ProcessIT SRT Seminar Rev 6 · 2013-08-18 · Källor: Manufacturing Execution Systems Market 2011-2016, MarketsandMarkets, 2011; Global Enterprise Resource Planning Software Industry

Page: 1 | 2013-04-23| © ProcessIT Innovations

ProcessIT Innovations

Anders OE JohanssonProcessIT Innovations

www.processitinnovations.sewww.ProcessIT.EUwww.processindustriellautomation.seanders.oe.johansson@ltu.se


Bothnia Bay Areaplants &facilities

Tornio

Kemi

Oulu

Raahe

Kokkola

Örnsköldsvik

Umeå

Skellefteå

Kalix

Gällivare

Kiruna

Rovaniemi

Mining andsteel production

Mechanichalindustry

Pulp andpaper

Metals andstainless

Energy

• Boliden Skellefteå Fields• Boliden Rönnskär• Skellefteå Kraft

• Alimak• Brokk

• Hydrauto• KMT

• Boliden Kokkola

• Rautaruukki

Piteå

Luleå

• Stora Enso• Kemira

• Outokumpu Mine• Stora Enso

• Metsä-Bothnia

• Stora Enso

• Outokumpu stainless

• Billerud

• LKAB• Nybergs Mekaniska

• LKAB• Mecon

• Boliden Aitik

• Ferrufom• Gestamp Hardtech

• SSAB• LKAB/EBF

• swerea-MEFOS

• SCA• Smurfit Kappa• BL Gasification

• SCA• Bio Fuel• Komatsu

• Volvo• Ålö

UmU

LTU

UoO

Ore to steel

Precious metals• Domsjö• Mondi• M-real• SEKAB

• BAE-Systems• Hägglunds Drives• MacGregor Cranes


ICT Trends for device growth Towards Trillion Node Net (cum grano salis)

● "[In 10 years' time], everything hasconnectivity. We're talking about 50 billionconnections, all devices will haveconnectivity...” Håkan Djuphammar, VP ofsystems architecture, Ericsson (2009)

● “...at least 20 billion connected devices by2020 and a 300-fold increase in traffic...” JohnWoodget, global director, telecoms sector,Intel (2009)

● ... the smart grid network will be “100 or 1,000times larger than the Internet” Marie Hattar,vice president of marketing, Cisco NetworkSystems Solutions

● “The next billion SAP users will be smartmeters” Vishal Sikka, CTO of SAP (2009)

Källa: SAP

Page: 4 | 2013-04-23 | © ProcessIT Innovations

The BIG picture World population

increase x 4

World population

increase x 4Globalaeconomy

x 20

Globalaeconomy

x 20

Källa: McKinseyGlobal Institute

Blue Institute | Örjan Larsson | mars 2013

Demand on resources increased

600 to 2 000 %


600 to 2 000 %


The BIG picture World population

increase x 4

World population

increase x 4Globalaeconomy

x 20

Globalaeconomy

x 20




600 to 2 000 %


600 to 2 000 %

The BIG Picture



Commodity prices have increased sharply since 2000, erasing all the declines of the 20th century

The BIG Picture

DEMANDDEMAND

+ 2 Bpeople

+ 3 Bmiddle class

+ 40 %energy

+ 80 %steel



The BIG Picture

GlobalAssets

Resources

GlobalAssets

Resources

DemandNeeds

DemandNeeds

INDUSTRIALINNOVATIONSINDUSTRIAL

INNOVATIONSBlue Institute | Örjan Larsson | mars 2013


The Third Wave: Industr ia l IT and AutomationM A N A G I N G , A N A LY s I N G , O P T I M I Z I N G



Transparancy3. We will opimize use of resources and

energy more and better

1. We will measure more

2. We will be better to integrate


15 000 B USD = BNP in USAT h e v a l u e o f ” I N D U S T R I A L I N T E R N E T ” y e a r 2 0 3 0

