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