Next Dimension IIoT Presentation

Next Dimension
Business Impact of Smart Manufacturing
Presenter: Robert Mercier
Senior Network Services Lead
rmercier@ndinc.ca
www.nextdimensioninc.com

Case Study – Preparing to migrate from traditional manufacturing to ‘Smart Manufacturing’

First - What is ‘Smart Manufacturing’ or ‘Industry 4.0’ ?
Physical Systems
+
Increased Automation
+
Internet of Things (IoT) or Industrial Internet of Things (IIoT)

Are Smart Manufacturing & Industry 4.0 the same?
Smart Manufacturing Industry / Industrie 4.0
Generic term based on modern business practices Viewed as 4th Industrial Revolution
Industry initiative and coalition formed Government concept started in Germany by GTAI
Technology as an enabler for humans Machine Learning and Full Autonomous Systems

According to the National Institute of Standards and Technology (NIST) Smart
Manufacturing are systems that are:
“fully-integrated, collaborative manufacturing systems that respond in real time to
meet changing demands and conditions in the factory, in the supply network, and
in customer needs.”

INDUSTRIE 4.0 represents a paradigm shift from “centralized” to “decentralized”
smart manufacturing and production.
https://www.gtai.de/GTAI/Navigation/EN/Invest/Industries/Industrie-4-0/Industrie-4-0/industrie-4-0-what-is-it.html#1798424

How do businesses get ready for
‘Smart Manufacturing’ ?

How do businesses get ready for ‘Smart Manufacturing’
• Bringing the data from the 1960’s up to date….
• Most machines operate on PLCs (Programable Logic Controllers)
• First PLC was made in 1968 - Modicon 084 PLC (Modicon is now a division of Schneider Electric)
• PLCs typically use Ladder Logic
• CPU Check – I/O Module Check – Scan Input – Execute Program – Update Outputs – Repeat….
• Mostly use syntax that is basic – AND, OR, NOT, etc.
• PLC’s are slow and typically can handle at max 128K packets per second or 1,000 messages per second
BUT – PLC’s are reliable, durable and aren’t going anywhere anytime soon

• Bringing the data from the 1960’s up to date….
• PLC’s talk to ERP and MES (Manufacturing Execution Systems) systems through OPC (OLE for Process Control; or
more commonly now know as Open Platform Communications)

• Ok, I now have data output from the PLC in my machine to my plants MES running on a modern server that can do
317,900,000,000 instructions per second, versus the 128,000 on a PLC.
• Now what?

• Gather more information about your business – how does your business TRULY operate now
• Find what are the processes that are hidden from your operational flow charts
• Ask the people that actually build the products, machines or widgets what they wish they knew
• Identify anything that could be a fluctuating cost in your production process
• Find out what information your customer(s) make available to now, or could make available to you by asking
• Are you making something today that you will ship next month instead of when you could be making more of
something your customer would buy today and want shipped by tomorrow?
• Find tasks that are prone to manual errors
• Ask - who, what, when, when, why and how for your shop floor, sales, shipping, receiving, accounting, human
resources, etc., etc. over and over….

How do you gather that information

Challenges your business will face on it’s IIoT journey
1. Security
2. Standardization
3. Corporate Silos
4. Migrating to a data-centric business model
5. Device management
6. Power Efficiency
7. Acquiring Talent and Expertise

1. Security
Machines as a service, or machines with remote support contracts will mean third party vendors will require
access into your corporate and plant networks
• Using your VPN software to allow your contractor into your network is not enough
• Using their ‘firewall’ on their machine is not enough
• Using a separate Internet connection is not enough
• GoToMyPC, LogMeIn & TeamViewer are the enemy

2. Standardization
• How vendors get into your network
• How you label cables – critically important
• Active Directory OU’s, GPO’s, Service Accounts, etc.
• IT Inventory – When possible - OS, PC, Switches, Printers, Wireless
All Windows 8 or 10
All Vendor ABC, i.e. Cisco IE Series or Catalyst 3560-CX/2960-CX
All Zebra, Brady, or Honeywell
All Vendor ABC, i.e. Cisco 2800e / 3800e

3. Corporate Silos
Automation / Controls Groups
Vs
Corporate IT

Excuses you will hear:
• Cause we’ve always done it this way….
• We don’t need to know that….
• The data must be wrong….

Things you should focus on:
• Incorporating the insights you gain from the data into your day to day business
• Not only what your business does today, but what could be an entirely new business opportunity tomorrow
• Have a data strategy – What, Why & How
• Get the data to the right people

5. Device management
• Management will be more difficult if you run multiple shifts.
• You must stay on top of patches and updates.
• With more devices and data means IT systems will be bigger than they
are now – more of everything.
You will have more devices than you do now...

