CONIROL= ENGINEE Covering control, instrumentation, and aut Sharpen your OT and IT: Know both es, be worlds on s Remote monitoring vs. Corer eet i Flowmeter update: What's new? ba Tie tata mola Poller ay Lato ee mer CE Uy Cy oi vHigh-High Quality Level and Flow Sensors at everyday Low-Low prices ProSense® FTS Series Thermal, Flow Sensors (starting at $235.00) Offer a very cost-effective solution to ‘monitor water, glycol, or ai flow + Nomoving parts- advantage over, mechanical versions ProSense® VFL Series Vibration Fork Level Switches (starting at $137.00) Tuning fork technology detects reliable liquid point level for alarming and control applications «Ideal fr applications where conductivity, turbulence, buildup, ar bubbles, foam, pressure, temperature, and vscsity changes alfect other switches iy -Avalbleintwo process connection snes ‘wo insertion lengths, standardand high temp. © constructions and witha 3-wive OC switeh outputora 2wite AC/DC switch + -digi display and eary pushbutton setup + Probe lengths of 100 mm or200 mm + Two low or temperature outputs serve aslimit switches or for continuous flow rate /temperature monitoring ProSense® Flow Switches, Flow Transmitters, and Flow Meters (Starting at $129.00) —= — Offer low cost liquid media monitoring Pe. ave ide reliabl ei peters ton Flowline® Reflective + Mechatronic Flow Switches ‘ Technology™ EchoPod + Mechatronic Flow Transmitters {| Ultrasonic Level Sensors - SUNNEN sg ae " - GRAYBAR KNOWS TPL OrSa te SV-30 aq : }ANSWERS. COVER STORY: VIRTUALIZATION, CLOUD Michael Risse, Seeq C Workloads in the cloud for industrial manufacturers Cloud adoption in industrial and manufacturing organizations is growing. See five use cases of how manufacturers use the cloud and the potential benefits. he cloud is of the big three technol- ogy innovations, with Big Data and machine learning (ML), which are powering a new generation of solution and plant infrastructure. The cloud is also a buzzword in modern consultant-speak: Industry 40, Smart Manufacturing, digital trans- formation, and the Industrial Internet of Things (oT), The cloud has become the backbone of our personal lives with online shopping on Amazon, applications like Microsoft Office 365, and servic es like banking, At least we've agreed what to call on-demand computer rental since Amazon first offered vir~ tual machine (VM) and storage services in 2006, followed by Microsoft and Google in 2008. Since then we've seen the hype and progress of automa- tion company cloud-based services, and acquisi- More Ws ANSWERS KEYWORDS: Cloud, cloud ‘software, Industrial Internet of Things (ioT) The cloud is powering manufacturing growth and improving connecthity Use cases involving the cloud include the Industral Internet of Things (oT), data historians and reporting systems. Sottware-as-a-senice (SaaS) ‘manufacturing applications ‘are growing thanks to cious incustral sohwar. ONLINE Read this article onine at ‘wae controleng,com for adational articles trom the author CONSIDER THIS Has your plant used clous: based capabilties and what benefits di it provide? 16 © November 2019 tion after acquisition as vendors shore up and expand their online offerings. ‘The cloud has produced a lot of talk, pethaps too much talk because while the cloud is everywhere in our personal lives, the details of where the cloud will ‘matter first and best to manufacturing organizations is still an ongoing process. It’s more of a roadmap than reality. Further, there are specific require- ‘ments of industrial organizations that preclude some cloud-based deploy- ‘ments. Unlike consumer and general information technology (IT), industri- al cloud deployments have specific security requirements. They also need guaranteed. availability and require software-as-a-service (SaaS) versions of important enterprise asset manage- ‘ment (EAM), manufacturing execution systems (MES), and potentially super- visory control and data acquisition (SCADA) applications (see sidebar) ‘At the same time, despite the hesi- tancy and challenges of cloud deploy- (CONTROL ENGINEERING ments, there are five current and recognizable patterns of cloud use by industrial manufa with each described in detail below: + Born on the cloud: IloT + Lift and shift historians + Data lakes + Cloud reporting systems + Quick start analytes. These patterns, or use cases, are called “work- loads” by the cloud platform vendors, as in “early cloud workloads for IT departments included low- cost, long-term storage, and on-demand computing The list of cloud workloads will grow as issues such as the availability and acceptance of SaaS plant applications like MES are addressed. Using these as specific examples ofthe cloud in industrial tse will help enable the transition from an amor- ‘phous cloud to a discussion of specific tradeoffs and benefits, 1. Born on the cloud: lloT “The frst cloud workload is the HoT use case where new sensors are deployed on assets with the telemetry required to pipe their data to the cloud for storage, applications and analytics. Alternatively, the assets are existing, but there are new sensors deployed, “lick and stick” as one vendor referred to them, This born on the cloud scenario is reminiscent of countries that skipped ‘widespread phone use prior to the cell phone and ‘went straight to cell-based model vs. fully deploy- inga wired telephone network. ‘Born on the cloud HoT benefits: A fit for greenfield monitoring scenarios or expanding vis- ibility in an existing facility to additional assets or nw controlang com‘Amazon, Google, Microsoft and other leading information technology (IT) firms have indus- trial cloud service offerings. + Downside: I sill a work in process because end users must make decisions on each piece in the solution stack including sensor, device man- agement, gateway, security, communications layer, cloud vendor, data storage, etc 2. Lift and shift historians ift and shift” is taking an IT workload and ‘moving it out ofthe data center and into the cloud, running the application on a virtual machine (VM), which is an instance of an operating system decoupled from the underlying hardware, Vi tachines enable one physical server to host many Virtual machines, which run many applications, improving hardware utilization