© 2014 ibm corporation mfg in the age of iot and cloud: opportunity and challenge dave noller ibm...
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Mfg in the Age of IoT and Cloud:Opportunity and Challenge
Dave NollerIBM Industrial Sector Strategy & Integration
Agenda
2. IBM Approach
3. Role of Industry Standards
1. Background
Mfg in the Age of IoT and Cloud: Opportunity and Challenge2
Internet Of Things Forecast2020 View
• 212 billion installed things
• 30 billion autonomously connected
things
• Public Sector, Distribution & Services,
Manufacturing & Resources, and
Consumers lead segment growth rates
• Approximately 3 million petabytes of embedded systems data (excludes
streaming, surveillance-type data
• $8.9 trillion of business value
3 Mfg in the Age of IoT and Cloud: Opportunity and Challenge
Data will increasingly be a differentiator of business success, but not all data matters, so we must be selective!
4
You are here
44 zettabytes
unstructured data
2010 2020
structured data
90%
By 2017
Of data created over the last 10 years was never captured or analyzed
The collective computing and storage capacity of smartphones will surpass all worldwide servers
60%
2X
Of valuable sensory data loses value in milliseconds
Rate of data creation compared to the expansion of bandwidth over the past decade
The explosion of data created by changing tech represents both a challenge & opportunity
Mfg in the Age of IoT and Cloud: Opportunity and Challenge
Dynamic business and engineering processes enabling last-minute changes to production
Personalized, local production and mass customization
Creating value opportunities through services
The introduction of IoT into the manufacturing environment is ushering in a fourth Industrial Revolution
Industry 4.0 Characteristics:
5 Mfg in the Age of IoT and Cloud: Opportunity and Challenge
New System of Record for Production, Supply Chain, Material
Management and Engineering enable thru:
o New Sensor Data Collection
o Machine-to-Machine (M2M) Communication
o RFID Tracking
o Cyber-Physical Production Systems
o Consolidated data from Assets, Processes, Production
The IoT is enabling a new System of Record for Manufacturers to help them realize smarter factories
Mfg in the Age of IoT and Cloud: Opportunity and Challenge6
Source: Manufacturing 2.0: Service and Collaboration-Based Architectures for Manufacturing Right First Time—on demand - AMR Research, 2007
“Mfg 2.0” defined the need for “MES by Composition” (System of Insights from Systems of Record) and paved the way for Industry 4.0
7Mfg in the Age of IoT and Cloud: Opportunity and Challenge
Source: Recommendations for implementing the strategic initiative INDUSTRIE 4.0Final report of the Industrie 4.0 Working Group, April, 2013
“Industry 4.0” describes a Reference Architecture for connecting IoT to IoS
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Industry 4.0 (Integration + IoT + Cloud)
Feedback
Source: Prof. Dr. Dieter Wegener, VP ATS, Industry SectorFactory 2014, Tokyo / Japan, March 05th, 2014
Intranet of Things
Internet of Things
Industry4.0
1. Dynamic business and engineering processes enabling last-minute changes to production
2. Personalized, local production and mass customization
3. Creating value opportunities through services
Industry 4.0 Characteristics:
Mfg in the Age of IoT and Cloud: Opportunity and Challenge9
Agenda
2. IBM Approach
3. Role of Industry Standards
1. Background
Mfg in the Age of IoT and Cloud: Opportunity and Challenge10
Businesses have a choice to make
Open Source Only Proprietary Open “Plus”
‘Significant Assembly Required’
Vendor Lock-in Assured
Enterprise Innovation
Mfg in the Age of IoT and Cloud: Opportunity and Challenge11
IBM’s Approach: build better solutions with open technologies (aka “Open Plus”)
NOVA
HEAT
Bare metal
OS
Bare metal
OS
Compute node
VM Instance
OS
https://get.docker.io my_docker_container: type: DockerInc::Docker::Container docker_endpoint: { get_attr: [my_instance, first_address] } image: cirros
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with
Mfg in the Age of IoT and Cloud: Opportunity and Challenge12
API economy
Cloud operating environment
Software defined environments
IBM participates in, and supports, Open Standards efforts – for example, IBM is working to accelerate OpenStack success
Gold Sponsors
Because an open interoperable Cloud is critical for flexible cloud deployment and customer success…
IBM has 19 core contributors IBM has 19 core contributors19
IBMers working on OpenStack – from formation of the Foundation to Code Quality & New Function
IBMers working on OpenStack – from formation of the Foundation to Code Quality & New Function+400
IBMers are active developers in OpenStack projects
IBMers are active developers in OpenStack projects
2
Mar2013
Jan2015859
Contributors8,500 Members
3148Contributors18152 Members
Exponential growth
OpenStack Participant Growth
IBM is #2 in contributions to OpenStack integrated projects