6. Power Efficiency
• Centralize UPS devices
• don’t install dozens and dozens of UPS on the shop floor; plan ahead and centralize.
• Use double on-line / real-time UPS devices for better protection
• Utilize Power over Ethernet
• Utilize Energy Efficient Ethernet
• Do you need a full PC or will a tablet, Thin Client or Zero Client do?

7. Acquiring Talent and Expertise
The ‘IT guy’ that knows everything is no more,
it is a myth, and does not exist in the IoT world.
Find width and depth in your technology group
because there are as many disciplines in IT as there
are in the medical industry.
Cross train staff, but still ensure you have specialists
that are experts on your technology.

How we helped one of our clients make this change at two facilities

Improved Infrastructure
Previous Plants (Before) New Plants (After)

Previous Network Current Network
• Single power supplies on all switches
• Single fibre connection to all switches
• IDF’s placed anywhere there was a new need
• Poor wireless coverage
• One giant flat network
• Getting remote access for a third party took
weeks to arrange.
• Single MDF for core of network
98% Availability for the last year of operation
• Redundant & hot-swap power supplies on all gear
• Diverse, armoured and redundant fibre to all IDFs
• Proper IDF grid layout ensuring < 100m everywhere
• 100% wireless coverage with redundancy
• Network micro-segmentation (dozens of vlans)
• Local plant IT could provide remote access to a new
vendor same day the request came in.
• Split core using VSS between two MDFs
100% core network availability to date
(1.5yrs and counting)

Previous Servers Current Servers
• Dozens of physical servers
• Local Storage
• Slow I/O
• 9 cables per server
• Tape Backup
• Slow recovery, and high failure rate
• Tapes brought offsite by plant IT guy
• 2 VMware Clusters each site (4 + 3 servers)
• SAN Storage – 10Gbps iSCSI
• SSDs for SQL, SSD Caching
• 5 cables per server
(2 10G Data, 2 10G Storage, 1 1Gbps iLO)
• Veeam backup to NAS; SAN async Replication
• <5min VM recovery, and <30 min DR recovery
• Continuous backups onsite and offsite automated
copies throughout the day

Previous Power Current Power
• Four UPS devices in MDF + 10 in IDFs
• Low Runtime on each device
• No coordinated shutdown if the generator
failed to start
• No bypass around failed UPSs
• Not all equipment could be A+B powered
• Circuit breakers in multiple panels and
throughout facility
• Two 30kVA centralized UPS devices
• 1.5hrs run-time on both UPS (split load)
• Automated VM shutdown if generator fails
• Maintenance bypass cabinet on each UPS
• Centralized Load Centre as part of each UPS
• All equipment A+B power in MDFs and IDFs

Previous Software Current Software
• Windows Server 2003R2 & 2008R2
• Single Database server
• Single OPC Server
• Single Application Server
• Hard to maintain up to date because of
production schedules – some systems with
none.
• Thick clients only
• VNC remote viewing
• No testing platform
• VMware 6.5 clusters
• Windows Server 2012R2 + Windows Server 2016
• SQL cluster split between two VMware clusters
• Clustered OPC Servers using Kepware
• Clustered Application Servers
• Maintained at one revision behind current release
• Thick and thin clients
• Screen Connect remote viewing and support
• DR systems are used for testing all updates

Previous Wireless Current Wireless
• Spotty
• Slow roaming
• Insecure (WPA-PSK)
• Low bandwidth – 802.11 a/b/g
• Omni antennas
caused co-channel interference
• 100% coverage
• Fast roaming (< 2 packets)
• WPA2 Enterprise
• 802.11 a/b/g/n/ac
• Directional Antennas
max power worked

Results for our customer
• Automotive parts supplier is able to match OEMs production rates without their IT systems being an issue
• Parts sequenced correctly on production line with dozens and dozens of possible assembly combinations
• Production rates of over 65 vehicles per hour and 45 vehicles per hour respectively at the two facilities
• No risk of loss of trace data for manufacturing process – all test results captured – including imaging data
• Stations on the production line have up to three user interfaces including HMIs, MES and Trace / QC integration
• Able to maintain a heathy production buffer now allowing for mechanical issues to be resolved before customer impact
• Less waste, better quality, less manual rebuilds, and more importantly less incorrect parts shipped to their customer

Interesting numbers
Facility #1
• Building is 336,000 sqft and operates some equipment 24x7x365 – makes IT updates difficult.
• Over 384 network drops where installed in the primary MDF alone for office workers, conference rooms,
status boards, door controls, thermostats, wireless, sensors, and security cameras.
• This facility has 13 IDF locations
• The largest IDF has over 288 drops connecting to it
• There are over 3,000 networked devices facility wide
• Nine different third party vendors provide ongoing support for the facility – each requiring remote access

Thank-you.
Q&A

Next Dimension IIoT Presentation

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