Sesión Introductoria

31/05/2023 – Herramientas
15 de diciembre de 2022 digitales
 Smart Products
the Smart Assets differentiator

Customer self service. OEE KPI monitoring & anonymous benchmarking. Enabler for
Asset Insights Reporting & Benchmarking objective data driven decisions, operational excellence, Mission Zero reporting and risk
mitigation

Optimized Asset profiling. I.e. Optimal, efficiency / productivity / stability / quality / energy
Asset Optimizing Advanced Process Control
consumption / emissions. Instant maintenance & fine tuning through remote support

Increased availability, productivity and operation time. Timely availability of spares and
Asset Health wear parts. Reduced maintenance, TCO and CO2 emission.
Online Condition Monitoring Services
Timely asset reporting on current and future problems.

Information. Security, Cloud Intelligent connected equipment. Data collection from assets and plant subsystems ingested
IOT Platform
Storage & Integration to cloud. Instant deployment of new functionality, bugfixes, firmware & security updates

Personnel, Asset Safety & Reduce LTIF and asset breakdowns. Instant support through remote trouble shooting
Product Control
Control

Machines, Systems, Sensors

Plant Assets
& Process data
 Smart Products
x xxxx S Value chain

Smart Products
Sriram Seshadri

Product Management Delivery Management

Peter To Frederiksen
Peter Matthiesen & Sriram Seshadri Acting
Business Partners

Asset Insights Asset Insights

Commercial Support
Manikandan Rajendran Ramya Chakravarthy

Connected Assets
Asset Blueprint

Jeyamurugan Kandasamy
Jeyamurugan Kandasamy

Srinivasan Venkatramani
UX Experience

Shriram Viswanathan
IoT Platform

IoT Platform
Marta Perez Mata
Asset Optimization Asset Optimization
Sunil Rajaram

Hemanth Ranganathan Tejas Maru

Asset Health Asset Health

Steen Christian Knudsen Henrik Nysted

Product Control Product Control Execution

Karthik Koolpandi Lars Schultz

Industry, Regions & Digital Business Needs Plant Assets (Machines, Systems & Sensors)

May 31, 2023 3

• Presentation subtitle

Product Control System

31 May 2023
• What do you want from your
Asset?
- High Production
- Up time
- Fast troubleshooting
- Ease to operate and maintain
- Quality of the product
- Data driven control and decisions
- Health monitoring
- Future-ready technology

31 May 2023 5
 Product Control is the Answer

• Increase flexibility, reduce installation times, ensure safe,

reliable and efficient operation.

• Reduce down times and provide tools, data and

connectivity for smart digital services.

• Scalable, secure and easily integrated with future-ready

technologies.

• Is the FLSmidth solution that combines the latest tools

with the FLS process know-how and global footprint.

31 May 2023 6
 Why ECS/Product Control?

BEST VALUE DATA POWER SMART PRODUCTIVITY

 Reduce 70% Installation  Collect vital information of  Dashboard and smart  OEM software is designed
times. your asset. screens for equipment to safely run at peak
status at a glance. performance.
 OEM Software and  On board trending and
operation assurance. historian with operators  Diagnostic and fault  Remote connectivity and
log on the machine. analysis capabilities. 24/7 online assistance.
 Different PLC brands
standard support to match  Ready for integration with  Optimization and asset  Digital analytics to suggest
your needs. any protocols and health options. operational changes.
central/plant controls
 Solid ECS/Acesys library systems.  Ready for stand alone,
structure local and remote.

31 May 2023 7
 Connectivity How it Works FLS Controller Remote I/O

Plant
Control

FLS Cloud

Smart Hub

FLSA Wireless Control

via Industrial Tablet
(Optional)

31 May 2023 8
 Key Benefits
For FLS: For Customer ’s:

• Strengthen the FLS brand • Effective Control standard

and visibility
• Open door for
future opportunities.
• Increase chance of getting
data in the FLS cloud - Onsite
foundation for the
digital journey.
• Better Warranty Management.
(ACESYS) library and Data
driven decisions.
• Increased troubleshooting
ability
• Backed by FLSmidth know-how
throughout the lifecycle
• OEM Assurance
• Less Installation and startup
time and no extra cost.

