INDUSTRY 4.

0
CONFERENCE

Developments in Sensors for Automation &

Inventory Control
Sandhiprakash Bhide
Visionary IOT Leader, Strategist & Future Technologist

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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1.
2.
3.
4.
5.
6.

Agenda

All about Results

The Data Explosion
Lean Machine Architecture
Need for real-time device monitoring
Motivation behind sensor usage
How can sensors help in improving precision/accuracy,
mistakes avoidance
7. IOT Devices for Warehouses
8. Summary
INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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Agenda

1. Creating a lean machine architecture and limiting future mistakes

by using sensors as an extra pair of eyes
2. Advances in precision and properly maintaining sensors to ensure
accuracy
3. Best practices in real-time monitoring at and from remote locations
4. Take a load off: advancements in IoT devices designed for freeing up
warehouse space, eliminating overflow inventory, and parts
replacement

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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All about Business Results

Cost ReductionOptimize inventory, reduce shrinkage, and lower
labor costs
Increased RevenueReduce out-of-stock SKUs, better monitor sales
trends to optimize sales revenue
Improved EfficienciesIncreased accuracy, reduction of data entry
errors, and automated data collection to provide real-time monitoring
Increased VisibilityGain greater insight into key aspects of your
organization
It is all about Business Results (Increase top line and reduce bottom line)

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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Sensors to meet Business Results

Questions to ask:
1. What business results are you expecting?
2. Are they are measurable?
3. What is the allocated budget?
4. What is time duration of deployment?
5. What resources are available for ongoing expense?
And then:
1. Define what sensors, how many, specs, where to locate
2. Define the HW/SW/System architecture that supports the business
objective
3. Follow- through to make sure business results are achieved

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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Key Metrics
1. Inventory Control
1.
2.
3.
4.

Track inventory/eliminate overflow inventory

Free up warehouse space
Reduce cycle time reduction and improve flow
Improve accuracy

1.
2.
3.
4.
5.

Preventive/predictive maintenance
Predict the future needs
Improve quality and precision
Increase speed of execution
Catch/limit mistakes

2. Automation

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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To achieve this you need to:

1. Use sensors as an extra pair of eyes
2. Create a lean machine architecture

thereby limiting future mistakes, improving

quality/precision and ensure accuracy

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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But adding sensors means more data,

processing, communication, storage, power,
points of failure, and security vulnerabilities

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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Machine Architecture must support data

reduction and decision making at each level
Wisdom
Knowledge
Information
Sensors Data

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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Lean Machine Architecture

Environment Sensors for

Sensors/Devices for Automation
Building Management System
and inventory Control
(BMS)

Humidity

Lighting

Video

HVAC

Digital
Signage

Advanced
Metering
PACS

CO

Cloud

Compass

On premise

Altimeter

Edge IOT Gateway

GPS

WAN

(Array) Mic
Proximity
ALS

Camera

Accel/Gyro

PLC

Actuators

Sensor or device
level analytics

INDUSTRY 4.0 CONFERENCE

On premise

Edge IOT Gateway

On premise

Sandhiprakash Bhide , Sept. 22, 12016

Off Premise
Geo 1

Sync

Cloud

Edge IOT Gateway

Multi-device combinatorial
edge analytics

Cloud

Cloud

Cloud

Off Premise
Geo 2

Cloud analytics for

temporal analysis

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10

Building Management Systems

1. Precision is not as
important
2. Tolerable lag
between sensing
and actuation
3. Sensing may not
always be there
4. Downtime is
sometimes OK

Image above by: http://www.wbdg.org/resources/cybersecurity.php, Heating, Ventilating, and Air-conditioning Control (HVAC), BAC Building Automation and Control, VAV Variable Air Volume

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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11

Lean Machine Architecture

Environment Sensors for

Sensors/Devices for Automation
Building Management System
and inventory Control
(BMS)

Humidity

Lighting

Video

HVAC

Digital
Signage

Advanced
Metering
PACS

CO

Cloud

Compass

On premise

Altimeter

Edge IOT Gateway

GPS

WAN

(Array) Mic
Proximity
ALS

Camera

Accel/Gyro

PLC

Actuators

Sensor or device
level analytics

INDUSTRY 4.0 CONFERENCE

On premise

Edge IOT Gateway

On premise

Sandhiprakash Bhide , Sept. 22, 12016

Off Premise
Geo 1

Sync

Cloud

Edge IOT Gateway

Multi-device combinatorial
edge analytics

Cloud

Cloud

Cloud

Off Premise
Geo 2

Cloud analytics for

temporal analysis

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12

Lean Machine Architecture local sensor

or device level processing
Sensor
package

Sensing
element

Sensor
package

Sensing
element

Sensor
package

Signal
conditioning

Signal
processing

Signal
conditioning

Signal
processing

.
.