+100
Platinum Sponsors
Mfg in the Age of IoT and Cloud: Opportunity and Challenge13
Control and secure the data streaming from your instrumented devices
The first step is IoT applied to manufacturing devicesDriving innovation of tomorrow from insights today
Analyze data to extract insight, applying them where they matter most
Drive product and service innovation with foresight
1 2
Deliver operational improvement and efficiency from insight
3
Interconnected
Intelligent
Instrumented
Internet of Things
Innovation
Insight
Improvement
Operate, Analyze, Innovate, Transform
Mfg in the Age of IoT and Cloud: Opportunity and Challenge14
I operate and use a collection of things to provide a product or service.
I care about integrating a collection of things and making sure they work cohesively together to deliver customer satisfaction
I have to work with things built by others, understand how they fit together, and the data they generate
I make invent, design products and services.
I care about innovating things that matter and delivering seamless user experience
I can choose the things I build, the technologies I adopt and the depth of my analytics
IoT value creation will be led by Makers and Operators
Design products with customer relevant features quickly and effectively
Create services that generate new value, drive loyalty and increase market share.
Use analytics to improve product, service and customer interaction in real-time
Improve efficiency and streamline operation to reduce cost
Integrate diverse applications and business data across heterogeneous environments
Derive new value and insight from connections and system interactions
Innovate, prototype and develop faster with IBM Continuous Engineering
Compose IoT applications with IBM Bluemix and scale to production with IBM Cloud
Generate insights from data in motion with IBM Stream Computing and explore big data with IBM Big Data Platform
Transform into a predictive maintenance enterprise with IBM Asset Management and IBM Predictive Analytics solutions
Manage your complex business infrastructure in real-time with IBM Business Process Management
Convert operational and connectivity data into actionable insights with IBM Business Analytics
Mfg in the Age of IoT and Cloud: Opportunity and Challenge15
Industry-specific Solutions
Design & Engineer Operate Manage
Analyze and Optimize
IBM Internet of Things Foundation: what is it?
Products, Assets, Infrastructure
Protocols & Gateways
Se
cu
re
Connect, Collect and Store
Connect, Collect and Storeinformation from a range of things with range of volume,
variety and velocity
A new offering within IBM’s Bluemix PaaS offering that allows Internet-connected devices to be integrated directly into Bluemix solutions
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IoT as a Composable Business
IoT Foundation
IoT-related Bluemix services
Secure Device Registration, Scalable Device Connectivity, Historian, Visual wiring
Rules, Push, Geo location, Analytics, Asset management, Predictive Maintenance…
Devices & Gateways
REST APIs
IoT end-to-end solutions
REST APIs
Connected appliance solutions, Smarter home solutions…
Realtime MQTT APIs
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• Edge of Network devices enable Message Oriented Middleware
Gateways help with integration of SCADA/DCS & Device data
IBM
Inte
grati
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us (I
IB)
IBM
Mes
sage
Sigh
tTemperature
Flow
Pressure
Temperature
PLC
RTU
Sensor
RTU
PLC
Sensor
Pressure
Flow
Scheduling
SCADA
ERP System
Analytics
Maintenance
Reporting
Mfg in the Age of IoT and Cloud: Opportunity and Challenge18
{ humidity: 78, objectTemp: 24, temp: 18 } { closeValve : true }
Meeting the needs of On-boarding and Connecting Devices
TLS encrypted traffic Supports the industry-
standard MQTT protocol
Device Recipes Open Source Paho
MQTT client code
• Encrypted traffic• Low bandwidth• Varying Qualities of Service• Publish Subscribe• Always on connectivity
• Lightweight & low footprint client
• Device specific Samples
• Device specific Client Code
Device Registration
• Device Access Control
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Multiple cloud models exist, but “Hybrid” seems to be best suited to Manufacturing
Hybrid Cloud
Private Cloud Shared off-premise cloud
Dedicated off-premise cloud
Firms will need to build across traditional cloud boundaries to maximize investment
2020 Mfg in the Age of IoT and Cloud: Opportunity and Challenge
API economy
Cloud operating environment
Software defined environments
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Building on open from the ground up enables IBM to maximize client investment
Hybrid CloudPrivate Cloud Off-premises cloud
IaaS
PaaS
SaaSOAuth
Mfg in the Age of IoT and Cloud: Opportunity and Challenge
Bluemix: IBM’s Cloud platform
Bluemix service categories
Developer experience
• Rapidly deploy and scale applications in any language.