31 May 2023 9
• Product presentation

IoT Platform

31 May 2023
 IoT platform

SECURE SCALEABLE IN HOUSE AGILE Lorem PROTOCOLS

ipsum

 Safe and secure data  Rapid development,  Edge and cloud architecture  Continuous improvement,  Capability to handle
collection from equipment management and scaling of developed totally inhouse deployment and feedback popular industrial protocols
in cement and mining the data services offered with support of externals from end user for data communication -
industry. Ethernet, Modbus, OPC UA,
FTP, MQTT etc.,
 The collected data is
processed and stored for
future retrieval and use

31 May 2023 11
 Field Agent – Types

Small FA Big FA Soft FA (Win 10 PC) Linux Edge device

 Model: FFA-S 2.0
 FLSmidth: 180 EURO*
 4G LTE, Ethernet, GPS
 RS 485, TCP/IP
 2 Digital input, 2Analog input
 24 VDC power
 Handle up to 1000 Signals
 Internal storage 32 GM
 Model: FFA-L 2.0
 FLSmidth: 690 EURO*
 4G LTE, Ethernet, GPS
 RS 485, TCP/IP
 2 Digital input
 24 VDC power
 Handle up to 15000 Signals
 Can handle edge computing
 128 GB SSD
 Model: OptiPlex 7060 Micro
 Dell: 650 EURO*
 Ethernet
 No limitation on signal
 Can handle edge computing
 Up to 512 GB
 Dell 5100: 1200 EURO*
 4G LTE, Ethernet, GPS, Wifi
 RS485,232, TCP/IP, canbus, zigbee,
LoRAwan, BLE
 2 Digital input
 24 VDC power
 Handle up to 15000 Signals
 Can handle edge computing
 Up to 64 GB

31 May 2023 12
 Edge Capabilities
• Remote Field Agent configuration from IoT Cloud Portal
• Remote Monitoring from Cloud
• Field Agent Health KPIs
• Events and logs
• Portfolio of ready-to-use edge applications
• Edge application = purpose build software that runs on the field agent
• Realtime signal - time series data capture
• Batch signal data capture
• Data reduction algorithms
• Extensible Linux platform
• Easy to develop and roll-out new edge applications
• Edge applications are docker based micro-services (runs in a lightweight docker container)
• Software that can be packaged into a Docker container can run on the edge
• Multiple applications can use the same network port

31 May 2023 13
 FLSmidth IoT Platform –
Security Focus

• All communication between plant control

system and cloud will go through FLSmidth
FA.

• No direct connection from the control

network to the Internet.

• Network is isolated and all communication is

managed by FLSmidth FA.

• FLSmdith FA is running Linux so not

vulnerable to Windows viruses etc.

• All unused ports is closed and all unused

functionality disabled.

31 May 2023 14
 FLSmidth IoT Platform –
Security Focus
• Automatic updates pushed to device
when available
• Firewalls separate FLSmidth FA from
cloud and from plant control system.
• All communication to the cloud is
encrypted.
• All relevant technical requirements
from IEC 62443 implemented
• Penetration and vulnerability testing
has been done successfully by
independent experts.

31 May 2023 15
 FLSmidth IoT Platform Components & Dataflow
Data collection environment FLSmidth Cloud
SiteConnect™
Machine Controller/PLC Small
SmallFA FA

Real-Time
Data
Power BI
Factory MS Broker
with soft FA BigBig
FA FA

Batch
Data Cloud Time
Gateway Series DB CMS / DA
Asset Data Linux Gateway soft
Asset collector FA

Data
Data Fetching & Data Transfer to Cloud Data Processing & Data
Data Stream & Input to FA(s) Monitoring
Conversion (Realtime & batch) Storage Publishing & Usage
 IoT platform Management
• Structured visibility in connected
assets
• Rapid onboarding of site or asset
• Global operation with centralised
onboarding and deployment

• End to end live monitored platform

• Dedicated team to attend issues
and getting the site online
• Live statistics on platform
performance and integrity

31 May 2023 17
• FLSmidth

Asset Health Service Products

31 May 2023
 Why Asset Health Service Products?
Provide asset health prediction
1 during warranty
Input for better planning
• Better shutdown planning
• Reduce risk for consequential
damages
• Reduce Safety risks
Spare parts in due time
Efficient mobilisation
• Field service
• Remote expert support
 Customer satisfaction
 Less warranty cost
31 May 2023
Provide asset health prediction
Provide asset health prediction
2 after warranty 3 for Total Cost of Ownership
contracts
Input for better planning Reduce TCO
• Better shutdown planning Reduce risk in offering TCO contracts
• Reduce risk for consequential
damages
• Reduce Safety risks
Service sale opportunities
• Spare part proposals
• Field service proposals
• Remote expert support
 Customer satifaction  Customer satisfaction
 Increased service sale  Higher contract profit
19
What is
Asset Health
Service?

