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Connecting machines and devices in a reliable
way: What you need on your factory floor?June 20th , 2017
Uroš Merljak, Partner Channel Sales Director
IIoT brings benefits across the automation journey
Asset Performance
Augmented
Operator
Control Optimization
Design &
Engineering
Commissioning &
Operation
Maintenance &
Services
Cost & Time to market Efficiency Availability
What: Empower the operator with the right info
How: Mobile devices, wearable, wireless
Benefits:
• Worker productivity improvement
• Ready for millennials (knowledge work
automation)
What: Optimize asset use
How: Analytics, secondary sensing, cloud
Benefits:
• Unplanned downtime reduction
• Maintenance cost reduction
What: Bring control at the enterprise level
How: Local OT autonomy, global IT connectivity
Benefits:
• Process/Factory productivity improvement
• Energy consumption reduction
At SE, we focus on three pillars to tap into the potential of IIoT
Augmented operator Asset performance Control optimization
• Connected ProductsThe Internet of Things starts with things and it is intelligent products like
connected breakers, sensors, actuators and motor drives that serve as the
foundation of smarter operations. Digital twin.
• Edge Control: Automation & Control systemsWe enable our customers to have real time solutions for control at the
Edge of the IoT network. For mission critical scenarios, not all control
decisions can be made remotely and overridable control of devices at the
Edge of the network of things is a must.
• Applications, Analytics and ServicesOur customers come with a variety of hardware and systems.
EcoStruxure enables the most extensive breadth of agnostic Applications,
Services and Analytics working with any hardware, any systems, and any
control.
Technology Layers Explained
ANALYTICSCLOUDMOBILITY SENSING SECURITY
Open data management for seamless IT/OT convergence
Partner ecosystem
Connected
Products
Edge control
Apps,
Analytics &
services
From machine applications, such as HVAC and pumping, to process automation in F&B, WWW, MMM, and O&G
Innovation at Every Level in Industries:
Process Engineering
SimSci PES
SimSci EYESIM
Pipeline Mgmt Suite
Planning &Scheduling
SimSci Spiral Suite
Struxureware SDO
Asset Management
Avantis EAM
Avantis PRiSM
APMaaS
Operations Control
Wonderware System Platform
OASyS DNA
Citect SCADA
ClearSCADA
InformationManagement
Vijeo 360
Wonderware Online
Wonderware Historian
Wonderware SmartGlance
Industry Solutions
Line Performance Suite for F&B
APM for Power
Unit Performance for O&G
Operations Management
Wonderware MES
SimSci APC
Struxureware Operations Ampla
ResourceAdvisor
Supply Demand Sustainability
Operations Control
InTouch Machine Edition
Vijeo D, Vijeo XD
InduSoft Vijeo XL
Prometheus
Touchscreen Panel
Valve Positioners
Variable Speed Drives
MCC/PCCElectrical Panel
IndustrialSensors
Motor Starters
PowerStruxure
En
d-t
o-e
nd
Cyb
ers
ec
uri
ty
Clo
ud
i/i
lin
alo
ka
cij
i
PlantStruxure
ModiconPlantStruxure
Modicon, Foxboro, Triconex
Continuous ProcessDiscrete Process
EcoStruxure.io
Machine Automation
MachineStruxure
Altivar
Efficiency improvement as a result of convergence of IT/OT technologies
EcoStruxure for Machines
TRACK – Value proposition
Needs & Wants of Schneider Electric’s OEM customers and End Users
OEM Engineer
Maintenance
technician
End-user line manager
“I have many machines, with various purposes, ages… Handling full
history is a nightmare”
“Replacing parts on my machines interrupts production and should
be optimized”
“I would save a lot of time if I could access all machine latest
documentation and information in one place”
“I want to know if spare parts are available before I go on site”
“It is annoying when the machine logbook is not complete”
“Service to my customers would be much faster if I could have
access to machine information and location instantly”
“With standard and complete information about my customer’s
machines, I would be able to better understand what to offer them”
TRACK is a repository service for OEMs that enables online
access to documentation and history of all their machines
Bill of material, technical documentation, localization, service log,