Source: General Electric | inkluderar viss flyg- och medicinsk teknikBlue Institute | Örjan Larsson | mars 2013


STRONG MARKET GROWTHS T R A T E G I C , I M P O R T A N T A N D U N D E R I N V E S T E D M A K E S T H E M A R K E T I N T E R E S T I N G

We expect the global industrial automation market to grow at

about 1.5 times global industrial production (IP) over the next

cycle…

C r e d i t S u i s s e , a u g u s t i 2 0 1 2



ERP

MES

DCS

Källor: Manufacturing Execution Systems Market 2011-2016, MarketsandMarkets, 2011; Global EnterpriseResource Planning Software Industry 2012-2017, Lucintel, 2012; Bearbetad av Blue Institute, 2012


STRONG MARKET GROWTHS T R A T E G I C , I M P O R T A N T A N D U N D E R I N V E S T E D M A K E S T H E M A R K E T I N T E R E S T I N G





Technology Trends in Industrial Systems● Increasing usage of Internet Technologies e.g. TCP/IP, web

services etc.● Information Driven Interaction vs. Communication focus● Distributed Business Processes● Virtualization and Cloud Computing● Multi-core Networked Embedded systems and GPU computing● SOA-ready devices and systems● Commercial DBs and tools for vizualisation & management● Integration with business systems e.g. ERP, GIS etc.● High performance analytics, asset management, reporting, etc.

Källa: SAP


The Future Internet and its services will depend on CPS

Källa: SAP


Some facts

Swedish process industry43% of exports 13% of Sweden's GDP 25% of business investment

Important customers for Swedish automation suppliers

Swedish automation industry

10% of the global automation industry

Turnover of around 50 billion SEK

> 1500 new jobs needed over the next five years in Mälardalen

The Global Automation Market €188 billion 2007.

(€ 500 bn estimated to 2020)


SUMMARY CHALLANGES

Productivity create growth. Industrial IT & Automation are both practical and strategic conditions for productivity and for sustainable industrial processes.

R O L E

The industry needs to create new business models that releaseinvestment and that valuate improvements. The industry needs to increase RDI investments.

T E M P O

The industry must develop robust solutions for data analysisand for process optimization that are simple to manage and implement.

TECHNOLOGY

The industry needs to attract new skills and talents in the area of methodology and analysis but also increase its knowledge about production processes.

COMPETENCE


Page: 20 | 2013-04-23 | © ProcessIT.EU

Good and accessible IT systems and developed process automationGood and accessible IT systems and developed process automation

More efficient maintenanceMore efficient maintenance

Improved production processes

Improved production processes

Higher capacity for change

Higher capacity for change

Good market flexibility

Good market flexibility

increased competitivenessincreased competitiveness

Results in

Industrial process automation projects

Higher plant capacityHigher plant capacity Better utilization of resources

Better utilization of resources

Niche productsproducts from

secondary flows

Niche productsproducts from

secondary flows

Leads to


Accelerating IT development continues ... examples

• Artificial Intelligence: High-frequency trading, Software agents, Natural language interpretation, Machine translation, Procedural storytelling, VR-only lifeforms, Machine-augmented cognition

• Internet: Cloud computing, Cyber-warfare, 4G, Mesh networking, Internet of things,Virtualcurrencies, 5G, Reputation economy, Interplanetary internet, Remote presence, Exocortex

• Interfaces: Multitouch, Gesture recognition, Speech recognition, Augmented reality, 4K, Haptics, Holography, Telepresence, Immersive virtual reality

• Sensors: Depth imaging, Near-field communication, Pervasive video capture, Biometric sensors, Smart power meters, Biomarkers, Machine vision, Computational photography, Optogenetics, Neuroinformatics

• Ubicomp: Tablets, Volumetric (3D) screens, Flexible screens, Boards, Picoprojectors, Eyewear-embedded screens, Context-aware computing, Fabric-embedded screens, Reprogrammable chips, Skin-embedded screens, Retinal screens

