The Internet of Things (IoT) is the network of intelligent devices, that has embedded electronics and software to capture and transmit information. Integration of such information enables physical to digital convergence and gives a real-time status of the equipment condition and performance. Such network of industrial devices is also often called as connected IoT devices, industrial internet, and industrial IoT.

Industrial IoT applications and associated smart manufacturing technologies are referred to as Industry 4.0. Each generation represents the major technological developments that took place to alter the fundamental nature of the industry and transform into a newer plane. Mechanization, Mass production and computers and automation represent the three past generations and  Industry 4.0 represents the fourth generation of convergence of physical and digital systems.

Internet of Things (IoT) Market and Benefits:

According to Gartner research, 8.5 Billion devices are connected in the year 2017 and it is expected to hit 20 Billion devices by the year 2020.  Masayoshi San of SoftBank and ARM predicts an installed base of 1 Trillion Internet of Things (IoT) devices by the year 2035.

Internet of Things is all pervasive and is revolutionizing every industry, from personal health monitors, household appliances, energy monitors, shopping systems, micro-irrigation controllers, smart cities etc. in remarkable ways. In the industrial space, Internet of Things (IoT) will provide greater agility via automated processing and reduced human intervention to provide improved asset utilization, process efficiencies, and product mix, without impacting cost, quality or speed.

Impact:

When a billion people connected to the Internet, it altered the fundamental ways in which people communicated (emails, messaging), socialized (social media), shared (photos, documents) and collaborated (video conferencing). Newer business models emerged (Amazon, Netflix) and some older businesses got disrupted (Borders).

Industrial internet is real and happening. With a trillion devices connecting to the network, it’s going to transform businesses in unprecedented ways. Every equipment, system, and is going to spawn numerous data points every second relating to their health, operation conditions, environment, and performance. Resulting information explosion will upend the way we consume information.

Information will become a commodity and competitive advantages will accrue to those that process the information differently to get more actionable insights. Organizations that can model digital twin of their operations can have sustainable strategic advantages relating to monitoring, control, and optimization.

Building Blocks:

MaintWiz Technology Framework for Integration of CMMS with Internet of Things to enable Industry 4.0

  1. Intelligent Devices: A variety of devices are being built as an embedded component of the new age equipment and systems to track the information. In parallel, many of the older equipment is retrofitted with sensors and other external devices to capture such information externally and propagate. Such intelligent devices today capture a wide variety of information like temperature, pressure, vibration, geo-positioning, thermography, process counters, chemical composition, material strength etc.
  2. Connectivity & Normalization: Standardization of information exchange and communication between devices and other medium has not kept pace with the rate of change in the information capture domain. A wide variety of data formats and protocols are in use creating interoperability challenges. While open standards are gaining traction, some manufacturers are still resorting to proprietary formats and encryption to exercise control. Automation, real-time data capture, and pervasiveness of IoT projects across industries have resulted in significant increase in volume, velocity, and variety of information. The first step in any IoT platform implementation is information capture at scale and to normalize such information at the first possible point of interaction.
  3. Device Management: Capturing information from multiple resources and each at different frequency requires the system to be intelligent to manage the communication process effectively. This includes managing latency, missing packets of information,  broken communications, deciphering of errors in real time, omissions and commissions and start-stops. Additional functionalities may include secure access, controls, encryption etc. and can even extend to remote management of the devices and managing their software versions and updates.
  4. Data Repository: Managing such very large data sets requires specific n-tier architecture, that is designed to process information at scale while ensuring such intensive computing is not loading on the primary system performance. Quantum of data, their variety, performance cycles, computational complexity and real-time availability determine both the hardware – the number of processor cores, high-speed memory requirements, online/offline storage etc. and software architecture – database selection, parallel processing, algorithms, optimization etc.
  5. Information Processing: Different parameters require different types of analysis. Some need to be analyzed in real time while certain parameters require historic analysis to derive meaningful insights. Equipment performance can be compared against standards and benchmarks,  against its own historical performance and against its peer class.  Often computations may span multiple parameters and modeling. Rules engines are built to support automation of analysis. A wide variety of computational analysis tools and algorithms are used to process the data to identify patterns and compliance and detect abnormalities.
  6. Alerts & Notifications: Intelligent business rules are set up to deal with exceptions, along with escalation path. Such escalations may include alerts and notifications for human processing and further actions. The wide variety of alert mechanisms are used including emails, text messaging (SMS), automated calling with recorded messages, embedding such alerts in self and third-party mobile apps (eg. Slack) etc and automatic creation of work orders and assignment.
  7. Analytics: A wide variety of analytics can be generating by correlating the data points. With information becoming a commodity and similar information available to competitors, differentiation is coming in the way information is processed to actionable insights. Analytical tools, algorithms, and the visuals play a big role in translating the information into actions resulting in sustainable competitive advantage.
  8. Machine Learning: Machine learning is an application of artificial intelligence (AI) to learn and improve automatically without explicit programming. Machine learning algorithms analyze large data to discern patterns, build rules set, determine downstream actions and reinforces from past experiences. It can lead the direct intervention in operations of complex systems and redefine human-machine interactions of the future.
  9. Enterprise Integration: Industry 4.0 integrates information beyond the connected devices to include other enterprise systems like SCADA, ERP, data warehouses, Sales and Demand planning systems etc. Interoperability and integration with internal and external systems will become a key driver.