warranty info, spare part availability, and more
TRACK is a cloud repository service
To access key information
about my machine
Machine info trackingWeb application Spare part management
Architecture
Machine and components
documentation
Localization of Installed Base
Spare part availability
information
Easy order placement
(For SE components)
Lifecycle management
Maintenance / service
logbook
Warranty status of
machine and components
0 1 2 3
Life cycle management
Asset registration
Warranty and maintenance log
Spare parts management
Spare parts availability and order options
Machine info tracking
Machine architecture
Machine documentation
TRACK: wireframe examples of user interface
EcoStruxure for Machines
MONITOR – Value proposition
Needs & Wants of Schneider Electric’s OEM customers and End Users
OEM Engineer
Maintenance
technician
End-user line manager
“I want to make my producing line more stable and efficient”
“Health, performance and efficiency are key aspects I need to
control on my machines”
“Real-time data from my machines is very valuable”
“I would save a lot of time if I could diagnose the issue remotely and
travel on site only if necessary”
“It is annoying when I can not find the root cause of a machine issue”
“After I ship the machine, I would love to have some info on how it is
performing, what the issues are, …”
“I value all services that can help me support my customers”
“I need to reassure my customer about privacy and security to get
connected to its data”
MONITOR is a cloud based service for End Users to remotely
monitor and analyze machine health and performance
Customizable dashboards for live KPIs, notifications & alerts,
predictive maintenance, performance optimization, expert reports, and more
TRACK is a remote monitoring and analytics service for End Users
To access machine
insights through a
dashboard
Machine Raw DataWeb application Remote expertise
Live KPIs in visual form
Programmed notifications
(threshold breach)
Advanced analysis to
interpret data and
provide
recommendations
Analytics on machine
Machine condition analysis
(health, performance,
efficiency)
0 1 2 3
Pain points to be addressed by analytics
Health
Monitoring
Utilization
Monitoring
Efficiency &
Optimization
• Monitor efficiency
energy, utilization efficiency,
• Optimize
taking into account several
conditions / parameters
• Anticipate ageing
through use monitoring
• Predict failures
based on collected variables
(internal or external), for different
types of failures
• Monitor utilization
working time and statistics on
past usage, on-off time, stand-
by time etc.
Analytics
Level 2
Advanced monitoring
Level 3
Expert monitoring
Level 1
Basic monitoring
MONITOR: wireframe examples of user interface
Notification & Alerts to be programmed Automatic Report
Analytics processed data
Fault, Ageing, Use optimization…
Link with expertise
(OEM – SE) for - Diagnostic
- Data interpretation
- Expert reports
- …
Dashboard with Raw data and
Notifications
EcoStruxure for Machines
FIX – Value proposition
Needs and wants of Schneider Electric’s OEM customers and End Users
OEM Engineer
Maintenance
technician
End User line
Manager
“I cannot afford downtimes on my line, problems must be solved for good, and fast”
“My machines are complex and very different; yet, I want my people on site (including my
operators) to be able to troubleshoot”
“I want to provide best maintenance quality and solve issues fast”
“I have to be as efficient for new products as for those I am used to.”
“In case I need it, I should have immediate access to expert assistance.”
“I don’t want to take a long flight to solve something basic”
“Whenever possible, I want technicians on the line to solve problems by themselves”
“But when necessary, I want to take remote control over the machine for faster and better
maintenance, wherever the machine is”
“I don’t want to send technicians on site when I don’t need to”
“When something goes wrong, I want to be able to keep my machine running without
having to wait for someone to come”
End User
Operator
FIX is a service to facilitate maintenance operations with the
help of step-by-step procedures and remote experts leveraging
augmented reality
What do I get with FIX?