• Robotics: Appliance robots, Smart toys, Robotic surgery, Self-driving vehicles, Powered exoskeleton, Commercial Unmanned aerial vehicles, Domestic robots, Swarm robotics, Embodied avatars, Utility fog

http://envisioningtech.com/envisioning2012/?ncid=edlinkusaolp00000008

Source: Envisioning Technology


More short-term automation solutions

More short-term automation solutions

Unstable system environment,

increased system maintenance

Unstable system environment,

increased system maintenance

Reduced internal control system

support

Reduced internal control system

support

Reduced adaptability to new customer and market requirements

Reduced adaptability to new customer and market requirements

Reduced competitiveness and lower profitabilityReduced competitiveness and lower profitability

Increased supplier dependency.Worse internal automation expertise.Lower internal purchasing expertise.

Leads to

gives

Risks with increased complexityin IT and automation systems

More downtime, lower availability, reduced customer flexibility, etc.More downtime, lower availability, reduced customer flexibility, etc.

More difficult to see the potential in new solutions.

Harder assess skill needs.More functionality can not be utilized

Increased high competence and skills competition.

Worse holistic approach to systems support.


Bothnia Bay Areaplants &facilities

Tornio

Kemi

Oulu

Raahe

Kokkola

Örnsköldsvik

Umeå

Skellefteå

Kalix

Gällivare

Kiruna

Rovaniemi

Mining andsteel production

Mechanichalindustry

Pulp andpaper

Metals andstainless

Energy

• Boliden Skellefteå Fields• Boliden Rönnskär• Skellefteå Kraft

• Alimak• Brokk

• Hydrauto• KMT

• Boliden Kokkola

• Rautaruukki

Piteå

Luleå

• Stora Enso• Kemira

• Outokumpu Mine• Stora Enso

• Metsä-Bothnia

• Stora Enso

• Outokumpu stainless

• Billerud

• LKAB• Nybergs Mekaniska

• LKAB• Mecon

• Boliden Aitik

• Ferrufom• Gestamp Hardtech

• SSAB• LKAB/EBF

• swerea-MEFOS

• SCA• Smurfit Kappa• BL Gasification

• SCA• Bio Fuel• Komatsu

• Volvo• Ålö

UmU

LTU

UoO

Ore to steel

Precious metals• Domsjö• Mondi• M-real• SEKAB

• BAE-Systems• Hägglunds Drives• MacGregor Cranes


The Mining Industry in Sweden.The Mining Industry in Sweden. LKAB. Number one industry investor in Sweden 2010. Invest 5 – 6.000 MSEK / year

Boliden Investments in Garpenberg 3.900 MSEK (2012-2013) 17% of all cost is energy Recycling of electronics. From 45 KTon to 120 Kton

SMIFU - Sustainable Mine and Innovation for the Future LKAB, Boliden, KGHM + a number of global suppliers Strive for zero accidents, 30% reduction energy consumption, CO2, emissions ore losses

Energy /electricity LKAB approx 4.0 TWh/year energy 2012.

With 1.5 %of the nation’s total consumption Boliden 3,7 TWh 2010.

(72% of all energy is Electricity) Energy usage 2011 (est.) 384 TWh

Industry 36%, Transport 25% Service&building 38%

Energy in Industry (2008)50% Pulp & paper, 15% iron&steel, 8% Chemical, 3% mining