versus a dedicated server for each application deployment, The drive for moving application workloads out of on-premise data centers is lower costs: the fully burdened cost of server in a data center can be 50 times the price of the server itself. Amazon's AWS. team, for example, advises companies to aim for a “zero square foot data center” with all applications running in the cloud (Figure 1). Companies have been moving IT applications tothe cloud for years, including email, enterprise resource planning (ERP) and accounting systems. Historians, from a cost- savings perspective, are waiting their turn. + Lift and shift historian benefits: If correctly executed, the users of the historian wont see any impact on their use of historian data, and cloud- based historians are more accessible to TT. ual Time Series - the Fastest Growing Database Trond of the Last 24 Months | © ies 3 é in data lakes and greenfield Industrial Internet of Things (lloT) deployments are matched by the growth and interest + Downside: Internet bandwidth, historian read access, and security are issues to be addressed — but the cost advantages of cloud-based deployment ‘make this more a “when” than an “if” discussion. 3. Data lakes The big bang option for cloud workloads is building a data lake, which is an aggregation of unlike data types in one system, for example a pharmaceutical company combining sensor data from historians laboratory information manage- iment systems data, batch data, quality data and November 2019 © 17 CONTROL ENGINEERINGANSWERS. COVER STORY: VIRTUALIZATION, CLOUD other areas, to enable a global view into operations nal company business analysts who need reporting, and business outcomes by data science and IT. The and “known’ views on production processes. benefits of this approach may be considerable, but For the third audience, visualizing data is done the list of challenges is just as long. with business analytics products and SaaS appli- Data lakes are always bespoke in the details — cations. The challenge is giving these users access schema, data requirements, use cases, and other to the right data given the challenges visualization details — and they are complex and expensive. products have with time-series data ‘As one example, moving time series data The answer is creating tables of process data and doesnit make it easier for analysis. From an end storing them in a relational database service for user data analytics perspective, moving histori- easy access by business intelligence products. These an data to a data lake, for example, doesn't solve data tables dorit enable all the flexibility required 1 problem; it just changes the location of the data. _ by process engineers, but for known questions like overall equipment effectiveness (OEE) or produe- tion accounting reporting, they provide access and flexibility. + Cloud reporting system benefits: Using dloud-based relational database services to store data that answers known or defined questions for ‘non-production specialists + Downside: The architecture creates an infinite loop of requests back to IT based on data structure and context to chase queries in new or unexpected directions Quick start analytics ‘The benefits of the SaaS application model are known to any consumer who has bought some- thing online and any employee who has worked ‘Advanced analytics applications like Seeq have a software-as-2- with online applications in their workplace: fast service (SaaS) offer access, browser-based user experience, and little, if required for deployment. any, deployment overhead. This model is available for manufacturing applications including MES sys- tems and will expand in the years to come. The second biggest challenge with data lakes The highest end-user priority, however, is is the timing and infrastructure used to copy and improved analytics software to enable faster and update the data lake while the source data is con- deeper insights on expanding data volumes in man- stantly flowing from the system. Too slow of an _ufacturing. End users need more and new types of update wastes insight opportunity; too fast can be insights, such as predictive analytics, and the kind very expensive to implement and still may not guar- of collaboration and knowledge capture features antee high-speed concurrency. offered in modern workplace applications. + Data lake benefits: The aggregation of dispa- Advanced analytics applications leveraging rate data types enables access by data science and machine learning to accelerate insights are in high other IT experts to find new insights to improve demand. Applications offering this functionality as production and business outcomes via a view across SaaS offering for fast deployment and low IT costs the organization (Figure 2) are of particular interest as first use eases for com + Downside: The cost, time to insight, and com- panies exploring cloud-based opportunities for pany-specific challenges of data lake projects mean innovation (Figure 3). this is not an effort to be taken lightly: years and + Quick start analytics benefits: End users millions of dollars are the right denominations for can implement and access advanced analytics for implementation. their data on premise or in the cloud with little to no IT touch, In particular, they can do so without 4. Cloud reporting systems first moving, copying, or changing their system of Three audiences need access to time series or _ record (one or multiple historians) production data for analytics and insights. First is » Downside: Like all cloud deployments, band- data scientists, typically associated with data lakes width and security are requirements for success- and IT. The second is process engineers and plant ful implementation, but there is limited downside employees, typically working with data in histori- with subscription models for software licensing. If ans and manufacturing applications. Third is inter- it doesn't work, the user can turn it off. 18 © November 2019 contro: enaInesans nw controlang com‘These five examples of using cloud platforms to benefit industrial manufacturers shows the cloud is more than its hype as the center and component of everything interesting. These workloads will expand as objections are overcome