big data meets measurement in manufacturing

8/13/2019 Big Data Meets Measurement in Manufacturing

1/12

CONTENTSTacticalBrief

Sponsored by

The Internet of Things

02. Big Data Meets Measurement in Manufacturing

04. Ethernet and Wireless Enable Manufacturing Internet of Things

07. Automation Technology Futures

09. Report Targets Power Transformer Monitoring Hardware

11. Weaving a Tapestry of Automation Technology
http://www.automationworld.com/http://leadwise.mediadroit.com/redirect/9416/26257/


2/12

2TACTICAL BRIEF Sponsored by /12Sponsored by

Big Data Meets Measurement in ManufacturingAll of the analog data acquired from manufacturing and productsa.k.a. the Internet of Things (IoT)dwarfs what is currently known as Big Data.

By Gary Mintchell, Automation World Co-Founder

Big Data headlines not only tech news but also popular newsas

in whats the government doing with all the informaon its stor-

ing about us. Big Data comprises just a twig compared with the full-

grown oak that Big Analog Data can generate. Naonal Instruments

Fellow Tom Bradicich menoned twice in separate interviews during

NIWeek last month that all of the analog data acquired from manu-

facturing and productsa.k.a. the Internet of Things (IoT)dwarfs

what is currently known as Big Data.

When thinking about data, consider the ow. First is acquision

from analog measurements. This may or may not be used in real

me. Then there is data in moon and data at rest. Finally there is

archiving the data. Then characterize data by where it is. The insight

comes from how the data is used. Real me is important if you are

monitoring a motor about to catch re. On the other hand, maybe

you want to go through three years of data to look for trend.

In test and measurement, we might debate with IT about whose

data is bigger, Bradicich says. It s not just size, but also velocity.

When data leaves NI devices, its in moon. Then rst it hits a switch,

server or workstaon. Now it is at rest in an IT server. Now the IT

world takes over for analycs, then archiving. The queson for us

is, Where do customers want to derive insight? Maybe closer to the

instrument, or maybe later at the desk. The four variables of data

classically are volume, velocity, variety and value. We have added a

hvisibilityfor who needs to see and analyze results.

Since NI is a measurement company, it has partnered with several

companies to bring a Big Data soluon. IBM has become a close

partnernot surprising given that NIs senior vice president of R&D

and Bradicich are both from IBM. Specically, the product from IBM

is InfoSphere Streams, part of the IBM Big Data plaorm. It processes

vast amounts of generated streaming data in real me and allows

user-developed applicaons to quickly ingest, analyze and correlate

informaon as it arrives from thousands of real-me sources. The

soluon can handle very high data throughput ratesup to millions

of events or messages per second.

Terabytes of dataAn NI partner, Phasor Measurement, has developed a soluon to

monitor the electric power grid. Bradicich says it can generate 5 TB

of data per month. A wind turbine can generate 10 TB per day, and a

jet engine can generate 20 TB per hour. Its easy to see how this fast,

streaming data could add up quickly.

Duke Energy built a system to conquer the problem of monitor-

ing and analyzing diagnoscs of its fossil fuel eet of generang

plants. The old way sent condion monitoring specialists to each site

with handheld data collecon devices. The company gured that the
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3/12

3TACTICAL BRIEF Sponsored by /12

ContinuedBig Data Meets Measurement in Manufacturing

specialists spent 80 percent of their me merely

collecng data while using only 20 percent of

their me actually analyzing the data. Imple-

menng a Big Analog Data soluon, predic-

ve maintenance specialists in remote centers

watch key signatures from equipment and note

abnormalies. They can then compare these

signatures when necessary to a fault signature

database and take correcve acon much more

quickly.

When you delve into the guts of a buzzword,

somemes you nd a soluon to some intrac-

table problems. So, dont get turned o by all

the hype of Big Data. See how you can use it to

solve your major engineering problems.

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/994TACTICAL BRIEF Sponsored by

Ethernet and Wireless EnableManufacturing Internet of ThingsThe concept of an Internet of Things (IoT) has morphed from its origins in RFID

to one that encompasses all networked devices, both within and external to amanufacturing operation. The push to adopt IoT in manufacturing coincides witha concurrent enabling trend toward use of industrial Ethernet and wireless networktechnologies within the production environment.

