For analog environments, i.e. environments without smart devices, it is important to start by defining the possibilities that can be easily implemented, to then serve as a proof of concept in order to prove the advantages. One can think for example of intelligent alarms or interfaces with existing equipment, serving to provide information facilitating operations and maintenance. The important thing is to keep it simple and prepare a roadmap that takes into account factors such as scalability, cybersecurity, capital and operating costs, training and change management.
Even for sites already equipped with smart devices, new sensors and instruments with diagnostic, health and performance indicators are now available and can be used to provide warnings and prevent outages and service interruptions. By deploying field and communication devices as well as additional infrastructure, the understanding of equipment and operations will be improved thanks to the data and analyzes provided.
This information can be used to develop digital twins, augmented reality, and other visualization options that promote efficiency and reliability. Even when already using programmable logic controllers (PLCs), distributed control system (DCS) or integrated management software (ERP), relevant data that was not visible in the existing control system will then most likely be put in light. Thanks to Industry 4.0, it is possible to collect and enhance additional information in order to transform it into prospects.
SaaS or outright purchase
Many products, including software, have moved to the “as-a-service” model, which involves a subscription rather than an outright purchase. This model has a number of advantages, such as access to a technological infrastructure with a low entry cost. This reduces initial capital expenditures and spreads them over predictable and consistent operating expenditures, year after year, based on the lifespan of your critical assets and equipment.
When subscribing, the software provider (and not IT or technical departments) is responsible for maintaining and upgrading the system. And since these systems are based on a cloud environment, disaster recovery will require minimal effort compared to recovery in an on-premises solution.
The Value of Data Capture
There are many ways to leverage data to save time and money. One of the most common is preventing unplanned downtime and associated costs due to lost production and reallocation of resources.
Other costs relate to the repair and replacement of equipment, from vibration analysis on motors and actuators to corrosion of electrical gears due to environmental conditions. In these cases, circuit breaker condition monitoring can be used for predictive maintenance, for example.
Use the cloud to organize data and make sense of it
The cloud enables operations to be optimized through data analysis, pattern recognition, classification and adaptive techniques to put data into context and gain insights that can then be converted into actions . While not new, artificial intelligence and machine learning tools are becoming mainstream in cloud services.
As a result, we have moved away from extensive programming towards adaptive models. However, complex problems will always require data scientists and developers. For example, data from sensors and actuators can be correlated to determine setpoints and production parameters, enabling tighter specifications, reduced weight and fuel and energy consumption, etc. .
With data, it is important to think about transparency and interconnectivity. For system users, it doesn't matter where the data resides as long as they can access it anytime, anywhere, and in the appropriate format, resolution, and detail. Having a central repository can therefore help bring data together and provide programs for users to act on it.
Cybersecurity and vulnerabilities
Many businesses wonder if the cloud is a safe place to store and manage their data. While the answer is generally yes, it depends on many factors, including proper hardware design using firewalls, network segmentation, managed devices, and limited access to premises. On the software side, this involves antivirus and malware defense programs, data backups, encryption, multi-factor authentication, proper certificates, data protection and permissions, and vulnerability scans. .
In conclusion, there are many factors to take into account to calmly and effectively approach Industry 4.0. It's also important to find a solutions provider who can help you identify opportunities for improvement and advise you on which tools and technologies to focus on. But with an adequate view of the information needed to improve business operations, it is certainly possible to deploy digital innovation to its advantage.
Tribune by Arnaud Laugier, Marketing Director at EATON