IoT Technology CMMS:

With the availability of inexpensive sensors, cloud / SaaS applications, cheap and large storage footprint, big data and artificial intelligence technologies, Internet of Things (IoT) is gaining significant traction.  Industrial IoT applications is expected to account for 24% share in IoT led digital transformations.  Smart shopfloors with its intelligent machines require a common platform to connect and talk to the external world. Computerized Maintenance Management Systems (CMMS) has risen to play the role of integrating the information from different sources and be the common platform connecting the production floor to the enterprise systems.

Principal applications that will be fueled by CMMS – IoT sensors integration include predictive maintenance, production flow optimization, quality control, tracking and traceability, adaptive/autonomous machine management and industrial safety and security. With IoT technology  led humongous data explosion, data management, and intervening actions shall be left to the best of breed Industry 4.0 platforms. CMMS platforms stand a good chance to transform itself to an industry 4.0 layer connecting the intelligent devices with enterprise systems.

Why is MaintWiz an ideal solution for you

MaintWiz CMMS helps in integrating the Internet of Things (IoT) to implement a robust Industry 4.0 solution by connecting the devices and systems, enabling condition monitoring and predictive maintenance and provide outcome driven analytics to accomplish enterprise goals.  It is a Simple, Easy to use, Integrated, Cost effective and Scalable solution.

MaintWiz CMMS is the ideal solution for organizations that would like to embrace Industry 4.0 in their factory floors.

Business benefits include:

  1. Easy to build Information capture Platform: MaintWiz features a flexible hierarchy to build your enterprise assets in the way you want, and attach the equipment parameters that you want to track. Flexible, yet comprehensive system-component-parameter definitions can aid in easily mapping the system to any number of parameters tracked by one or more Internet of Things (IoT) devices.
  2. 360 Degree View of Production Operations: Enables the complete and total view of the assets including history, operations, performance, utilization, breakdowns, component replacements and more. Facilitates comparison of key parameters against industry standards, against the historic performance of the same equipment or system and peer class performance. Aggregate analytics can be rolled up at the system level or analyzed at the individual equipment level.
  3. Integrated System: MaintWiz can integrate with a wide variety of devices and systems, both on the information capture side and enterprise consumption side. Seamless connectivity ensures streamlined information processing and flow and thus enables a single source of truth and One Enterprise concept.
  4. Predictive Maintenance: Critical information gathered from multiple devices and systems can be combined to provide predict equipment failure before they occur, saving precious time, effort and cost.
  5. Human Machine Interactions: MaintWiz is easy to use and configure, requiring very less implementation time and learning time. Mobile app with its one-click maintenance can capture information at the point of work easily. Automated data capture can coexist with manual data entry to provide comprehensive views. Intelligent configurations and rules enable information to seek you, rather than you searching for information.
  6. Business Intelligence: MaintWiz provides comprehensive tools to analyze and act upon the large information data sets. Features a wider range of reports, interactive charts, and other visual analytical tools. Business rules for downstream actions can be defined based on conditions to alert on first symptoms or generate work orders for resolution.

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