To access insights about a machine
and maintenance help
Maintenance insightsMobile App in Augmented
Reality
Remote Maintenance
Services
Step-by-step procedures
(displayed via the app)
Over-the-shoulder expert assistance
Remote troubleshooting
1 2 3
Level 1
Self-troubleshooting with
digital procedures
Level 3
Remote troubleshooting
Level 2
Remote expert assistance
Level 0
Visualization of machine
Point of Interest
Show me how this looks like: focus on the mobile App
Step-by-step digital
maintenance procedures
Step-by-step AR maintenance
procedures
Advanced access to experts
(screen sharing)
Simple access to experts Remote Troubleshooting
service (ticketing system)
Machine PoI
Real time information Tunneling to machine
Customer Success Stories
Customer Challenge• Automate maintenance data collection
• Improve availability & utilization of production
assets
• Developing standardized solution for 9 separate
production facilities
The Solution• Avantis EAM®
• Avantis PRO®
• Avantis VIP Advanced Scheduling
Customer Benefits
• Inventory reduction via better asset utilization
• Minimize potential loss when kiln is offline
• Advanced planning and scheduling software
resulted in more planned maintenance activities
The Results: Life is On with...
$2M reduction in first year inventory
“By closely monitoring and managing what we use, reorder
activities, and parts and materials pricing, we have reduced
inventory by at least $2 million in the last few years. This is a
significant contribution to keeping our prices competitive in the
marketplace”.
Mike Ralls,
Plant Systems Administrator,
Ash Grove Cement
5th largest cement manufacturer
in the USA with annual production
capacity of >8M tonnes
Ash Grove
Cement, USAEnterprise Planning, Scheduling &
Compliance Management
Edge
control
Connected
products
Apps,
analytics,
and services
Edge
Control
Connected
Products
Avantis
EAM®Avantis
PRO®
Avantis VIP
Advanced Sched.
Industry
Customer Challenge• Improve asset utilization across 5 mines
• Flexible solution for local operating conditions
• Ensure new system drives continuous
improvement through the business
• Capture of real-time data and root-cause analysis
of ‘less than perfect’ utilization
The Solution• Ampla operations management system
• Schneider Electric consulting services, project
design, implementation, training and support
Customer Benefits
• Significant productivity improvements
• Provide clear root cause analysis
• Provides clarity on how to achieve optimum
productivity
• Drives improvements to assets, resources &
processes
The Results: Life is On with...
Asset utilization improved by 10-20%
“The asset utilization project is already delivering significant
results. We have achieved around 10-20% capacity
improvement globally”.Dan Curry,
Group Manager, Processing Operations,
MMG
Diversified base metals company
which operates & develops base
metal projects across Australia,
DR Congo, Laos & Peru
MMG Limited,
AustraliaStandardization of asset utilization
Edge
control
Connected
products
Apps,
analytics,
and services
Connected
Products
Ampla Operations
Management System
Industry
Edge
Control Schneider Electric Project
Management
Customer Challenge• Outdated analog SCADA system
• Nuisance alarms
• Dependence on external support
The Solution• StruxureWare SCADA Expert – ClearSCADA
• ClearSCADA Mobile System
• Trio Digital radios
Customer Benefits • Simplified troubleshooting
• Reduced maintenance costs
• Integrated diagnostics
The Results: Life is On with...
80% reduction in external support costs
Number of faults reduced by 66%
Provider of water & sewerage
services to 1.7 million people
and 50,000 business over
4,000 km2
“We used to average 150 SCADA incidents per month.
Within 4 months this had reduced to less than 50”.
Roger Brown,
Yarra Valley Water
Yarra Valley Water Powerful SCADA alarm capability and mobile data
access
Apps,
analytics,
and services
Edge
control
Connected
products
Industry
Asset Management
StruxureWare
Trio Digital Radios
Customer Challenge• Expand daily capacity of water supply
• Provide safe drinking water
• Integrate existing pumping station with new plant
The Solution• Wonderware InTouch® HMI
• Wonderware ActiveFactory™ Software
• Wonderware Historian Software
• Wonderware SCADAlarm
Customer Benefits • Real time reporting has enabled more effective
maintenance during downtime
• Increased water supply capacity
• Historical reporting enabling greater visibility
The Results: Life is On with...
Increase daily water supply by 75% &
Project ROI of 2 years
Thunder Bay, CanadaCommissioning new water treatment plant in city
Major city in Canada with
population of more than
120,000
“It’s very easy to use. I am able to pull whatever parameters
I need into one trend and see how they’re related and make
better-informed decisions”.