and new servic- es are offered, but they already provide a short-term opportunity for manufacturers to realize immedi- ate value. ew Michael Risse is the CMO and vice president at Seeq Corp. Edited by Chris Vavra, production editor, Con- trol Engineering, CFE Media, cvavra@efemedia.com. Othe highest end-user priority is improved analytics software to enable faster and deeper insights on expanding data volumes in manufacturing. y SaaS manufacturing applications the quantity and quality of cloud applica- A ane eataner ast nee tions increases, a new category of software has emerged: cloud industrial software. These are "cloud native” applications, meaning they have been Saar ee cae nets cloud, as opposed to cloud versions of existing on- Serra Rai] aes ocean ae ores oe Se eaemen eee ete on investment (RO!) from the untapped value of the data in on-premise systems. In a typical application, data is stored in the cloud for access worldwide (side- bar photo). Here are a few examples - of the many — in several popular categories of SaaS offerings: Er area era aoe ZS eS management system (CMMS) that promises the ben- efits of cloud efficiencies and cost advantages with Sea rare metrics and analytics. Sea a cee omer cneeee es (OCS) - OCS is intended to aggregate and aug- ment operations data. The vision is for end users to ea eee ee ee facilities in the cloud for real-time planning and moni- toring that drives process improvement. © Manufacturing applications: Tulip - Tulip ir ce Oma eS ene ante ces mera ce while still taking advantage of back-end systems and data sources. dds ee eters eee ‘Al-powered platform that augments existing systems on the factory floor by delivering improved accuracy in detecting defects. Spyglass deploys in the cloud for a Lean approach to leveraging advances in emerg- ing Al and machine vision technologies to tinuous quality improvement. Vibration analytics: Petasense — Makes indus- trial machines smarter by offering a stack of sen- sors, connectivity, and cloud solutions to enable web. and mobile applications to provide acoustic-based insights for improving asset reliability and predictive maintenance. The benefit for end users is reduced downtime and lower repair costs on assets and pro- duction facilities. A general benefit of SaaS-based _manufactur- ing applications is a low-cost trial or proof-of-con- cept phase with connections to live operations data, along with low IT overhead. SaaS also allows proto- typing and iteration without large capital investments, in hardware or systems. With SaaS, how far or fast a manufacturer proceeds is a matter of choice without the constraints if there are significant sunk costs. Cover: SaaS offerings usually provide worldwide access via many types of devices, Including smartphones, conTmoL enanecrnc November 2019 * 19ANSWERS. COVER STORY: SOFTWARE STRATEGY Andrew Lichey, FS Get the right software for field service management, product lifecycle needs As companies’ field service offerings, managing people, hardware assets, and software bring additional challenges, field service management software must address the entire service lifecycle. Consider three options. s the number of mobile applications and wearable devices being used in field service grows, so does the choice of field service management software. This new breed of service software allows enterprises to meet emergent and contract- ced service demand, improves technician utiliza- tion and ensures service level agreements (SLAs) are met. While this software can be sold as-a-service (SaaS) or owned outright through a. perpetual license, some software companies only sell through ‘more profitable subscription-based licensing, This shouldnt be the only choice when investing in cloud-based software, though. Companies should consider these three options. « Reverse logistics is another key requirement for businesses working within complex repair environments, as is project management for instant communication with remote personnel in the field. 5 20 November 2019 ‘1. Lower upfront costs with a subscription license ‘Buying software on a subscription basis enables castomers to pay for software on an expense bud- get as opposed toa capital budget, This is desirable as the expense may be assigned to a given depart. (CONTROL ENGINEERING i ven If manson people and atsets seems “old hat," field services software may help. Courtery: Mark. Hoske, CFE Media and Tech- nology ments operating budget and is well below the nor- ral threshold fora capital budget spend. The lower upfront investment of Saa8 is also attractive for businesses starting with a small- ex footprint because they can scale up and down depending on fluctuations in technician numbers Organizations can implement field service manage- ment in one division or office as a proof of concept. When starting with fewer SaaS users, businesses can consider a wider rollout and scale the solution across more users when required. 2. Peace of mind with one-off payments Before the internet and broadband connectiv- ity became central to most businesses, software was sold through perpetual licensing. Purchased through a one-time license fee, the salution can be applied on a company’s hardware or private cloud. nw controlang comSpreadsheets weren’t designed for time series data analytics. Seeq is. am. vans, AS wie 202 a * Bae o Puree eet eter Ca os With Seeq?, difficult and time-consuming work in spreadsheets is a thing of the past. Seeq’s multiple applications enable you to rapidly investigate and share insights from data stored in multiple enterprise data historians, such as OSIsoft PI, Honeywell PHD, and GE Proficy, as well Dee eee nee tee autre LN Seeq’s support for time series data and its challenges - connecting, displaying, interpolating, Cae en Cue eC ECOG cts De eee ee ak ue oka you've already been collecting, and gives organizations data transparency and the ability to Certain ee Teed oO” Re) ah ee ee ee Oneness eee eadNS SUA ts Pay DECISIONS eS ACQUISTION SYSTEM Mission-critical software owner. ship for business operations seems to be important for some consumers. They want to own the software to con: fidently build vital processes around it; owning software outright also allows companies to use it indefinitely. It