Internet of Things Manufacturing Business Value Presentation by Bill Lydon, Chairman - PLCopen North America at the OPC Foundation Information Revolution 2014 Conference held at Microsoft's Redmond Campus. Bill Lydon is an experienced industrial, process control, and building automation professional with technology and business experience including product design, corporate experience, co-founder & president of a start-up company. Bill is an industry consultant, editor of Automation.com and editor International Society of Automation InTech magazine. For more details contact Bill Lydon bill@automationfocus.com 414-704-5004 * LinkedIn: www.linkedin.com/in/billlydon * Twitter: https://twitter.com/wlydon

1. Bill Lydon
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Chairman of PLCopen North America
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Editor of Automation.com & InTech Magazine
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Automation Consultant

2. Entrepreneur
Applications
Hardware & Software Design
Bill Lydon Background
Controls &Automation

4. •
Customer Responsiveness
•
Profits
•
Order Synchronization
•
Supply Chain Synchronization
•
Work In Process Tracking
•
Genealogy & Traceability (TnT)
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WEB Visibility
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Compliance Documentation
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Paperless Systems
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Investment Justification?
Manufacturing systems NOT advancing at the rate of other business systems.

5. ERP
Local HMIs
Automated
Controls
MES/Historians/HMI
Sensor/Actuators
Hardwired, Proprietary; Semi Proprietary
Low Quality Data Sources
Multiple Databases
Historians, Batch Records, LIMs etc.
DUPLICATION
Crude Data
Non-Standard
Low Refinement
Poor Syntax
No Context

6. ERP
Local HMIs
Automated
Controls
MES/Historians/HMI
Sensor/Actuators
Hardwired, Proprietary; Semi Proprietary
•
Duplicated Data
•
Multiple Layers
•
Throughput Bottlenecks
•
Communication Translators
•
Complicated Routing
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Low COTS Adoption
•
Configuration Control Challenges
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Holding back innovation
•
Holding back productivity
Complicated & creates a great deal of cost, ongoing configuration control and lifecycle investment.
Low Quality Data Sources
Crude Data
Non-Standard
Low Refinement
Poor Syntax
Multiple Databases
Historians, Batch Records, LIMs etc.
DUPLICATION

7. Striving for Manufacturing Success
Creative & Innovative Automation
Low labor cost is not a winning manufacturing strategy…
Industry 4.0 Smart Factory Industrial Internet
Manufacturing IoT Intelligent Manufacturing

8. Copyright 2010
Synchronize: Customer, Supply Chain; Manufacturing
Make to Order Manufacturing
Increase Factory Throughput
Increase Quality
Frictionless Communication
Reduce Application Engineering Time
Simplify Enterprise Software Interfaces
continuous real-time business optimization
The Big Ideas: Real-time Digital Factory
Precision & Efficiency

9. Analytics
Macro Level
Processes, Machines & Plants

10. Embedded Computing -Sensors , Actuators, Pumps, Flow Sensors, …
Control & Automation Driving to the Edge
“the internet of things”
32/64 bit CPUs, Integrated Communication (Wired & Wireless),
Embedded Real-time Operating System, Web Server, Email, Web Services
Analytics
Micro Level
Drives, Motor Controls, Sensors, Actuators
Etc…
Macro Level
Processes, Machines & Plants

11. Wider Application Possibilities
Machine •Multi-Process •Multi-plant •Supply Chain •Energy
Methods Understood -Model Based Control * Model Free * Self Learning
Limiting Factors –Processing Power, Communications, & Weak Software Platforms
Analytics
Macro Level

12. Wider Application Possibilities
Machine •Multi-Process •Multi-plant •Supply Chain •Energy
Micro Level
Sensor & Actuator
Embedded Computing -Sensors , Actuators, Pumps, Flow Sensors, …
Control & Automation Driving to the Edge
Refinement Analytics Web Server Email Web Services OPC UA
Methods Understood -Model Based Control * Model Free * Self Learning
Limiting Factors –Processing Power, Communications, & Weak Software Platforms
Analytics
Micro Level
Drives, Controls, Sensors, Actuators, Etc…
Macro Level
Processes, Machines & Plants

13. OP C UA
OP C UA
OP C UA
ERP
Automation & Controls
Sensor/Actuators
OP C UA
OP C UA
the cloud

14. Copyright 2010
P
L
P
L
P
L
P
L
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ISA-95
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ISA-88
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B2MML
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IEC 61131
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MTConnect
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PackML
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OPC UA
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OPC UA ADI
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OPC UA -WITSML
Open Standards Deliver Interoperability
Device to Device and Device to the Enterprise
Enterprise

15. IEC = International Electrotechnical Commission
Founded in 1906 Over 50 participating countries
Common Industrial Control Programming Standard
IEC 61131-3 Global Standard
Founded in 1992 Worldwide
Vendor Independent Not for Profit
Focus –Open Architecture Controls Programming
PLCopen

16. STRONG DATA TYPES
Open Controls Programming Standards
BOOLREAL & LREAL
INTEGERSTRING
TIMEARRAY
VENDOR DEFINED
USER DEFINED
STRUCTURES
Ladder Diagram (LD)
Function Block Diagram (FBD)
Sequential Function Chart (SFC)
Structured Text (ST)
Instruction List (IL)

18. •
Transparent Access
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Transparent Communication
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XML Interchange Standard

19. Goal: to define a set of FBs for UA Client communication
Basis for Machine-to-Machine communication

20. OP C UA
OP C UA
OP C UA
ERP
Automation & Controls
Sensor/Actuators
OP C UA
OP C UA
the cloud

21. Copyright 2010
Synchronize: Customer, Supply Chain; Manufacturing
Make to Order Manufacturing
Increase Factory Throughput
Increase Quality
Frictionless Communication
Reduce Application Engineering Time
Simplify Enterprise Software Interfaces
continuous real-time business optimization
The Big Idea: Real-time Digital Factory
Precision & Efficiency

22. Design
Specification
Risk Analysis
Verification
Coding
Testing
Refining
Integration
Commissioning
Maintenance

23. Design
Specification
Risk Analysis
Verification
Coding
Testing
Refining
Integration
Commissioning
Maintenance
Open Standards Simplify Automation
(Just as it has in other applications.)

24. Mapping between BACnet and OPC-UA
Building Automation Function Block Libraries

25. •
Standard IEC 61131 Programming
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230 Beckhoff BC9000 Controllers
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HMI: Webpage/Internet Explorer
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Ethernet TCP/IP I/O
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27,500 I/O Points
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Room Control via Internet
Use Case: Building Automation
Courtesy of OPC Foundation/PLCopen Member Beckhoff

26. Copyright 2010
Building Blocks
Real-time Digital Factory
continuous real-time business optimization
OPC UA Business Value
Bill Lydon
•
Chairman of PLCopen North America
•
Editor of Automation.com & InTech Magazine
•
Automation Consultant
bill@automationfocus.com
414-704-5004