By Chantal Polsonetti, vice president of theARC Advisory Group

Along with intelligent sensors and machines,

IoT encompasses cloud compung, analyt-

ics, Big Data, mobility and universal visualizaon.

Improved business performance, producon

eciency and asset opmizaon remain the core

objecves for manufacturers to implement this

technology.

In a manufacturing context, these objecves

are achieved by gathering data locally from the

myriad of sensors, devices, machines and other

enes operang on the plant oor. This data is

then made available globally via a cloud or similar

infrastructure plaorm to all sanconed pares

for use in analycs, opmizaon, and a variety of

other applicaons.

The push to adopt IoT in manufacturing

coincides with a concurrent enabling trend

toward use of industrial Ethernet and wireless

network technologies within the producon

environment. These technologies not only oer

incremental benet over dedicated automaon

soluons in many applicaons, they also

favorably posion manufacturers to support the

data transfer requirements inherent in IoT.

On the plant floor

Industrial Ethernet networks have sustained

a connued downward march in the industrial

automaon hierarchy. Originally viewed pri-

marily as an IT technology best suited for en-

terprise-level applicaons, Ethernets potenal

to provide a single network technology for use

in vercal and horizontal integraon through-

out the enterprise, plus its improved industrial

performance, make it increasingly popular. The

network is now a staple at the control level of

the automaon hierarchy, with most suppliers

IoT and Big DataCombine Forces

This white paper will first show whymanufacturers should integrate the

IoT and big data into their industrialautomation systems, and then it willreveal how this can be done usingproducts and systems available to-day. The white paper will concludewith a look at the future of the IoTand big data, illustrating how theseconcepts will help create the factoryof the future.
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ContinuedEthernet and Wireless Enable Manufacturing Internet of Things

oering an Ethernet-based control backbone.

Numerous I/O and device-level products are

also available.

Both manufacturing engineers and their IT

counterparts now have years of experience with

the IEEE 802.11 Wi-Fi wireless standard. Most

manufacturers have already established best

pracces for its usage in their facilies. These

COTS-based wireless networks are widely used

throughout producon operaons and the digi-

tal oileld, whether to support mobile devices,

in-plant material handling, locaon tracking,

safety, compliance, or mulple other uses.

Manufacturers already recognize the incre-

mental advantages these networks provide

compared with dedicated automaon networks,

parcularly for data delivery. Ethernet and wire-

less both oer bandwidth greater than most

dedicated automaon networks and largely rely

on established standardizaon organizaons and

a large supplier base for connued development.

Ethernet in parcular has shown its ability to

reliably deliver the right data to the right place

at the right me, while manufacturers broadly

apply cable-free wireless instrumentaon to ad-

dress business challenges ranging from improved

process performance, reliability and eciency to

conformance with government mandates.

IoT relies on production dataThe enabling infrastructure behind IoT is com-

posed of intelligent sensors and machines, data

delivery networks, and cloud or similar plaorm

compung architectures that support analycs,

massive database management systems, and

any number of applicaons. This infrastructure

is designed to support the data gathering, analy-

sis and presentaon necessary to improve pro-

ducon eciency and performance, opmize

asset ulizaon, ensure safety and compliance,

and generate incremental gains in these and

other areas that were not previously achievable.

A core concept behind IoT is that minimal

potenal currently exists for improvements at

the device or machine level. Instead, this more

holisc approach contends that the potenal

for more robust improvements that incorporate

all the potenal variables and elements lies at

the system level. IoT also promises to support

real-me decision-making that incorporates

real-me informaon, rather than the typical

reliance on historical data.

