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Industrial Internet of Things (IIoT) Applied SolutionsDiscover how digital transformation can turn real-time data into increased efficiency and reduce operating cost
Uncover actionable insights that drive operational improvement
Operational challenges
Devices/Equip-ment
Predictive Maintenance
•Machinesanddevicesoffernoconditionmonitoring,leadingtounexpecteddowntime
•Unabletoidentifyproblematicdevicesandschedulemaintenance
Sustainability
•Machineperformanceisnotmonitoredleadingtohigherenergyconsumption
•Lossesandleaksgoundetectedleadingtowastedenergy
•Undetectedissuescreatelatestagequalityissuesleadingtoscrappageandmaterialwaste
Globalcompetitionrequiresmanufacturerstostriveforoperationalexcellencetoensuretheyarecompetitiveandprofitable.Thisrequirescontinuousimprovementsintermsofgreaterreliability,reducedunscheduleddowntimeduetoequipmentfailures,lowermaintenancecosts,extendedequipmentlife,optimizedenergyconsumption,improvedsustainabilityandgreaterthroughput.
Manufacturesoftenoperatewithlittleinformationaboutthehealthandperformanceofdevicesandmachines.Thiscancreateatrialanderrorapproachtotroubleshooting,leadingtoexcessivedowntime,highermaintenancecostsandlowerefficiency.Manufacturersareincreasinglylookingtodigitallytransformtheiroperations,changingfrommanual-basedworkpracticestoautomated,digital,software-basedanddata-drivenwaysofworking.
IIoTapplicationsareenablingcompaniestoleveragetechnologyandexpertisetodigitallytransformoperations.Awealthofusefuldataistrappedinsidedevices,equipmentandmachines.IIoTtechnologiespresentsanopportunitytogaineasierandfasteraccesstoactionableinformationthatsupportsbetterdecisionmakingandoperationalperformance.
Alackofactionableinformationpreventsperformanceimprovementsinthedomainsofreliability,sustainability,productivityandsafety.Belowareexamplesoftypicaloperationalchallengeswecanassistwith.
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Productivity Improvements
•Criticalparametersrequiredtooptimizemachineperformancearenotmeasured
•Unplanneddowntimereducesequipmentavailabilityandproductivity
Safety
•Additionalcomponents,costsandcomplexityrequiredtoimprovesafety
•Greatercomplexitycompromisesproductivity
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IIoT opportunities
IIoTcreatesanopportunitytorevolutionizemanufacturingoperationsbyenablingtheacquisitionandaccessibilityofgreateramountsofdata,atfargreaterspeeds.Butobtainingadditionaldatafromtheplantfloorthroughabroadrangeofsensorsisjustthestart.Youmustbeabletoturnrawdataintoinformationthatcanproduceactionableinsightsthatenhanceoperations.Butinordertodothat,youfirstmust:
•Developacleardefinitionoftheproblemandscale
•Understandthecurrentsourcesofdataandpotentialmissingdata
•Createtheplanforhowinformationwillbecollectedandtransferredtoaction
•Calculatethereturnoninvestment(ROI)foryourIIoTapplication
FormanymanufacturersthereisstillnotaclearunderstandingofhowtheIIoTwillcreatequantifiableimprovementsfortheirbusiness.InvestmentsindigitalizationandIIoTtechnologycanbesignificant,butwhateverthesizeofcapitalexpenditure,itisimportanttoconsidertheROI.Someapplicationexamples:
•Anicecreammanufacturermadeaone-offinvestmentontechnologythatenabledthemtoanalyzemachineperformance,identifyleakages,andpreventunplanneddowntime.ThisinvestmenthelpedthemtoimproveOverallEquipmentEffectiveness(OEE)andincreasemachineproductionsignificantly,withaROIoflessthanthreemonths
•Aglobalmanufacturerinvestedinasolutionthatprovidedpredictivemaintenancetopreventreplacementofcostlycylinders.Thisnotonlyreducedmachinedowntimeandlaborcosts,butalsosavedthemanufacturerexpensivepartreplacements.TheROIwasoneyear
ToidentifyIIoTopportunitiesinyourorganization,areassuchastheautomationarchitecture,machinecontrolsystems,SCADA,safetysystems,PLCs,networkingtechnology,sensors,machineryhealthmonitoringandinstrumentationshouldbereviewed.