The Forrest industryThe Forrest industry

A QUANTUM LEAP IN Innovation Efficiency!www.processitinnovations.se

● 10 -12 % of Swedish Industry employment, value added, export

● Export value 2009. 123 BSEK

● Small import of goods – large contribution to trade balance

● Directly employs 70 000 people and about 200,000 indirect

● Invest, on average ,10 billion per year

● High-tech processes

● Leading Swedish exporter

● Lowest CO2 emissions per ton ( pulp & paper) in the world

Source: Skogsindustrierna och TVA-underlaget


Innovation System model

NEW BUSINESS

PROCESS INDUSTRIES -Plant owner

ACADEMIA -University & institute

PUBLIC AUTHORITIESand CLUSTERS

TECHNOLOGY and SERVICE SUPPLIERS

IDEA● Needs● Big potential● Risk

RESULT● Regional growth● Stronger SMEs● Regional partners

Meetings – PROJECTS● Studies● R&D Projects● Commercialization


Martin Ärlestig

Steering BoardLars Atterhem Chairman BiosteamN N Govenor VästerbottenThomas Brännström InternetBayKent Tano LKABMargareta Rönnqvist SSABJerker Delsing LTULena Gustafsson Umeå UniversityAnders Kyösti SCA Packaging MunksundUlf Marklund BolidenTomas Lagerberg ABB Corporate ResearchSeved Lycksell Skellefteå KraftMarin Ärlestig Komatsu Forest

Industry Advisory BoardKnowledge in industry processes and needs

ProcessIT Management

Executive ManagementAnders OE Johansson ProcessIT, LTUPer Levén ProcessIT, UMUThomas Gustafsson LTUKatrin Jonsson UMUJan Björkman LKABKajsa Andersson Expandum

Project officers (full or part time)Pär-Erik Martinsson LuleåAnders Jonsson UmeåRobin Norrman UmeåUlf Andersson LuleåKjell Olsson Luleå

Staffan Sandström Seved LycksellLena Gustafsson


ProcessIT Innovations● Recognized by OECD as a strong national

R & I Milieu● High and growing number of innovations

and commercialization● Constantly increasing revenue and growing

industry relations● Increasing primary industry and supplier

involvementOver 80's companies involved in our project activities

● Building projects from continuous need inventory studies

● Strong impact on universities and research groups

● More and growing number of strategic partnerships


The ISA Pyramid


ProcessIT AreaINDUSTRIAL SYSTEMS

ICT-BASED

measure-ment

moni-toring

control inter-action

communi-cation

INTEGRATION

TECHNOLOGIESEMBEDDED SYSTEMS TECHNOLOGIES

Production

Maintenance(e-maintenance)

Training

Engineering

Logistics

COLLABO-RATION

INFORMATIONEXCHANGE

IND

US

TRIA

L P

RO

CES

SES

Defined by today’s and tomorrowsindustrial processes and ICT systems


PS

Large scale Process industry M&C scenarioP

roce

ss

Equ

ipm

ent

Fiel

d de

vice

s, s

enso

rs, I

/OP

roce

ss C

ontro

lE

nter

pris

e m

anag

emen

tM

anag

emen

t exe

cutio

n

PowerSubstation

Othersubsyst.

Control Network

Enterprise Network

PS

Fiel

d bu

ses

PS

Remote access

Inte

rfac

eG

atew

ay/A

PI

Firewall

Fiel

d bu

ses

Fiel

d bu

ses

History

Training

GWY

GWY

Black-box

LegacyDCS

BBdevices

Handhelddevices

Operator consoles

Control and eng. room/rooms Control and eng. room/rooms

Operator Engineering

Black-box

controlsystem

prop

rieta

rybu

sses

/con

nect

ions

Engineering

Process section Process section Process section

BackupUPS

PLCs

ERP MES QMS MIS

Managers, planners etc desktops

crushing, screening, conveying, feeding, grinding, separation, pumping, concentration, processing, pelletizing, materials, transformers, switchgearProcess equipment Process equipment Process equipment Process equipment

GWY

Asset mgmtMaintenance

Process section

LocalHMI


• Regional• RDI-projects (in different stages - Pre-studies,

pre-projects, projects and need finding activities)

• Project portfolios (SCOPE, GRAM, ….. )

• Technology clusters (Optical, Interaction, simulation)

• National (Swe - Finland)• National strategic agenda

”Industrial Process Automation”• Project portfolios. Competence provision.• Collaboration. Automation region, PPI, PIC, FindIT etc.