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6/12


ContinuedEthernet and Wireless Enable Manufacturing Internet of Things

One of the further lures behind the IoT

concept is the promise to enable new

innovaons in products, processes and

procedures throughout the enterprise. IoT

data and analysis can be remotely accessed

via PCs, laptops, tablets, consoles, handhelds,

smartphones, other machines, etc., for

both process improvement and sources of

innovaon. As an extension of this concept,

many current and future products and

acvies will migrate into services oered by

both in-house and external providers. This is

already true in areas such as machine or eet

maintenance, where external suppliers provide

remote services reliant on local data.

Feed the beastOne way to view IoT is as a progression or

step-change in integraon that provides mul-

direconal access to a massively collaborave

environment, potenally enabling connued

improvements in business performance and in-

novaon.

Migraon toward IoT will require manufactur-

ers to connue to mandate compability with

COTS-based networks when specifying new

sensors, machines or systems. Ethernet and

wireless networks will form the bedrock of the

IoT architecture and, fortunately, many speciers

are already familiar with their use in produc-

on equipment. In general, plant oor sensors,

devices, machines and systems will be required

to transmit their data to the cloud compung

plaorm for analysis and then be capable of ac-

cepng real-me feedback from the analycal

engine(s) for performance improvement.

The ability to access producon data from with-

in the typically ered producon architecture

will be a major consideraon. Security of plant

oor operaon is a major concern when such an

integrated, network-dependent concept is raised.

Mul-direconal access control strategies will

be paramount, as will connual monitoring and

threat defenses. Again, many manufacturers have

experience with these issues through their adop-

on of Ethernet and wireless networks, and have

security provisions in place. Automaon suppliers

now oer their own rewalls and other security

products, and more standards are becoming

available in this area. The IEEE 802.1x standard

supported in many Ethernet switches, for exam-

ple, oers port-based network access control.

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7/12


Automation Technology FuturesThe concept of Internet-connected machines that collect data and communicate, often called Machine-to-Machine(M2M) or the Internet of Things (IoT), has been around for years. Now several leading companies have identified this

as a strategic market with enormous potential.

By Jim Pinto

Digital technology connues to permeate in the world at large,

and several growth inecon points are brewing in the new digi-

tal automaon world. Rapid shis are occurring in all industrial mea-

surement and control environmentsfrom wired systems to wireless

connecvity; from convenonal client-server systems to cloud-based

processing; from tethered PCs and centralized operator staons to

an abundance of mobile devices; from local data management to the

advent of Big Data; from relavely large centralized systems to the

distributed Internet of Things (IoT).

We are heading into a world in which intelligence is widely dis-

tributed across the physical landscape. Remote sensors will gener-

ate enormous amounts of data, and cognive processors will sort

the informaon to deliver knowledge and capabilies never before

thought possible.

The concept of Internet-connected machines that collect data and

communicate, oen called IoT or Machine-to-Machine (M2M), has

been around for years. Now several leading companies have iden-

ed this as a strategic market with enormous potenal, though they

sll see the shi from their own points of viewnot yet with a single

coherent vision.

Cisco esmates that more than 99% of physical objects are sll

unconnected, and champions the Internet of Everything to bring

together people, process and data, and convert informaon into

acons that create new capabilies and unprecedented economic

opportunies in almost every arena. IBMs Smarter Planet strategy,

more than ve years old, is targeted at using data and analycs to

build an intelligent and interconnected planet.

GE calls this the Industrial Internet, emphasizing focus on indus-

trial applicaons. Growth is viewed as a third wave, following the

industrial revoluon and the Internet revoluon. They believe that

46 percent of the global economy, or $32.3 trillion in global output,

can benet from these new developments. They esmate that this

could add $10 trillion to $15 trillion to the world economy in the next

20 years. To back up these projecons, they have commied R&D

funding of $500 million a year for the next three years, the rst major

commitment on a scale that could meaningfully accelerate adopon.

The Automation IndustryMcKinsey Global Instute ranks IoT as one of the most disrupve

technologies to 2025. They suggest that much of that growth will

be at the expense of older technologies and even enre industries


8/12


ContinuedAutomation Technology Futures

falling into obsolescence.

Since the 1970s, automaon technology has

had only incremental developments around

core developments: PLCs, DCS and SCADA.