Sensing
element

INDUSTRY 4.0 CONFERENCE

Signal
conditioning

Signal
processing

Multi-Chip Package (MCP)

Sandhiprakash Bhide , Sept. 22, 12016

Transient Data
Storage
Sensor Data
Processing
Communication
Security

Info storage

Data Encryption

Sensor Algorithms
Transient Data
Storage

Combo sensors
Redundant Sensors

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13

Lean Machine Architecture local sensor

or device level processing
Sensor Device
Sensor Device
Sensor Device
Sensor Device
Redundancy and Accuracy:
Redundant Sensors to ensure
high Availability
1

Sensor Device
25% 50%
Sensor Device
50% 75%
Sensor Device
50% 75%

Sensor Device
175% 100%
Efficient resource
Utilization: P2P Load
Sharing
2

INDUSTRY 4.0 CONFERENCE

Sensor Device
P
2
P

Sensor Device

Cloud

Sensor Device
Sensor Device

Availability: Dynamic allocation of resources for processing

in real time (latency may be an issue)

Sandhiprakash Bhide , Sept. 22, 12016

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14

Lean Machine Architecture

Environment Sensors for

Sensors/Devices for Automation
Building Management System
and inventory Control
(BMS)

Humidity

Lighting

Video

HVAC

Digital
Signage

Advanced
Metering
PACS

CO

Cloud

Compass

On premise

Altimeter

Edge IOT Gateway

GPS

WAN

(Array) Mic
Proximity
ALS

Camera

Accel/Gyro

PLC

Actuators

Sensor or device
level analytics

INDUSTRY 4.0 CONFERENCE

On premise

Edge IOT Gateway

On premise

Sandhiprakash Bhide , Sept. 22, 12016

Off Premise
Geo 1

Sync

Cloud

Edge IOT Gateway

Multi-device combinatorial
edge analytics

Cloud

Cloud

Cloud

Off Premise
Geo 2

Cloud analytics for

temporal analysis

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15

Lean Machine Architecture edge

processing beyond
Cloud
P
2
P

Redundancy: Redundant
Gateways to ensure high
Availability
1

P
2
P

Cloud
Cloud
On Premise

Efficient resource Communications Availability/Redundancy:

Utilization: P2P Load Redundancy:
Dynamic allocation of
Sharing
Multiple paths resources for processing in
2
3
real time 4

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

Cloud

Off Premise
Geo 1

Sync

Cloud

Off Premise
Geo 2
Extreme Availability: Real
time sync between geo
separated clouds
5

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16

Device monitoring at every level

Humidity
CO

Cloud

Compass

On premise

Off Premise
Geo 1

Edge IOT Gateway

On premise

Cloud

Edge IOT Gateway

On premise

Altimeter

Policy

GPS

Edge IOT Gateway

WAN

(Array) Mic
Proximity
ALS

Camera

Accel/Gyro
Actuators

Sensors/Actuators

Cloud
Cloud

Cloud

Off Premise
Geo 2

Device/asset management, remote monitoring of operation and (impending) failures, device updates of OS,
analytics, firmware, profile etc. at each level from end node, gateway, on-premise cloud, and off-premise clouds

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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17

Motivation behind sensor usage

Source: Big Data Analytics Predictive Analytics Gartner Glossary, www.gartner.com

INDUSTRY 4.0 CONFERENCE

Source: Ray Solnik, Appnomic Systems , http://www.datacenterjournal.com/it/time-analytics-delivers-operations/

Sandhiprakash Bhide , Sept. 22, 12016

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18

How can sensors help in improving

precision, accuracy, mistakes avoidance

1.
2.
3.
4.
5.
6.
7.

Redundant sensors/actuators for failure

Understanding trends to predict failures
Using accurate and robust sensors (cost more)
Multiple cheaper sensors to offset one costly sensors
Processing to extract sensors data/improve SNR
Temperature and other compensation
Signal conditioning/processing/Finer resolution ADC

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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19

IOT devices for Warehouses

1. Dense wireless network with reliability, speed, and capacity to

manage thousands of connections
2. Special devices (bar codes, RFIDs) material movement
3. Cameras and Microphones for security and material flow
4. Camera to track which stock items rotate fast connect to order
system
5. Chemical and gas sensors for rotting food
6. Temperature and humidity to maintain freshness
7. Location trackers (GPS) to monitor movement for goods,
understanding time in transit
INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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20

Summary

1. First a problem statement must be defined

2. What is the business result expected
3. Understand the upfront/ongoing budget, time duration, resources
4. Define success criteria, financial and operational
Then
1. Define sensors and lean HW/SW/systems architecture
2. Define redundancy, availability, fail-over, security criteria
3. Follow- through to make sure business results are achieved
INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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21

Speaker/Author Details
Sandhiprakash Bhide

Email: sandhibhide@gmail.com

LinkedIn: https://www.linkedin.com/in/sandhiprakashbhide
Press Links: http://bit.ly/1qJZk2V

Publications: http://bit.ly/238qBKH (Search for Sandhi

Bhide or Sandhiprakash Bhide on http://scribd.com

Founder, Coordinator, Singer: Soor Aur Saptak Bollywood

Music Charity Group, Benefit concerts for the Seva
Foundation (Berkeley, CA) to help restore eyesight to
hundreds of blind/visually impaired and financially
disadvantaged pediatric patients in rural India, Press Articles:
1, 2, 3 and 4

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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22

INDUSTRY 4.0
CONFERENCE
Thank You!
Questions?

INDUSTRY 4.0 CONFERENCE

Sandhiprakash Bhide , Sept. 22, 12016

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