
Visualization of machine
Point of Interest
Level 1
Self-troubleshooting with
digital procedures
Level 2
Remote expert assistance
Machine PoI
Step-by-step digital
maintenance procedures
Simple access to experts
Real time information
Step-by-step AR maintenance
procedures
Advanced access to experts
(screen sharing)
Level 3
Remote troubleshooting
Remote Troubleshooting
service (ticketing system)
Tunneling to machine
Customer Success Stories
Ash Grove
Cement, USA
Enterprise Planning, Scheduling &
Compliance Management
Customer Challenge
• Automate maintenance data collection
• Improve availability & utilization of production
assets
• Developing standardized solution for 9 separate
production facilities
5th largest cement manufacturer
in the USA with annual production
capacity of >8M tonnes
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...
Industry
Apps,
analytics,
and services
Edge
Edge
control
Control
$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
Connected
Connected
products
Products
Avantis
EAM®
Avantis
PRO®
Avantis VIP
Advanced Sched.
MMG Limited,
Australia
Standardization of asset utilization
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
Diversified base metals company
which operates & develops base
metal projects across Australia,
DR Congo, Laos & Peru
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
Industry
Apps,
analytics,
and services
Edge
Edge
control
Control
The Results: Life is On with...
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
Connected
Connected
products
Products
Ampla Operations
Management System
Schneider Electric Project
Management
Yarra Valley Water
Powerful SCADA alarm capability and mobile data
access
Customer Challenge
Provider of water & sewerage
• Outdated analog SCADA system
• Nuisance alarms
• Dependence on external support
services to 1.7
million people
and 50,000 business over
4,000 km2
The Solution
• StruxureWare SCADA Expert – ClearSCADA
• ClearSCADA Mobile System
• Trio Digital radios
Apps,
analytics,
and services
Customer Benefits
• Simplified troubleshooting
• Reduced maintenance costs
• Integrated diagnostics
The Results: Life is On with...
Industry
Asset Management
Edge
control
80% reduction in external support costs
Number of faults reduced by 66%
StruxureWare
Connected
products
“We used to average 150 SCADA incidents per month.
Within 4 months this had reduced to less than 50”.
Roger Brown,
Yarra Valley Water
Trio Digital Radios
Thunder Bay, Canada
Commissioning new water treatment plant in city
Customer Challenge
• Expand daily capacity of water supply
• Provide safe drinking water
• Integrate existing pumping station with new plant
Major city in Canada with
population of more than
120,000
The Solution
•
•
•
•
Industry
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
The Results: Life is On with...
Increase daily water supply by
Project ROI of
Apps,
analytics,
and services
Edge
control
75% &
Connected
products
2 years
“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)
Wonderware InTouch
HMI, Historian, Active
Factory, SCADAlarm
Vitens, Netherlands
Standardized , cost-effective process automation
Customer Challenge
• Harmonize multiple systems over 5 regions
• Reduce operating costs
• Maintain reliability per governmental standards
Largest Dutch drinking water
company serves 5.4
customers
The Solution
million
Industry
• PlantStruxure
• Vijeo Citect SCADA
Customer Benefits
• Modular approach lowers TCO
• Reliability ensured through robust TVDA
• Greater operational insight with scalable SCADA
Apps,
analytics,
and services
The Results: Life is On with...
Deployment time reduced by
Edge
control
65%
PlantStruxure
Vijeo Citect
SCADA
25% lower engineering costs
Connected
products
“We have a high-performance automation platform with high
reliability and maintainability”.
Doeke Schippers,
Vitens
Sydney Water
Holistic electrical, automation & energy
management
Customer Challenge
• Integrate renewable energies
• Achieve energy efficiency
• Ensure interoperability of 8,500 devices
• Streamlined project execution
Sydney desalination plant with
a 250 million litres per day
capacity supplies water to up to
1.5 million
Industry
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
Apps,
analytics,
and services
Edge
control
The Results: Life is On with...