Detection and prediction

Products:
2 1
1. Using existing process and
control signals for
notifications of failures

2. Using additional sensors for

earlier prediction of failures

31 May 2023 20
Asset Health Service Products - Data flow

Sensor data Alert

Machine / Plant FLSmidth Cloud FLSmidth 24/7 Global
Application Remote Service
Center
Implement
corrective action

Inform 1. Resolution
FLSmidth Service 2. Reporting
Maintenance

31 May 2023 21
 Asset Health Service Products - Road
to reliability
1  Identify failure modes
FLSmidth FMEA  Prioritize the failures with highest risk

2  Identify sensors to predict the failures

Instrumentation  Install and start condition monitoring

3 Monitoring and  Detect potential failures at an early stage

 Make analysis and diagnostics
analysis

4 Actionable  Observations
 Interpretation
recommendations  Recommendation

5  Maintenance planning
Customer Plan and repair  Risk management
 Prevent / Repair

6  Discover root causes of reliability

Improve  Correct

31 May 2023 22
 Asset Health Products
- Unique Selling Points
 FLS has:
 Knowledge about the machine and process
 Knowledge and access of service parts availability
 Asset experts and qualified site service

 The top features are:

 Adapting FLS machine and process knowledge into the service products
 Integrating recommended actions with spare part and field service
proposals
 Increased future asset quality, services and possibilities for
benchmarking

31 May 2023 23
• FLSmidth

Asset Optimisation
 What is Asset Optimization?
• Asset Optimisation improves the efficiency, productivity, stability of
any equipment using advanced instruments and Advance Process
control techniques for the existing design.

Remote
Monitoring

Advanced Process Control

Advanced Instrumentation

31 May 2023 25
 Why Asset Optimization?

Assist Operator

Improve Stability
Advance Process Control

Improve Quality Process Expert System

Increase Production

Advance Instrument
Inform operator
Example: Froth Camera

31 May 2023 26
 Asset Optimisation
Products
roducts - Unique
 FLS has: Selling Points
 Knowledge about the machine and process

 Knowledge of the latest Control Technologies

 The top features are:

• Adapting FLS machine and process knowledge into the advance process control

• Run a complete closed loops with adaptation of smart instruments in the control strategy

 Benefits to the customer:

• Increase in Production

• Increase Recovery

• Reduce Power

• Improve Stability

• 24*7 Remote support to ensure continuous operation

31 May 2023 27
 Advanced Technology
PID APC
1 Single Variable In & Single Variable Out 1 Multivariable In & Multivariable Out

Set up a target and control process variable to the target. Control strategy based on a cross correlated matrix
What would be a best SP is often unknown of key process variables

2 Feedback Control 2 Predictive Control

The controller will take no action unless the errors show in PV Dynamic models developed through process step tests
Future process behavior prediction and feed forward control

3 Poor Control Quality 3 Explicit Dynamic Models

During large time delays or complex dynamic interactions Leverage computer capabilities to calculate impact to the
product

4 PID Set Points Are Not Necessarily Optimal 4 Optimal PID Targets

With respect to plant wide objectives Continuously calculated, set, & modified

31 May 2023 28
Close to Ideal Operation

Ideal Operation
P2

Optimization

Stabilization
Operator

Advanced Process Control

P1

The information contained or referenced in this presentation is

31 May, 2023 confidential and proprietary to FLSmidth and is protected by 29
copyright or trade secret laws.
 Asset Optimization – Where are we

Advance Instrumentation Advance

Dolor sit Process
amet Control Application

 Impactmeter  Sag Mill

 Froth Camera  Secondary Grinding
 Floc Camera  Fulgrinding
 PSD Camera for crusher  Smart Cyclone
 Flotation
 Thickener
 Filteration Available
 Gyratory Crusher
 Cone Crusher
In progress
Future