is generally purchased with a contract for ongoing maintenance and support, but ‘most of the cost comes from the initial purchase. npanies also can provision soft- ware sold through a perpetual license con their own servers and support it with their IT personnel. They also can place it in a private or public cloud run by a third-party vendor, such as their soft- ware vendor. Running software this way allows a company to outsource common IT administration tasks while ensuring the server capacity can scale to demand. Commitment is key for organiza- tions opting for a perpetual license. The fact that the license purchase hits the capital budget is significant. From the top of the organizational chart down, there is potential for these processes to maximize the service organization’ profitability 3. Field service software options Field service software buyers should prioritize specific requirements before assessing deployment options. Whether AA subscription conse may lower upfront costs, Purchasing software may co: more but ofer stware options should look at the sonviee lifecycle, CONSIDER THIS ‘Aa:you expand review mode to lnclicle ‘more services, are your software models also advancing? ONLINE reading from the digital extion, cick on the headine for more resources, See the HoT webcasts under ening trainin st wwww.controleng com 22 + November 2019 control ena TEGY 6 strong support for serial- ation ensures compliance in regulated industries and recalls are supported when necessary — reducing lost revenue, broken SLAs and dissatisfied customers. 5 the solution is purchased through a per- petual license or by subscription, field service management software will fail if it does not address the entire service Lfecyee. Beyond scheduling, dispatch, and field ‘mobility, field service applica tions should allow automated call han- dling and routing, while dispatches are important to optimi tionalities. ‘Traceability systems and spare parts managen trol over supply chains, which helps keep businesses safe and compliant. Reverse logistics is another key requirement for businesses working within complex repair environments; so is project management for instant communication with remote personnel in the field. Strong support for serial- ization ensures compliance in regulat- ed industries and recalls are supported when necessary — reducing lost rev- broken SLAs and dissatisfied customers. call center func also give con- Don’t cut software corners No matter how software is paid for, companies need to remember they are buying new business capability. The choice should focus on if software meets key busi- ness requirements, and ifthe field service software vendor can assist in meeting and exceeding customer expectations through a deployment model that works best for the circumstances. e@ Andrew Lichey is product manager for field service management, IFS; Eat ‘ed by Mark T Hoske, content manag er, Control Engineering, CFE Media, mhoske@cfemedia.com.S Newark om 7 ee Breen BELDEN E:T-N (ruukey) ioe = SMO —molex —_mutleomp Tektronix: TENMA RadANSWERS. COVER STORY: Daymon Thompson, B= IT/OT CONVERGENCE off Aut IT/OT convergence provides a path forward Long before Industry 4.0 and cloud-connected architectures became possible, innovators championed PC-based technologies for industrial automation. More IT/0T convergence is accelerating the age ofthe loT and industy 40, IT/0T convergence started in the early 1980s with the rise of the modern PC, ‘Some companies converged fatty while others did o as the technology improved. became more cost effect Read this article onine at ‘war controlang,com for 10 adcilonal stoves about IT/OT ‘convergence and what it for manufactures. CONSIDER THIS When did your company IT/OT convergence, and what ‘were the short-and long-term, reauts? 24 + ANSWERS November 2019 s Industry 4.0 and Industrial Internet of Things (IloT) concepts become real applications, exciting conversations include integrating information tech- nology (IT) and operations technology (OT). Large IT companies have promoted ideas like ‘workload consolidation for businesses to optimize processes and be more competitive in their resp tive industries. This excitement, boosted by some of the largest players in automation technology (AT) ‘who are jumping on board, is well deserved. Great- cer system openness, real-time deterministic con- trol with many-core processors, the incorporation ‘of web technologies and machine learning (ML). among other advances, are possible by applying pop- ular technologies to industrial applications. TI/OT convergence continues to offer benefits to machine control architectures, as it has for more than 30 years. Many suppliers are only beginning to integrate PC-based technology into industrial auto- mation. Even so, the history of TT and OT convergence inthe context of automation technology dates back to the early 1980s with the advent of the modern PC and those who saw its potential for industri- aluse. ‘Of course, the adaption of these ideas follows the diffusion of innovations the- ‘ory, which describes how new ideas and technologies are adopted in order by: and sInnovators 2.5% «Barly adopters 13.5% Pies Early majority 34% A Late majority 34% Laggards 16%. ‘ai This theory helps provide perspective on how IT/OT convergence has evolved since the 1980s and where things are Teading today. (CONTROL ENGINEERING PC-focused innovation in the 1980s During this era, the larger technology world began to develop the PC and related technologies for more widespread business and consumer use far beyond the levels seen in the 1970s. These efforts led to transformations in standardized chip sets, board designs and eventually sophisticated operat- ing systems. At that time, most industrial technol- ‘ogy companies stayed far away from the PC path, The large. predominately programmable logic controller (PLC) platforms were using proprietary chip sets, board designs and, in most cases, pro- prietary programming software. Traditional PLC technology for industrial machine control evolved much slower than it should have due to an indus- try-wide aversion to change. As a result, the paths of hardware PLCs and consumer and business-fac- ing PCs would not converge for decades. Most industrial