NOV-DEC 2018

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18 INTECH NOVEMBER/DECEMBER 2018 WWW.ISA.ORG PROCESS AUTOMATION For example, a pump will break at some stage. We know how much pressure the pump generates at a given power consump- tion. An experienced employee keeps an eye on these values and knows that when power consumption rises, the pump will break in the near future. It is easy to monitor these two values (power and pressure) and trigger an alarm in your central con- trol system to signal that maintenance is needed. Looking forward: Will the process industry fully embrace Industry 4.0? Industry 4.0 will free humans from having to compete with machines, especially on speed and quality in repetitive tasks. Instead, we can take advantage of human strengths like creativ- ity, innovation, imagination, intuition, and ethics to full effect. But there are many small steps along this Industry 4.0 journey. Work with existing systems and architecture A form of IoT already exists in process industry plants, and even in discrete manufacturing assets like molding lines or die cast- ing cells. "The Internet of Things (IoT) is the network of physical devices and other items embedded with electronics, software, sensors, actuators, and connectivity which enables these things to connect, collect, and exchange data." (Wikipedia) In the past, to record a new measurement, you had to pur- chase expensive hardware, wait for a shutdown, wire it in, re write the control program, test the code in simulation, load the new program, and hope that the change did not reduce productivity. Because of the costs and risks involved, updates like these were rarely done, resulting in many missed oppor- tunities to optimize processes to decrease costs and increase profit margins. Integrate IoT devices IoT devices are comparably cheaper and easy to install, cus- tomize, and update. They can communicate with data col- lection systems without the need to run cables and rework production lines. The true power of IoT devices is to enhance data collection capabilities without disrupting production. Enhance existing data collection In edge computing , computation is done by the device (the sensor or actuator) itself or by a nearby computer system and not in a remote data center or the cloud. You can use edge computing with existing technology like DCS/SCADA and historian/MES systems. Existing infrastructure like DCS/SCADA and historians is valuable, well designed, and reliable. They belong in any Industry 4.0 architecture, but they are not designed for real-time analysis of data to iden- tify patterns. Edge computing working with these existing systems can analyze patterns and trigger actionable states, such as alarms. Implement data analytics, AI, ML, and digital twins As Greg Hanson, CTO and vice president at Informatica, put it, "If you put garbage [data] in, you'll get garbage [data] out." Too many companies fail to use data analytics effectively Engineers Sensors Actuators Robots Drives Level 0 (productionprocess) Level 1 (basic control) PLC, CNC, HMI, robot controllers Central control Level 2 (area supervisory control) IIoT devices Production data Data gateway Horizontal integration Edge computing Level 3 (site manufacturing operations and control) All production data necessary for higher-level processing Product tracking and genealogy Historian (data collection acquisition) Unit dispatching and labor mgmt. Quality mgmt. Resource allocation and status Performance analysis Process mgmt. (c)-MES Vertical integration LIMS CMMS WMS Level 4 (site business planning and logistics) Only necessary production data for site- and enterprise-level applications Edge/site data warehouse Edge applications "Top floor" users Level 5 (enterprise network) Only necessary data for enterprise-level applications Enterprise data warehouse Enterprise users Enterprise services (R&D, PO, ProjM, IT, SC, CC HR, CAD) WWW and cloud Cloud-based enterprise services (PLM, CRM, ERP, HRM, SCM/SCP, PDES) Cloud data analytics, business intelligence,machine learning, artificial intelligence Possible Industry 4.0 architecture based on ISA-95

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