• European / International• ProcessIT.EU• Projects. Arrowhead.• Roadmap

Regional – National – European /International


eMaint satsning i Malmfälten GramCOBS. Transportbandssystem MätteknikOnlinemätning av COD i bioreningsanläggning - fas II ScopeMätning i mobil miljö Styr & MätMätning flotationstank Styr & MätSimulering av bandtransportör SimuleringVSB ProITBeslutstöd via Interaktiv Display för Lean II InteraktionFibermätning MätningStendetektering MätteknikBrötdetektering BildanalysMassaindex MätningEnergieffektivisering vid malning MätningAESOP FP7 IP projekt KommunikationDeltagande i JILIN projektet ProITBranschanalys för VINNOVA (Gruv + IKT) ProITPlattformsstrategi för svensk processindustri (del B) ProITNationell agenda fas 2 processindustriell automation ProITSDR-radiomätning i Aitik GramGasflödesmätning fas 3 GrameMaintenance for Smart Asset Management ProITNOSEG ProITBeröringsfri mätning stock ProITSimulering av sekundärvärmesystem och energibalanser ScopeEnergy and Quality oriented modeling and control of REFiners ScopeNIR-kluster ScopeMobile Warp ScopeGlobal LinksLjud i kontrollrumsmiljöUtveckling av sensor för mätning av tvättföluster Scope


Entrance A

Entrance B

Entrance C

OperationsMonitoring

Engineering

Project

Management

SalesProcurement

Maintenace

HR

Logistik

Overall idea


Phase 2 – A SIO proposalAutomation RegionProcessindustriella Centran Li-LuProcessIT Innovations


More effective and broader corporate partnerships:

1. Establish an Industrial national leadership and a national collaboration platform for the area.

Stronger integration with the university and college world:

2. Coordinate projects and networking activities with university and college based RDI environments that are identified as particularly strong and relevant to the area.

3. Coordinate and implement combined skills development initiatives with both business community, university and college partners.

Strengthen the area’s role and position in national and international innovation systems:

4. Substantial investments in National RDI programs in this area.


Processindustriell automation



Our ambition is to highlight industrial process automation as a key enabler for the future

European process industry.

In the area ● Accelerate growth and technology development in Europe● Innovations in ICT and automation technology.● Incubation and implementation of strong R&D projects.● European automation world class research thru access to

highly challenging industry contexts.

PURPOSE


Ideal concepts.Identified “white areas” that require further development

ROADMAP IDEAL CONCEPTS ARE:

1. Instant access to virtual dynamic factory

2. Increased information transparency between field devices and ERP

3. Real-time Sensing & Networking in Challenging Environments

4. Process industry as an agile part of the energy system

5. Management of Critical Knowledge to support Maintenance

Decision Making

6. Automation service and function engineering

7. Open simulator platform

8. Automation system for flexible distributed production

9. System wide balancing of safety, security and production flexibility


● 5 application pilot domains:● 4 years● 80 partners● LTU / ProcessIT.EU coordinator● 69 Beuro● Sweden, Austria, Belgium,

Czech, Denmark. Finland, France, Italy, Latvia, Norway, Portugal, Spain, Netherlands, UK

1. Luleå tekniska universitet2. Eistec AB,3. Fotonic,4. Abelko Innovation5. SKF6. Boliden7. LKAB8. Noda 9. BNearIT10. Midroc Electro AB


Short time goal Target and goals in new projects 1. Instant access to virtual dynamic factory

Automatic model life cycle management, computational resources, business service development. Data to information. Training of staff and model based reasoning.

2. Increased info. transparency between field devices and ERPIP everywhere, middleware nowhere, seamless integration, industry requirements.