vendors and manufacturers shunned IT technology on the plant floor at first, though smaller start-up companies recognized both technologies could coexist. These innovators foresaw how intermingling them could capitalize on the technological advantages of both sides and provide a high performance, universal platform for manufacturers and machine builders. Using prov- ‘en industrial standards and emerging computer sci- ence innovations, smaller AT companies began the convergence of IT and OT in manufacturing. Early adopters of the 1990s In the 1990s, IT and OT technologies continued to advance. However, IT pioneers had surpassed traditional OT. The popularity of Microsoft Win- dows exploded, and it became ubiquitous in near- ly every area of technology. Microsoft launched ‘Visual Studio in 1997, which combined a number of programming languages in one convenient envi- ronment, which continues to evolve and remain important today. Industrial vendors that began implementing PC-based automation technolo- gies in the previous decade saw significant gains nw controlang com1996 1986 2003 2010 For controls technology innovators, IT/OT convergence was happening for decades before the oT and Industry 4.0 conversations that often draw attention to the concept today. Courtesy: Beckhoff Automation in hardware and software performance, which far outpaced traditional PLCs. The successful compa- nies created new tools for deterministic, real-time control designed to run on industrial PC controllers. with standardized operating systems (0S). ‘Automation vendors that saw an opportunity researched and launched computer-based control However, these early adopters realized developing software from scratch and maintaining it was expen- sive. They started using some off-the-shelf real-time operating systems, but often didnit promote them. Sometimes this happened because the vendor didn't really believe in the technology, and other times it was because the technology wasn't reliable. Some notable crash-and-burns gave PC-based plat- forms a bad reputation during this time. The truth is, many platforms were providing strong results in the field and extending the lead in performance over traditional PLC technologies. Early majority from 2000 onward ‘The turn of the millennium brought further developments in software and multi-core proces- sors. Major players on the consumer side, lke Intel, TBM and Microsoft, actively expanded into the OT realm. Likewise, a determined subset of the auto- mation space kept integrating IT with increased realtime capabilities. This was happening when Widespread loT was sill just an idea, Along with the automation and control advances, networking also was a major development. ‘The introduction of industrial Ethernet proto- wow contrlong. com cols, such as EtherCAT, created major performance improvements and a path forward from legacy feld- buses. Industrial Ethernet is another example of IT and AT convergence, with Ethernet and fieldbus technology merging, Others were trying to port leg acy fieldbus technology to run on Ethernet and, in the end, were not as successful. For example, TCP/ IP technologies, created to drive non-deterministc, ™massive-scale networks, required extensive ancillary components and complicated configurations to cre- ate a high-speed, deterministic fieldbus. However, FtherCAT eliminated the complexity and cost of switches and additional hardware while pro- viding deterministic control with up to 65,535 devices per network. This resulted from the same PC-based control innovators carefully considering what indus- trial Ethernet could offer by combining the open- ness and acceptance of Ethernet with the functionality expected of industrial fieldbuses. This was a different approach than creating workarounds, such as expen- sive managed switches for old fieldbus protocols, with- out regard to bandwidth utilization, Ethernet frame efficiency or the number of plant-floor IP addresses. Late majority in IT/OT convergence From automation software apps on smartphones to ‘many-core CPUs with processors in industrial enclo- sures, the IT/OT convergence continues to acceler- ate in the age of HoT and Industry 40. For another example, human-machine interfaces (HMIs) com- ‘monly rely on web technologies, and standards such as message queuing telemetry transport (MQTT) and ConTRoL enaivecrnc November 2019 25ANSWERS. COVER STORY: IT/OT CONVERGENCE JavaScript object notation (JSON) are being rapidly implemented in HoT contexts. Gigabit Ethernet technologies, such as Ether- CAT G, are also becoming key as machines become ‘more complex, and time-sensitive networking (TSN) is providing deterministic vertical communication ‘ Not actively seeking technologies that drive IT/OT convergence will lead to strategic disadvantages for tomorrow's laggards. 5 to address the limits of non-EtherCAT fieldbuses. In addition, industry is beginning to earnestly apply ML and other artificial intelligence (AI) technolo- gles, which already drives consumers online shopping ‘experience, directions and other phone apps. Rapid consumer technology advances provide ‘opportunities to deploy industrial technologies faster and accelerate risks of falling behind when some con- trols vendors ate slower to adapt. Not actively seeking. technologies that drive IT/OT convergence will ead to strategic disadvantages for tomorrow's laggards. The good news is the previous reluctance of ‘manufacturers and machine builders to implement PC-based technologies continues to evaporate as they see the benefits of applying IT technologies where it makes sense. In any field of technology, this is a moving target, but companies driving this convergence understand the stakes. Automation vendors and machine builders cant decide to throw untested IT technologies on a mmulti-million-dollar piece of equipment and hope for the best For companies that have championed 1T/OT convergence as a fundamental design philosophy for years, it is clear any IT principle carried over to OT products must be deterministic, reliable, avail- able for many years, and implemented in the most cfficient way possible. Done correctly, 1T/OT inte- ration produces results far above what traditional platforms can accomplish alone. Ws important to