Michelle Warywoda,
Process Engineer,
Bare Point (Partner)
Industry
Edge
control
Connected
products
Apps,
analytics,
and services
Wonderware InTouch
HMI, Historian, Active
Factory, SCADAlarm
Customer Challenge• Harmonize multiple systems over 5 regions
• Reduce operating costs
• Maintain reliability per governmental standards
The Solution• PlantStruxure
• Vijeo Citect SCADA
Customer Benefits • Modular approach lowers TCO
• Reliability ensured through robust TVDA
• Greater operational insight with scalable SCADA
The Results: Life is On with...
Deployment time reduced by 65%
25% lower engineering costs
Largest Dutch drinking water
company serves 5.4 millioncustomers
“We have a high-performance automation platform with high
reliability and maintainability”.
Doeke Schippers,
Vitens
Vitens, NetherlandsStandardized , cost-effective process automation
Industry
Connected
products
Apps,
analytics,
and services
Edge
control
PlantStruxure
Vijeo Citect
SCADA
Sydney desalination plant with
a 250 million litres per day
capacity supplies water to up to
1.5 million people
Customer Challenge• Integrate renewable energies
• Achieve energy efficiency
• Ensure interoperability of 8,500 devices
• Streamlined project execution
The Solution• EcoStruxure
Customer Benefits • Real-time visibility of operational performance
• Seamless integration of motor control centers
and instrumentation
• 100% of energy consumption offset by
wind power
The Results: Life is On with...
Energy savings of 1500 MWh per month
Sydney Water Holistic electrical, automation & energy
management
“Solutions to problems were developed within hours rather
than days. Schneider Electric had a sense of urgency, and a
willingness to work with you to get the job done, that you
rarely find with other partners”.
Peter Jones,
Project Director,
Aecom
Industry
Apps,
analytics,
and services
Edge
control
Connected
productsVariable Speed Drives
IP cameras for Security
Switchgear, Transformers
Quantum Unity PLC’s
CitectSCADA
Customer Challenge• Ensure far-flung sites are safe and reliable
• Accurately monitor critical indicators
• Maximise value and time of field operators
• Limit production downtimes
The Solution• Wonderware® IntelaTrac
Customer Benefits • Improve plant availability factor
• Visual inspection of equipment optimized and
standardised
• Identify and anticipate potential problems,
avoiding need for emergency intervention
The Results: Life is On with...
Plant availability factor of >90%
Infenium, ItalyMaximising plant availability with preventive
maintenance & operational management
Leading company in field of
petroleum additives for lubricant
and fuels, JV between ExxonMobil
& Shell
“Using IntelaTrac has made a major contribution to reaching
a plant availability factor above 90%, since it has integrated
perfectly with the other innovations added to our equipment”.
Mauro Tassistro,
Applications Team Leader,
Infenium International Limited.
Apps,
analytics,
and services
Industry
Wonderware
IntelaTrac
Edge
control
Connected
products
Customer Challenge• Address growing demands in biomedical field
• Integrating complex technology with ultra high levels of
functionality
The Solution• Wonderware System Platform
• Wonderware InTouch HMI
• Wonderware InBatch
• Wonderware Historian
Customer Benefits • Significant cost savings
• Reduced deployment time of products
• Reduction in development time, shortening time to market
The Results: Life is On with...
60% reduction in capital investment
Xcellerex, USA Achieving cost reductions & accelerating time to market
Leading supplier of innovative
manufacturing technologies for the
fast-growing biopharmaceutical
industry
“Integration of Wonderware’s software has resulted in an
overall reduction in development time of nearly 60%. This
directly impacts customers with reduced costs and shorter
time to market. In fact, we’ve been able to reduce deployment
time from 3-5 years to an amazing 12-18 months. This
results in huge implementation
savings”.
John A. Chickosky,
Chief Commercial Officer & President, Biosystems,
Xcellerex
Apps,
analytics,
and services
Industry
Wonderware
System Platform,
InTouch HMI,
InBatch, Historian
Edge
control
Connected
products
Customer Challenge• Ensure energy efficiency & centralized control
• Reduce costs
• Ensure open platform allowing products from
different vendors to work together
The Solution• Wonderware InTouch® HMI
Customer Benefits • Reduced energy consumption & cost savings
• Energy & money savings
• Solution brought software & development costs to
an affordable level
The Results: Life is On with...