31 May 2023 30
Summary
01 03
Intelligent Control is a key
Digitalization is key for technology- component for stabilization and
driven performance improvements optimization

02
Next-Generation Analytics and
Decision Support Systems are
fundamental for driving
productivity
04
Intelligent Control incorporates
multiple technologies, each one
solving a particular problem

31 May 2023 31
Asset Insights
 Data (Live/
History)
Threshold/
Stoppage
Alerts…
• The longer it takes you to gain
access to crucial business
KPI (Actual /
Target) insights, the less productive
you will be.
01 02 03

Challenge to take Inconsistent insights of

Geographical constrains
INFORMED DECISIONS qualified decisions when and an Asset due to
not being on premises rigid work environment guesstimates & Lack of
Executive @ HQ / Region Analytics

Plant Manager @ Plant Product Manager

Production Manager @ Plant Industry / Region
Department Manager @ Plant

31 May 2023 33
 Asset Insights – Current Status (Internal use only)
• Monitor multiple plants & Assets
• E2E Plant Performance & Operation
Real time MOBILE INSIGHTS Monitoring
+
Batch
Batch • Dashboard & Trends
• Notifications for custom limits breach
EXTERNAL CUSTOMERS
• Tenant administration E.g., Executive @ HQ / Region
• Asset KPI (E.g. OEE, CO2…) Plant Manager @ Plant
• Stoppage reason (T/V), History Production /Department Manager @
Connected Secure Cloud Analytics • Maintenance Schedule, History
Plant
plant Storage Platform • Costing – Raw material, Fuel
or equipment Engineer / Technicians e.g., Shift in
charge
&
• Benchmarking – Operation,
Performance, Peer Assets / Plants INTERNAL CUSTOMERS
• Interactive Analytics Eg., What if Industry & Regions
EXPLORATORY
WORKSPACE analysis Available for Sale
(Power BI Web)
Internal
• Baselining & Standardize
Pipeline (WIP)
• Forecasting, Predict
• Reporting – Automated
31 May 2023 34
Siteconnect

31 May 2023 35
INNOVATION
IN CEMENT AND MINING
THE CHALLENGE
Without accurate data and
the digital systems needed
SiteConnect™ Mobile Insights App to identify non-performing
areas of operations,

REAL-TIME productivity will suffer.

THE SOLUTION
PRODUCTIVITY DATA A mobile app that provides
real-time insights (Process,
KPIs…) on critical assets.
Monitor the performance and health of
your critical assets anywhere, anytime.

SiteConnect keeps you connected with

your equipment and plant. With on-the-go
real-time monitoring and dashboards, you
are empowered with the information you THE BENEFITS
need to manage and boost productivity.  Improves productivity
 Optimises efficiency
 Enables additional
uptime
FLSmidth ENABLR platform OPERATIONAL
INSIGHTS

enhancing the benefits of

Industry 4.0 by enabling data-
driven analytics SECURE CLOUD
STORAGE

Connected plant
or equipment

SITECONNECT APP

31 May 2023 37
 Overview of Siteconnect

300
Users

36
Sites

31 May 2023 38
 Critical insights to help you making
better decisions

31 May 2023 39
Asset KPIs

31 May 2023 40
 Advanced Insights about your Assets…

01 OEM / Custom KPIs

02
KPI Benchmarking
- across similar Assets /
Department / Site

03
Self servicing analytics
- What if, Forecasting Scenarios…

31 May 2023 41
Boosting benefits in the Industry 4.0 era with
Mobile Insights / SiteConnectTM

IMPROVE VISIBILITY OF UNDERSTAND THE WHY AND MAXIMISE DISCOVER & OPTIMISE ASSET QUICKLY RESPOND TO UNPLANNED
PLANT AND EQUIPMENT THE THROUGHPUT MANAGEMENT EVENTS
PERFORMANCE

Stay up-to-date on how your plant Stay on top of the game by Discover the potential gap against Respond quicker to unplanned
and equipment are running – knowing where you will be Benchmark – and optimize your events that might otherwise
wherever you are weeks and months from now assets have disrupted operations

31 May 2023 42