remember this IT/OT integration didsit start with ToT, and it won't end there. As cloud- connected architectures and Industry 4.0 concepts ‘become commonplace in factories globally, its impor- tant to be aware of what's next and of the technology leaders driving innovation inthe industry. ce Daymon Thompson, automation product manager ~ North America, Beckhoff Automation. Edited by Chris Vavra, production editor, Control Engineer- ing, CFE Media, cvavra@efemedia.com. )* ) lloT Series: Part 4: Machine Learning CFE Edu introduces “IloT Series: Part 4: Machine Learning," an on-demand course that is accessible 24/7 with a computer, tablet or smartphone. In. course, our instructors will discuss the emerging machine learning paradigm for process control and enterprise management, as well as examine some real-life case examples that are already delivering results. Learning objectives: + An overview of machine learning «Distinguish between supervised ‘and unsupervised learning + Review machine learning case examples, + Differentiate between Cloud ‘This course is FREE and students can earn one (1) Professional Development Hour ‘and Edge applications. (PDH) after receiving a passing grade for the final exam and finishing the exit poll To register, go to cfeedu.cfemedia.com/catalog SPONSORED BY “Ilo Series Part 4: Machine Learning." You can also ate MIRE register for the lloT Series: Part 1, Part 2, and Part 3. Ea i Pe BECKHOFF Changes forthe BetterANSWERS. COVER STORY: IT/OT COLLABORATION Tim Geliner, Maverick Technologies Connecting IT/OT data From raw materials to finished goods, data flow between the information and operations technology (IT/OT) system layers increases efficiency, quality and agility. 1m today's evolving industrial automation world of smarter, better, faster system and software applications, data remains a con- stant. For manufacturers, the most impactful source of information they have is data from the operational technology (OT) layer. The whole point of manufacturing, after all, is to produce fin- ished goods from raw materials in the most effi- cient manner possible and sell those finished goods to customers. The flow of data between the OT and information technology (IT) system layers has increased in the last decade because of open system architecture and innovative software applications, For instance, the widespread adoption of the EtherNet/IP Ethernet protocol for process control and automation systems and the migration of older protocols to operate within the Ethernet framework hhas moved manufacturers away from proprietary communications and hardware to open connectiv~ ity across the enterprise. The convergence of these underlying communications has increased. the interoperability between the automation layer and the business layer. ‘This convergence also opened the door to Indus- trial Internet of Things (IloT) technologies and devices, enabling the Big Data explosion and helped bring other technologies such as digital twins and artificial intelligence (Al) to the forefront. Under standing the wider integration and flow of data between the OT layer and IT applications gives, ‘manufacturers the opportunity to leverage real-time data to make more informed and timely business decisions. IT/OT application roles ‘Among the most familiar of these TT/OT inte- rations is the interaction between the enterprise resource planning (ERP) system, process control sys- tem (PCS), manufacturing execution system (MES), laboratory information system (LIMS), computer- ized maintenance management system (CMMS), supervisory control and data acquisition (SCADA) and some others. When going from raw materials to finished goods, each application uses OT data to ful fila specialized role ‘The ERP is the “system of record” for maintaining the company’s books. It manages orders, inventory, wow contrlong. com production and finished goods from an account- ing perspective. Ata very high level, the ERP system. software tells the MES what and how much of some- thing to produce via a production order. The MES, in turn, tells the PCS what materials it needs, the quan- tities and the equipment needed to fulfill the order. ‘The PCS acts on the information to do the work required to produce the material while reporting its progress to the MES. During the normal product production, specific steps in the process may require the material being produced be sampled and ana- lyzed in the LIMS to determine ifthe product meets, specifications. The results of this analysis can initiate actions within the PCS that may include scrapping ‘material, sending material back through the process for rework or sending it to be shipped. The CMMS also may be monitoring the real- time health of the equipment, runtime, idle time, downtime, power consumed, and a host of other associated data that all originate in the OT layer. ‘The CMMS also tracks equipment maintenance hi tory, spare parts, parts used, spares inventory, ven~ dors and costs, maintenance scheduling, and other attributes. ‘The SCADA system monitors process alarms and events, including any opera- tor actions taken during a production process. The process historian continual- ly collects and stores this data, along with time series process data, batch data and other measurements. The wealth of data the PCS produces and the historian cap- tures form the foundation for a holistic view of the production environment. For PCS data and all its interacting components to be usefull beyond a ret- rospective view. the data must be framed within the context provided by the IT layer systems. To do this, the data in these upper-level IT systems must be accessible. In today’s modern historian platforms, the historian data is available to OT and IT systems over Ethernet via universal and open interface technolo- gies, including OLE for process control (OPC) and structured query language (SQL). integrator? ConTRoL enaivecrnc November 2019 BO Avers KEYWORDS: information rene sma Soe ter oun por iapeee prea Sooo lpokaainae manera toe pa retin hee eeherranae es noes ees Read thie article onine at \warw.controleng,com for more stories about digital twins and their beneiits for menafacturers, CONSIDER THIS What immediate benefits cou your facity gain from IT/OT 2ANSWERS. COVER