• Compose applications quickly with useful APIs and services and avoid tedious backend config.
• Realize fast time-to-value with simplicity, flexibility and clear documentation.
Enterprise capability
• Securely integrate with existing on-prem data and systems.
• Choose from flexible deployment models.
• Manage the full application lifecycle with DevOps.
• Develop and deploy on a platform built on a foundation of open technology.
Built on a foundation of open technology.
Build, run, scale, manage, integrate & secure applications in the cloud
• DevOps• Big Data• Mobile• Watson• Business Analytics
• Database• Web and application• Security • Internet of Things• Cloud Integration
• API management &Integration
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Bluemix leverages CloudFoundry, Docker and OpenStack as key elementsContinuing our history of embracing and extending Open Source
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Bluemix Dedicated
Services Integration Portability
Flexible Deployment Models
Bluemix Dedicated – Bluemix running in a SoftLayer environment dedicated to a single-tenant
Mfg in the Age of IoT and Cloud: Opportunity and Challenge24
Addressing many types of Use Cases• Extend existing applications
- Add user experience such as mobile, social
- Add new capabilities integrating other services/APIs
- Rapid experimentation for new capabilities
• API enable applications
- Scalable API layer on top of existing services
- Simplify how composite service capabilities are exposed via APIs
• New applications
- Systems of Engagement
- Different state management models
- 12-factor applications
Backend Systems andIntegration
API Creation & Management
New Channels &Opportunities
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Smarter Manufacturing – IBM view
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Equipment Operator
Remote Monitoring
Mobile Access
Production Engineer
Control Center
Maintenance
Data Services
AdvancedAnalytics
Optimization
Data Acquisition
ERP, EAM, SCM, PLM
Enterprise Systems
Direct & Indirect Procurement
MRO
Material Management
SRM
Logistics & Distribution Mgmt.
Inventory Management
BOM ManagementPerformance Analysis &
ReportingFinancial Control
SCM
Create Sequenced Production Schedule
Demand / Supply Planning & Scheduling
Labor Management
Quality & Traceability Management
Production Planning
Finished Goods Management
EAM
Printers
Devices Robots
PLCs /Controllers
Plant Floor Systems
Plant Floor Integration
Line Sequencing /Re-sequencing
Broadcast
Buffer Control(PBS, WBS)
WIP Tracking
Order Status / Management
Data Collection
Flow Control Reporting and AnalysisAsset Monitoring &
Maintenance
SCM
Final Finish
Error Proofing Material Management
Quality ManagementTrack & Trace
Part Pick / Kitting /Labeling
MES / ALC
Material Handling
BarcodeScanner
RF Antenna & Tags
Plant Floor IntegrationIntegration Bus – Manufacturing Pack/Gateways
IntegratedOperations
Information ModelMDM Data Warehouse
Business Rules Predictive AnalyticsModeling / Simulation Optimization & Decision Mgmt
GIS Services
Streaming Data Integration Bus AdaptersFile Transfer
Business Process Mgmt
Role Based VisualizationWorkflow
Alarms / Alerts Realtime Visualization
Reports
MES, CNC, PLC
Data Acquisition
Mfg in the Age of IoT and Cloud: Opportunity and Challenge27
Agenda
2. IBM Approach
3. Role of Industry Standards
1. Background
Mfg in the Age of IoT and Cloud: Opportunity and Challenge28
ISA 95 hierarchy
OAGIS
F O U N D A T I O N
Vertical and Horizontal integration standards (content exchange and information/analytics models) – too many options!