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Industry Example Challenge Solution Opportunity Benefit
Factory Automation
Frequentreplacementofrodlesscylindersresultingincostlydowntimeandlosses
Monitorhealthstatuswithsimpletwo-positionsensorstomeasuremovementanddampingspeedofshockabsorbers
•Predictfailuresofcylindersandcomponentsbeforetheyhappen
•Reduceunexpecteddowntimeeventsthatcostproduction
Food & Beverage
Highcompressedairandsteamconsumptionandlowenergyefficiency
Monitorairandsteamflowandpressureprofile,andotherparameterstodeterminethecausessuchaswasteorleaks
•Reducedpneumaticairconsumptionandimprovedenergyefficiency
Tire Manufacturing
Increasedmachinecycletimeisreducingthroughput
Monitormachinecomponentcycletimeandkeyparameterssuchassteamtemperature,pressureandflowtodeterminethecauseofincreasedcycletime
•AbletomakeinformeddecisionstoimproveOverallEquipmentEffectiveness(OEE)
Automotive
Increasingmachinesafetyaddscomplexityandreducesproductivity
Isolatethreesafetyzonesfromasinglevalvesystem,reducingcomplexityandcomponents,andanalyzeproductiondatatoconfirmanycompromise
• Increasedsafetywithoutcompromisingmachineproductivity
IIoT applications
EmersonhasbeenapplyingIIoTtechnologyforseveralyears.Ourexpertsunderstandyourindustryandapplicationrequirements.TheyareexperiencedinidentifyingopportunitiestoimplementIIoTsolutionsthatwillprovidetheperformancegainsyouneed.HerearesomeexamplesofhowwehavehelpedourcustomerstoimplementIIoTonkeyapplicationsthathavecreatedsignificantbenefits.
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Industrial automation and machine control capabilities
IntegratedsolutionsincludingIIoTapplicationsfromasingleautomationproviderhelptosimplifythedesign,commissioning,procurement,andlifecyclemanagement,leadingtolowercostsandgreateroperationalefficiency.Emersonistheleadingindustrialautomationcompanythatoffersacompletemachineautomationandcontrolportfolioincludingintelligentsensorsanddevices,controlsystemsandHMI/SCADA,fluidcontrolandpneumatics,motioncontrollers,safetysystems,wiredandwirelessnetworkdevices,andmore.
IIOT
&SO
FTW
AR
EC
ON
TRO
L &
CO
NN
ECTI
VITY
FLUID CONTROL PNEUMATICS
PLC/PAC
SCADAHistorianGateway Cloud Storage & Analytics
IP20 I/O
Machine Network (Ethernet)Industrial Switch
Rodless Cylinder with Linear Position Sensors
Visualization & Dashboards
FilterRegulator
WirelessTransmitter
WirelessGateway
EdgeGateway/Controller
Mobile & Web HMI
ServersMachineLearning
Safety
ProductionReliability & Maintenance
Sustainability
BCFlow Pressure Temp pH Level
W.A.G.E.S. Sensors - Water, Air, Gas, Electric & Steam
Particles
IP20 SafetyI/O FRL with
Safety Valve
MOTION CONTROL
AC Motor
SYSTEM ARCHITECTURE
ON/OFFValve
ControlValve
PositionSensor High
PressureRegulator
W.A.G.E.S.Sensors
MotorizedValve
Angle SeatValve
AsepticValve
FRL
Fieldbus Network
ProportionalValve
Fieldbus Network
VFD/VSD Servo Drive
Servo Motor
FRL with Pressure & Flow Sensors
PLC/PACHMI
Factory Network (Ethernet)
Valve Solenoid Valve
Positioner
LimitSwitch Box
IP65 I/O & Valve System IP65 I/O & Valve System
Cylinder withPosition Sensors
IP65 I/O & Zoned Safety Valve System
Cylinders with Position Sensors & Mechanical Locking Units
7
IIOT
&SO
FTW
AR
EC
ON
TRO
L &
CO
NN
ECTI
VITY
FLUID CONTROL PNEUMATICS
PLC/PAC
SCADAHistorianGateway Cloud Storage & Analytics
IP20 I/O
Machine Network (Ethernet)Industrial Switch
Rodless Cylinder with Linear Position Sensors
Visualization & Dashboards
FilterRegulator
WirelessTransmitter
WirelessGateway
EdgeGateway/Controller
Mobile & Web HMI
ServersMachineLearning
Safety
ProductionReliability & Maintenance
Sustainability
BCFlow Pressure Temp pH Level
W.A.G.E.S. Sensors - Water, Air, Gas, Electric & Steam
Particles
IP20 SafetyI/O FRL with
Safety Valve
MOTION CONTROL
AC Motor
SYSTEM ARCHITECTURE
ON/OFFValve
ControlValve
PositionSensor High
PressureRegulator
W.A.G.E.S.Sensors
MotorizedValve
Angle SeatValve
AsepticValve
FRL
Fieldbus Network
ProportionalValve
Fieldbus Network
VFD/VSD Servo Drive
Servo Motor
FRL with Pressure & Flow Sensors
PLC/PACHMI
Factory Network (Ethernet)
Valve Solenoid Valve
Positioner
LimitSwitch Box
IP65 I/O & Valve System IP65 I/O & Valve System
Cylinder withPosition Sensors
IP65 I/O & Zoned Safety Valve System
Cylinders with Position Sensors & Mechanical Locking Units
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ScheduleanIIoTIntroductorySessiontolearnhowtoreducemachinerydowntime,increaseequipmentreliability,enhancesafety,makeenergyefficiencysavingsandimproveproductionefficiency.
EmersonIIoTIntroductorySessionsprovidetheopportunitytolearnhowtobuildsuccessfulIIoTstrategies,turnactionableinsightsintooperationalimprovementsandcalculateareturnonyourIIoTinvestment.Signuphere:go.emersonautomation.com/IIoT-introductory-sessionsYourlocalcontact:Emerson.com/contactus
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