STORY: IT/OT COLLABORATION G With tighter OT and IT system integrai Time to innovate By taking a closer look at the breadth of data the ‘OT has produced and IT applications have consumed, and are contextualized within the boundaries of each application, manufacturers have the raw material from which they can construct a digital twin model. A digital twin is a virtual model of production ‘equipment, products and processes. The concept was described in a University of Michigan presentation at a Society of Manufacturing Engineers conference as the foundational model for product lifecycle mau agement (PLM). Digital twins are used to optimize the operation and maintenance of physical assets, systems and manufacturing processes and product manufacturers realize the benefits of more timely, actionable data. 28 November 2019 lifecycle management, If we take the contextualized dlata that resides in the IT applications along with real-time and historical data from the OT layer, we can construct a complete digital twin model of fac ties, equipment and products from the receipt of an ‘order through shipping and beyond. This model can encompass the ingredients, parts ‘used and quantities. This includes the equipment used to process them and the operators running the equip- ment. The equipment includes the temperatures, pres- sures, alarms, operator actions, quality control (QC) tests taken and the results; when the production start- ced, completed and all the stops in between. It also can include waste, final products, amount and cost of energy, building environment conditions, if break- down occurred, who respondent, parts used, time for repair ifthe problem happened previously, total cost ‘of production, and other measurements ‘While this wealth of information is crucial for a facility, the real promise lies in using this informa- tion to make data-driven decisions to predict possi- ble business outcomes, such as + Small changes in the operating environment + Minor differences in the quality of raw ‘materials + How operator actions affect the systems efficiency + How a series of minor process alarms can be used to determine ifa major process upset may occur (CONTROL ENGINEERING 6 Use information to make data-driven decisions to predict possible outcomes 5 + The ability to operate proactively instead of reactively. ‘Thanks to tighter OT and IT system integra- tion, manufacturers are realizing the benefits of increased availability of timely and actionable data. An example of this is the reduction in time for an organization to adapt to a production event. ‘That can include a short-term event, such as an unforeseen equipment breakdown, or a longer~ term event, such as a change in product specifi- cations. This type of manufacturing agility is a strategic component in securing and maint a competitive advantage. Anew era, smarter industries Manufacturers are in the beginning phase of what is being called the fourth industrial revo- lution, Industry 4.0, This era will be driven not just by data, but also by the intelligence that can be derived from it and applied across the indus- trial landscape of equipment, processes, facili- ties and people. Integrating OT and IT systems is ‘an important first step along the path. Emerging ar «> Ye (OTIT information integration looks at who needs data when, and why to make smarter decisions. Courtesy: CFE Media and Technology technologies such as machine learning and other aspects of Al, can revolutionize a manufacturer’ ability to use integrated IT/OT data to build and ‘employ models that form the basis for increasing overall efficiency, quality and agility. e@ Tim Gellner is senior consultant, Maverick Technolo- ‘gies, a CFE Media content partner. Edited by Chris Vavra, production editor, Control Engineering, CFE Media, cvavracefemedia.com. nw controlong.comBaldor-Reliance® explosion proof motors Certified safe solutions BALDOR: RELIANCE When you specify a Baldor-Reliance explosion proof motor, you can trust it’s the right solution for hazardous locations. We are committed to making r motors that are readily available and perform efficiently throughout their entire lifecycle, without ever compromising safety. aro.c4s-ans ma baldecsbcom Vy input #39 at wom.controlengcomvinformationANSWERS. COVER STORY: IT/OT COLLABORATION Michael Bingaman, Siemens Indust Ine IT/OT collaboration must drive digitalization Converging information technology (IT) and operations technology (OT) does little to move end-to-end digitalization forward. What makes digitalization really work is successful OT and IT collaboration and an understanding of what the other side needs. See 7 tips for smarter OT and IT collaboration. dustry talk about the convergence of oper- ations technology (OT) and information technology (FT) assumes the two sides will merge into some common domain using IT methodologies, devices, tools, and team expertise — with all of it being as applicable to a plant floor as to front- and back-office operations. That notion, however, can be seriously mis- leading. By itself, ITIOT convergence does little to actually move end-to-end digitalization forward. While it might provide short-term cost savings through more technology sharing and consolidat- ed IT and OT teams, the performance gains will be incremental, at best, and not the quantum gains Othe real point of IT/OT collaboration is to establish vibrant digital threads of data running transparently, seamlessly and securely through businesses from the factory floor to the board- room and everywhere in between. y 30 November 2019 digitalization can unleash. Shop-floor applica tions of IT-oriented hardware, software, connec- tivity, and services always will need to be far more robust, precise and reliable than those needed in offices. Instead of IT/OT convergence, industrial enter- prises require a deep, cross-functional, and pro- active collaborative approach that combines the respective intellectual power, know-how, and (CONTROL ENGINEERING experience of IT and OT teams to make today’s industrial operations fully digital enterprises. The goal would be to collectively understand the unique terminology and design requirements for all network environments, especially in context of the network as the strategic