OPC DA/HDA
ISA-95 / B2MML
ISA-88 / BatchML
OPC UA
SPEC 2000/STEP
PLM Services
PLCS/AP 239
ISO 15926
En
gin
ee
ring
Ma
inte
na
nce
MIMOSA
Operations
Level 4BusinessLogistics
Level 3ManufacturingOperations
Level 2SCADA
Level 0/1Process Control
Inter-Company
SPEC 2000
PLCS/AP 239
ISO 15926
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A lightweight publish/subscribe protocol with predictable bi-directional message delivery
Lossy or Constrained Network
Lossy or Constrained Network Monitoring &
Analytics Server
Commands or Data Visualisation
High volumes of data/eventsIT Systems
In the era of a Smarter Planet, open source and standards are essential
1999 Invented by Dr. Andy Stanford-Clark (IBM), Arlen Nipper (now Cirrus Link Solutions)
2011 - Eclipse PAHO MQTT open source project
2004 MQTT.org open community
2013 – MQTT Technical Committee formed
Cimetrics, Cisco, Eclipse, dc-Square, Eurotech, IBM, INETCO Landis & Gyr, LSI, Kaazing, M2Mi, Red Hat, Solace, Telit Comms, Software AG, TIBCO, WSO2
Evolution of an open technology
IT standards, e.g. MQTT - open connectivity for Mobile, M2M and IoT
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Do canonical object models for interoperability (e.g. ISA-95, OAGIS, OMG PLM services) really matter? After all this time, to what extent are they really being adopted? If not, why not? These standards do not seem to come up much in “real life” projects.
Assuming the answer is “yes”:
Consider new forms that are more web and programming tool friendly, e.g. JSON vs XML
Continue to work on rationalizing overlap so that choices are more clear
Today’s interoperability standards are “heavy”, consider developing lightweight versions aimed at IoT integration (e.g. MQTT)
How can industry standards efforts help?
F O U N D A T I O N
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Manufacturing Use Case (A Need Description)
IoT and Cloud Support through “migration”, not “Big Bang”: Adoption of IoT and Cloud needs to consider existing “brownfield” environments in a secure way.
Business Challenge • Manufacturers wanting to adopt new, innovative technologies such as IoT and Cloud (or the vision of Industry 4.0) need a way to migrate gradually with support of existing systems
• Manufacturers want flexible systems that can react to change and minimize vendor lock-in.
Business Benefit of addressing challenge; estimated quantification of benefit
• Evolving existing manufacturing systems today (through upgrades) is very costly and time consuming. New technologies can, potentially, lower the time and cost of bring up new systems or changing existing systems.
Open Cloud Opportunity
• Cloud based systems based on open standards and technology have the potential to address both of the business challenges mentioned above. For manufacturing, however, security concerns and the need for “brown field”, or “hybrid” systems must be addressed.
Technical Issues & Initiatives
• Interoperability standards are still not widely adopted, so “mapping” still has to occur somewhere and is difficult.
• Interoperability standards today are “heavy”, and do not lend themselves to easy usage for “agile” creation of applications (e.g. for mobile) in the “integration cloud”.
• MES tends to be trying to act as the vertical integration layer today, but is not well suited to “out of the box” integration needed to support “Industry 4.0” type initiatives. Would be easier if it could be treated as a set of capabilities easily integrated through APIs (services).
Standards Role • Take a hard look at what is inhibiting adoption today (for customers and vendors)• Try to simplify the picture vendors and customers who would like to adopt the
interoperability standards• Create new forms of standards that lend themselves to web programming models and
light weight, IoT messaging (as well as traditional)