Accelerang technology has generated rapid

product obsolescence and drasc reducons in

system lifecycles. A lot of hardware is slipping

back into the commodity supply chain.

Automaon majors are all involved with pro-

mong the Industrial Internet. They sense strong

interest among large end-user customers, espe-

cially on the issues of cung costs and improv-

ing producvity. The queson remains: Which

automaon companies have the will and see the

payback required to commit serious resources to

generang major growth in these new markets?

Beyond lip service, there just doesnt seem to be

strong evidence yet that they are anywhere close

to reaching the pping point.

For almost two decades, PLC inventor Dick

Morley and I have been preaching peer-to-peer

(P2P) control systemssuggesng that signi-

cant new advantages and benets would emerge

through distributed architectures. Convenonal

hierarchical control systems are prone to failure

when complexity increases. Few have achieved

praccal I/O point counts of more than a few

hundred thousand. By contrast, intelligent,

autonomous I/O systems with algorithmic (rule-

based) response mechanisms have no theorecal

complexity limit. Vastly improved performance

can be achieved at a fracon of the cost of de -

terminisc hierarchical systems. The huge invest-

ments in the Industrial Internet seem to back this

viewpoint.

McKinsey cauons that by the me these dis-

rupve technologies are exerng their inuence

on the economy in 2025, it will be too late for

businesses to plan their responses. Nobody can

aord to be the last.

The Coming Era of SmartDevices and the Internet ofThings

Advantech welcomes Harry Forbes,Senior Analyst, ARC Advisory Group,

to discuss the business and technol-ogy drivers behind IoT. In this video,Harry Forbes looks at all the causesof the Internet of Things. The mar-ket size, applications, industries, and

business models.
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9/12


Report Targets Power Transformer MonitoringHardwareThe Internet of Things (IoT) makes its presence felt in the electrical power distribution segment with this report fromGTM Research on transformer monitoring for the smart grid. Despite slow adoption of the smart grid by utilities (andmunicipalities), the new report shows low-hanging fruit for the implementation of transformer hardware monitoringand sensors.

By Grant Gerke, Contributing Writer

The Internet of Things (IoT) and sensors needed to enable it are

receiving quite a bit of aenon as manufacturing and industrial pro-

ducon turn to smarter devices and systems. The hype is real and not

only for machine design; networks and systems are geng smarter. A

recent report from GTM Research entled Transformer Monitoring

Markets, 2013-2020: Technologies, Forecasts, and Leading Vendors

sees a huge opportunity for ulies to install smarter monitoring

devices for crical transformers. The report also nds a solid return

on investment (ROI) for the technologya key aspect of the smart

grid challenge.

GTM Research denes the smart grid transformer market as acocktail of monitors, sensors, soware, diagnoscs and analycs

that promises to guard against outages and beer protect ulity grid

assets. The reports overall projecon paints strong growth from the

U.S. market for transformer monitoring hardware, increasing from its

current valuaon of $112 million annually to $755 million by 2020.

With an aging electric grid and soaring demands being placed on

itsuch as smart meters and distribuon automaon hardware

U.S. ulies have been scrambling to nd cost-eecve soluons and

polical will, in some cases, to implement a basic strategy. Uli -

es must invest in monitors, sensors and soware for their new

and aging transformers, says Ben Kellison, smart grid analyst, GTM

Research. They are the backbone of the U.S. alternang current grid,

and they range from one of the most expensive ulity assets to low-

cost street corner devices manipulang power to ensure our toast-

ers work properly.

The report says that the installaon of the new and retrong of

the old power, distribuon and secondary transformers with addi-

onal sensors and monitoring equipment will take quite some me,

as they are replaced gradually as they fail or are phased out due to

perceived or veried insulaon aging.

At GTM Research, we have seen the overall smart grid market

slow down, but we see transformer monitoring and soware mar-

kets as a high-growth area driven by the strength of the secondary

transformer market, adds Kellison. Grid giants like ABB, Alstom,

GE, Schneider Electric and S&C Electric have already caught on to

the opportunity the transformer technology oers and are well-


10/12


posioned to lead the market.