backbone of a fully digital industrial enterprise. Roots of the IT/OT convergence myth The idea of IT/OT convergence is under- standable. After all, IT and telephones were once separate functions and networks in most large ‘companies, but they converged years ago thanks to packetized voice-over-IP (VoIP) technology. ‘What's more, OT engineers have adapted many enterprise IT technologies to address the needs of a diverse industrial landscape that spans factories, warehouses, logistics facilites, plus power, marine, ‘mining, and oil and gas industries. ‘Among those technologies are Ethernet enabled wired and wireless local area networks (WLANs) as well as industrial PCs, switches and routers. Industrial operators are continue to adapt. emergent enterprise IT technologies, such as the cloud, Big Data, and advanced analytics, com- pelled by the economic advantages and com- petitive imperatives of the industrial Internet of ‘Things (Ilo), ‘The benefits of these IT adaptations have included big reductions in costs, latencies, cycle times and data collection errors. Industrial com- munications — the digital thread — also has helped interconnect what were once islands of activities and data, while helping to break down operational silos. Greater transparency and oper- ational visibility also enable far better decision support for optimizing asset utilization as well as production quality, flexibility and costs. nw controlang com‘Adapting enterprise IT for complex OT applications ‘Adapting IT solutions for complex OT applica- tions goes far beyond putting a veneer of rugged- ization on devices For example, OT automation systems consist- ing of hundreds or even thousands of field-level devices — sensors, actuators, valves and instru- mentation — need precise, millisecond synchro- nizations of activites. Supporting networks must be deterministic. Data commands must arrive when they are supposed to and not on a best- effort basis. A network hiccup that delays an outbound email by a half-second might not be noticed by a user, buta similar delay in a control- ler command arriving at its destination could dis- upt a production line. ‘The consequences could be missed custom- er commitments, costly restarts, or, worst of al, worker injuries. Many leading industrial enter- prises are not converging IT and OT technologies because they know doing itis beside the point. The real point of IT/OT collaboration is to establish vibrant digital threads of data running transparently, seamlessly, and securely through businesses from the factory floor to the board- room and everywhere in between, Facilitating IT/OT collaboration for end-to-end digital enterprises Rather than pushing their and OT teams to force even a blending of two necessarily distinct technology environments, these companies prefer them collaborating to make an end-to-end digital enterprise a reality for their companies. To do so, each team needs to understand the other's exper- tise and points of view, which includes their chict Three concerns for IT and factory digitalization 1. Environmental, health, and safety impacts. While technology failures or security incidents can certainly disrupt enterprise operations, similar incidents in an industrial environment ean cause disruptions and consequences on a different scale, even threatening lives and the environment. 2. Asset availability and utilization. Net- worked industrial systems can create business risks most IT teams may not yet had to consider, such as the damage or loss of expensive equipment or the production of faulty goods. Production dis- ruptions also can cause industrial enterprises to miss customer commitments. Poor asset avail- ability and utilization also can lower investment returns, 3. Outdated or custom systems. IT is used for applying frequent and consistent software patch- wow contrlong. com Mitzmmtely by anceeencing feral potential of modern indust | communica’ ns, IT and OT can work together to ensure more operational efficiency, visibility, flexibility and security in production. 5 es and upgrades, while industrial environments tend to be more systemic: one small change in one component or subsystem can trigger changes or disruptions elsewhere. Many legacy plant and fac- tory control systems, as a result, may be running outdated operating systems that cannot easily be swapped out or a custom configuration that isn't compatible with the standard enterprise IT secu- rity packages. Four concerns for OT with enterprise connectivity 1. Physical risks and safety. Threats to life sale ty are still aconcern, but OT teams now face threats that are potentially outside of their control, Connecting machines, equipment and control systems to more ‘open enterprise networks can leave them vulnerable to hacking. Hacks can technology, operations technology, TOT override valve controls and emergency Yechnology shut-offs, exposing employees to danger and production to costly disruptions. 2. Productivity and quality con- trol. Losing control of the manufactur- ing process or any related devices are an OT teamis worst nightmare. What if some malicious party was able to repro- ‘gram an assembly process to skip a few steps or halt production entirely — resulting in a faulty product that could potentially injure a customer user? technology. ‘Successful information technology and operations technology (07) convergence needs o rely on calaboration between the two sides. FF concerns stemming fron colaboration include asset avalebily and outdeled More WO! Swers KEYWORDS: information OT concerns inchide risks to physical safety, quality control 3. Data leaks. While data breach 24 data leaks. es have long been a top concern for ONLINE traditional IT teams, they are some- Read ths article onlne at what new to OT teams used to work- ing with closed systems. However, given the types of industrial systems coming online, securing transmitted data is critical 4. Industrial security. While OT teams can see the benefits of moving from closed systems to open networks, convergence? ConTRoL enaivecrnc November 2019 \warw.controleng.com for ‘additional inks to T/OT integration and collaboration. CONSIDER THIS. What is the biggest challongs for your compary when it comes to M/OT collzboration and 3