Total annual savings of $30,000 &
40% savings in energy
Echelon Corp., USANew Building Automation software for HQ
building
Worldwide leader in automation
systems provider for buildings
“Wonderware makes system design much easier and saves
both time and money for our customers”.
Steve Nguyen,
Director, Corporate Marketing,
Echelon Corporation
Building
Apps,
analytics,
and services
Edge
control
Connected
products
Wonderware
InTouch HMI
Customer Challenge• Ensure maintenance planning application is in pace with
growing business
• Ensure the migration to new system is within prescribed
budget
The Solution• Avantis PRO®
• Avantis DSS®
Customer Benefits • Significant cost savings
• Reduced inventory management and purchasing costs
• New system automates maintenance planning and
tracking activities
The Results: Life is On with...
Approx. cost savings of $2M
CF Industries, USA Upgrading existing system software to improve
structured maintenance
One of the largest manufacturers
and distributors of nitrogen and
phosphate fertilizer products in
North America
“We’ve installed the Avantis DSS solution and it paid for itself
almost immediately. It turns raw data into business
intelligence and that improves our performance”.
Dave Wiedenfeld,
Group Project Leader, IT,
CF Industries
Apps,
analytics,
and services
Industry
Edge
control
Connected
products
Avantis PRO® Avantis DSS®
USA based foam producing
company producing packaged
materials for meats, baked items &
deli foods
Customer Challenge• Maximize speed & efficiency in foam production
• Overhaul outdated and obsolete control
component used in thermoformers
• Invest in new machinery that would be more
capable, more cost-effective & fast to build
The Solution• Magelis G5U HMI
• Lexium LXM52 servo drives
• BMH motors
• PacDrive Controllers
Customer Benefits • Increased productivity
• Easy to use interface
• Integrated and end-to-end solution enables quick
and easy identification of issues
• Access to real-time diagnostics and WW support
The Results: Life is On with...
70% increase in productivity & 15% cost
savings on machine setup
Commodore Sols., USAIncreasing productivity & reducing overhead costs
“It makes much more sense to have an integrated solution,
which is why we chose Schneider Electric for all the
control components”.
Kurt Bartosch,
Engineering Manager,
Commodore Technology Solutions
Connected
products
Industry
BMH Motors
Apps,
analytics,
and services
Edge
control
Lexium
Servo Drives
PacDrive
Controllers
Magelis G5U
HMI
Zahtjev kupca• Povećati transparentnost proizvodnje
• Upravljati rasporedom operacija u proizvodnji
• Iskoristiti postojeće kapacitete proizvodnje
Rješenje• Wonderware MES performance softver
Postignuto• Ukupna efikasnost proizvodnje(OEE) povećana s
45% na 65% u 2 godine
• Smanjeni prekidi proizvodnje za više od 50%
• Efikasnost proizvodnje povećana za 25%-30%
Rezultat: Life is On sa...
$400,000 u godišnjim uštedama
“Energetska efikasnost je naš
prioritet, ne samo zbog
ekonomskih razloga već i zbog
našeg opredjeljenja zaštite
okoliša”.
Joe Herrick,
Packaging System Manager,
New Belgium Brewing
New Belgium BreweryOdgovor na zahtjev za povećanjem proizvodnje piva
Povećanje kapaciteta pakirnice na
oko 1.3 milijuna barela
godišnje
Customer Challenge• Develop a sustainable environment
• Reduce energy consumption
• Reduce water consumption
The Solution• PlantStruxure solution
• Modicon Premium
• Vijeo Citect SCADA
Customer Benefits • Reduced engineering time for fine-tuning process control
• Decreased production costs
The Results: Life is On with...
20% in energy savings 38% water savings
700 million bags of Lays,
Ruffles, Doritos, Fritos snacks,
2,700 employees in the plant
“Energy efficiency is a priority for us, not only for economic
savings but because of our commitment to the
environment”.
Matutano Snack Ventures,
S.A., Spain
Matutano, SpainSnack food company reduces energy consumption
Edge
control
Connected
products
Industry
Vijeo Citect
Modicon
Premium PlanstruXure
PowerLogic Meters
Apps,
analytics,
and services