According to GTM Research, trans-

former technologies are not typically

rolled out in waves at ulies, but over

the last few years notable excepons

have arisen in North America: San

Diego Gas and Electrics 2020 Reliabil-

ity Plan, Arizona Public Services TOAN

program, American Electric Powers

adopon of ABBs Asset Health Center

Soluon, and Toronto Hydros pilot

secondary transformer monitoring

program.

Instead, monitoring is generally

added at the most crical or expensive

assets or added into specicaons dur-

ing the acquision of new transform-

ers. GTM Research says the spread of

eld area networks, the demand for

edge grid data and associated the me

delay will create demand for monitors

at the transformer level that will ramp

up to exceed the tradional power

transformer market by 2015.

ContinuedReport Targets Power Transformer Monitoring Hardware
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11/12


Weaving a Tapestry of Automation TechnologyThe things I see coming in the fullness of time are those that are built upon the control platforms that help us manageplants and factories more effectively.

By Gary Mintchell, Automation World Co-Founder

Welcome to 2013I hope. Im wring this editorial days before

the end of the world, according to an interpretaon of an old Mayan

calendar. Whether we are crumpled at the boom of the scal cli

is also unknown now. Such are monthly magazines.

Assuming were all sll around to read this, I thought Id take a

shorter view about automaon than the Mayans and a longer view

than our polical leaders seem to be able to muster. While there are

sll improvements in control plaorms, programming, sensing and

moon, the things I see coming in the fullness of me are those that

are built upon the control plaorms that help us manage plants and

factories more eecvely.

Menoning Cloud Compung in a publicaon targeted to enter-

prise informaon technology people doesnt even draw a yawn any

more. Automaon people are moving with the usual haste (mean-

ing not quickly) toward adopng cloud technologies. The reasonis that the cloud is a place to house lots of informaon. Expect to

read more about the cloud. Also expect to hear your suppliers talking

more about it.

Building huge repositories of informaon does no good unless

there is a way to make it all understandable and to deliver it in

disnct ways to help people make decisions. Fortunately, another IT

innovaon is availableanalycs. Look for the various technology

suppliers to bring out advances in analycs, dashboards, operator

screens, mobile support and more.

Something has to feed that beast, and arrays of connected de-

vices oen talking among themselves and databases without human

intervenon are that something. The evoluon of this technology

has been painfully slowjust like everything else in our market. The

Internet of Things, the Pervasive Internet and the Industrial Internet

are just some of the new names for this new world of connected

devices. Automaon companies as diverse as GE and

Advantech have made this technology a cornerstone of strategy.

There will be ever greater connecvity using all the strands of net-

working technology weve discussed for the past 10 years.

InteroperabilityOne other technology and standards thread is required to weave

this informaon-rich industrial future. That is interoperability. I re-

cently visited a Belden plant where wiring cables are manufactured.

Management researched new Computerized Maintenance Manage-

ment System (CMMS) applicaons. One manager told me, I sure

wish that these packages would communicate with other soware

packages such as our enterprise resource planning (ERP) system.

OPC UA has been more than ve years in development. In 2012 we

began to see a crical mass of applicaons and products. OPC is one


12/12


industry standard for interoperability

that has proven itself for many years.

The advancements that come with UA

make it even more valuable. The Open

O&M Iniave is yet another industry-

led interoperability standard that is

beginning to gain mass in the oil & gas

industry. Watch for more to come this

year.

January 2013 marks the second year

of reporng on the results of our open-

ended reader poll of companies you

choose to be on your First Team as

automaon suppliers. Youll also nd a

secon where a variety of automaon

suppliers are promong their prod-

ucts and soluons and asking you to

go online and select them as a Leader

in Automaon. These are a couple of

ways you can make your voice heard.

January 2013 also marks the 10th

Anniversary of the founding of Automa-

on World. I joined the start up team

with Dave Harvey and Jane Gerold in

Feb. 2003 with rst issue published in

June, and I owe both much gratude

for having condence in me as the

founding editor. It has been a lot of fun.

ContinuedWeaving a Tapestry of Automation Technology
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big data meets measurement in manufacturing

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