3. Real-time Sensing & Networking in Challenging EnvironmentsRobustness, calibration, energy harvesting, IoT, in situ sensors, cyber physical systems,M2M

4. Process industry as an agile part of the energy systemAgile Integration, production flexibility. Automation for short and long term variations. Collaborative automation. Technologies for “look up, loosely coupling and late binding”,.

5. Management of Critical Knowledge to support Maintenance DecisionsQuality assurance, context awareness, targeting and timing of information, business models

6. Automation service and function engineeringFunctionality for systems of systems, configuration and requirement management, model based development,

7. Automation system for flexible distributed productionFaster product changes, faster ramp-up/down. Scheduling. Material tracking.

8. Open simulator platformInteroperability, numeric's, reusability, development tools.

9. System wide balancing of safety, security and production flexibilityRisk management. Cryptography and intrusion detection & prevention. System architecture


And what is this?

Something to worry about?


“known” physical world camouflage in an office near you ! (?)

• The industry's first enterprise-class penetration testing drop box. Through its innovative, patent-pending design, the PwnPlug covers the entire spectrum of a full-scale pentestingengagement, from physical-layer to application-layer.

• Includes all release 1.1 features• Includes 4G/GSM cellular, Wireless (802.11b/g/n), high-gain

Bluetooth, & USB-Ethernet adapters• Fully-automated NAC/802.1x/RADIUS bypass!• Out-of-band SSH access over 4G/GSM cell networks!• Text-to-Bash: text in bash commands via SMS!• Simple web-based administration with "Plug UI"• One-click Evil AP, stealth mode, & passive recon• Maintains persistent, covert, encrypted SSH access to your

target network [Details]• Tunnels through application-aware firewalls & IPS• Supports HTTP proxies, SSH-VPN, & OpenVPN• Sends email/SMS alerts when SSH tunnels are activated• Preloaded with Debian 6, Metasploit, SET, Fast-Track, w3af,

Kismet, Aircrack, SSLstrip, nmap, Hydra, dsniff, Scapy, Ettercap, Bluetooth/VoIP/IPv6 tools, & more!

• Unpingable and no listening ports in stealth mode• Includes 16GB SDHC card for extra storage• Includes stealthy decal stickers• Compatible with SIM cards from AT&T, T-mobile, Vodafone,

Orange, and GSM carriers in over 160 countries• HSDPA/UMTS (850/1700/1900/2100MHz)• GSM/GPRS/EDGE (850/900/1800/1900MHz)


Stuxnet: Lessons Learned• Security awareness low and risk assessment is faulty.• Many live on the “don’t touch a running system” / “I am not on

the Internet” motto• Security problems of 2+ years old were not addressed• Lifecycle management of assets and processes has to include

security and be adjusted/revised on-demand for critical systems• Do NOT trust single sources of data / verify independently

(multiple information paths / checks). TRUST at device and system-wide level needs to be assessed!

• Security 101: ask/verify/check security/safety/quality requirements on supplier

• Prepare for the known threats, and plan for the unknown (e.g. via heuristics)


ProcessIT – the next steps• More and deeper industry engagement

• Higher share of corporate automation R & D located ProcessIT cooperation • More and stronger ICT companies

• Both regional and within the ProcessIT Network • Stronger university collaborations • More frequent interaction with students. • Regional, national and European • Initiate and drive the national strategic agenda "Automation for

process industries“• Powerful presence on the European arena thru ProcessIT.EU • Increased interaction with various regional growth actors. Eg municipalities, regional, clusters, industry associations, etc. • An organizational supporting a long-term responsibility for regional development • Build on established structures and practices

• To further accelerate the creation of innovation projects • Establish “ProcessIT Academy” for regional knowledge transfer !?


TACKFor more info please visit:www.processindustriellautomation.sewww.processitinnovations.sewww.processit.eu

Or contact: [email protected]

Documents

ProcessIT SRT Seminar Rev 6 · 2013-08-18 · Källor: Manufacturing Execution Systems Market 2011-2016, MarketsandMarkets, 2011; Global Enterprise Resource Planning Software Industry