Energy savings of
people
Quantum Unity PLC’s
CitectSCADA
1500 MWh per month
“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
Connected
products
Variable Speed Drives
IP cameras for Security
Switchgear, Transformers
Infenium, Italy
Maximising plant availability with preventive
maintenance & operational management
Customer Challenge
•
•
•
•
Ensure far-flung sites are safe and reliable
Accurately monitor critical indicators
Maximise value and time of field operators
Limit production downtimes
Leading company in field of
petroleum additives for lubricant
and fuels, JV between ExxonMobil
& Shell
Industry
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
Apps,
analytics,
and services
Edge
control
The Results: Life is On with...
Plant availability factor of
>90%
“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.
Connected
products
Wonderware
IntelaTrac
Xcellerex, USA
Achieving cost reductions & accelerating time to market
Customer Challenge
• Address growing demands in biomedical field
• Integrating complex technology with ultra high levels of
functionality
Leading supplier of innovative
manufacturing technologies for the
fast-growing biopharmaceutical
industry
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
Industry
Apps,
analytics,
and services
The Results: Life is On with...
60% reduction in capital investment
“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
Edge
control
Connected
products
Wonderware
System Platform,
InTouch HMI,
InBatch, Historian
Echelon Corp., USA
New Building Automation software for HQ
building
Customer Challenge
• Ensure energy efficiency & centralized control
• Reduce costs
• Ensure open platform allowing products from
different vendors to work together
Worldwide leader in automation
systems provider for buildings
Building
The Solution
• Wonderware InTouch® HMI
Customer Benefits
• Reduced energy consumption & cost savings
• Energy & money savings
• Solution brought software & development costs to
an affordable level
The Results: Life is On with...
Total annual savings of
Apps,
analytics,
and services
Edge
control
$30,000 &
Connected
products
40% savings in energy
“Wonderware makes system design much easier and saves
both time and money for our customers”.
Steve Nguyen,
Director, Corporate Marketing,
Echelon Corporation
Wonderware
InTouch HMI
CF Industries, USA
Upgrading existing system software to improve
structured maintenance
Customer Challenge
• Ensure maintenance planning application is in pace with
growing business
• Ensure the migration to new system is within prescribed
budget
One of the largest manufacturers
and distributors of nitrogen and
phosphate fertilizer products in
North America
The Solution
Industry
• Avantis PRO®
• Avantis DSS®
Customer Benefits
• Significant cost savings
• Reduced inventory management and purchasing costs
• New system automates maintenance planning and
tracking activities
Apps,
analytics,
and services
The Results: Life is On with...
Approx. cost savings of
Edge
control
$2M
“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
Connected
products
Avantis PRO® Avantis DSS®
Commodore Sols., USA
Increasing productivity & reducing overhead costs
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
USA based foam producing
company producing packaged
materials for meats, baked items &
deli foods
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
Industry
Apps,
analytics,
and services
Edge
control
Lexium
Servo Drives
The Results: Life is On with...
70% increase in productivity & 15% cost
savings on machine setup
“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
Magelis G5U
HMI
Connected
products
PacDrive
Controllers
BMH Motors
New Belgium Brewery
Odgovor na zahtjev za povećanjem proizvodnje piva
Povećanje kapaciteta pakirnice na
oko 1.3
godišnje
milijuna
barela
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
Matutano, Spain
Snack food company reduces energy consumption
Customer Challenge
• Develop a sustainable environment
• Reduce energy consumption
• Reduce water consumption
700 million
bags of Lays,
Ruffles, Doritos, Fritos snacks,
2,700 employees in the plant
The Solution
Industry
• PlantStruxure solution
• Modicon Premium
• Vijeo Citect SCADA
Customer Benefits
• Reduced engineering time for fine-tuning process control
• Decreased production costs
Apps,
analytics,
and services
The Results: Life is On with...
20% in energy savings 38% water savings
Edge
control
Modicon
Premium
PlanstruXure
Vijeo Citect
“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
Connected
products
PowerLogic Meters