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Maximize profitabilitythrough actionableinsights from your data.Data Services @ FACE -23 to 24th Jun2016
Siemens.com/dsRestricted © Siemens Ltd 2016
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Digitalization : The future of Manufacturing
From Industry 1.0 to Industry 4.0
1800 1900 2000 Time
Degree ofcomplexity
FirstIndustrialRevolution
SecondIndustrialRevolution
ThirdIndustrialRevolution
FourthIndustrialRevolution
First mechanical loom, 1784
First conveyorbelt, Cincinnatislaughterhouse, 1870
First programmablelogic controller (PLC)Modicon 084, 1969
based on the introductionof mechanical productionequipment driven bywater and steam power
based on mass productionachieved by division oflabor concept and the useof electrical energy
based on the use ofelectronics and IT tofurther automateproduction
based on the use ofcyber-physical systems
Repair shops Standardization / Processknowledge
SoftwareUpdates
Data Driven Services
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Data is the key to the future of manufacturing
Really
“Big Data”The volume of datais increasingexponentially
The datacollected canbe used tocreatevaluableinsights
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Internet of Things (IoT) technology is being widely adopted
By 2020estimated
5.4 BillionDevices will beconnected toIoT.
Source: Gartner
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Product Innovation
Industry 4.0 is set to revolutionize manufacturing
Main pursuits of Industry 4.0 are
Increased Collaboration
Operational Process Enhancement
Cyber-Physical Production
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With data Siemens can help you to..
Data Services- Intelligent, Simple & EconomicGet a running start on the future of industry – with Siemens Plant Data Services
Enhanceindustrialsecurity
Optimizeenergy
performance
Masterasset
uptime
Maximizeprocess
efficiency
We understand:
monitoring and analytics capabilityfor critical applications plant-wide
We know:
expertise in core systems / componentsof critical industrial applications.
We integrate:
technical integration of monitoring-functionality in sub-systems and OEM-equipment.
We act:
reliability and up-time-centeredcustomer care.
We protect:
ensured industrial IT security standards.
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Industrial Network validation & Analytics
Control Performance Analytics
Siemens Offers
Energy Analytics
Drive Train Analytics
Customer
Siemens
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Mea
sure
men
t
Production
Line 1
Line 2
Con
sum
ptio
n
Prod
uctio
n
Wasted energy
21th14th7th 28th
MonitoringAction
Achieve transparency Realize savings Enhance efficiency
Your Benefits
Improve transparency of your energyconsumption via basic analytics anddashboard views
Improve energy efficiency and reduceenergy costs
Improve process efficiency, quality and outputby implementing measures based onadvanced data analytics
Assess energy data at yourfingertips
Identify hidden savings potential withadvanced analytics
Enhance business results by reducingoperation costs
Optimization
Energy Analytics at a glance
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Siemens Answer to Industry -Energy AnalyticsSimple, intelligent & economic solution
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Energy Analytics addresses all levels of metering………
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Real solution -Switching from time-based to efficiency-based controls
Saving Potential%
Current
Analytic Workflow: Controls Optimization
1 | Identify current control scheme tomeet target production
2 | Identify regions of economicallyefficient operation
3 | Optimization: Identify economicaloptimal control scheme
Time of day Time of day
Aver
age
Ener
gyC
onsu
mpt
ion
Aver
age
Ener
gyC
onsu
mpt
ion
Ener
gyC
onsu
mpt
ion
Compressed Air Production
Estimatedconsumption
4 | Verify savings and identify how operations can be optimized into the future
Compressor 1 Compressor 2 Optimized Compressor 1 Compressor 2
Pastconsumption
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Case Study 3 - Paint Shop Energy Management
1*
3*
3* Water1* Gas or HSD
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Industrial Network validation & Analytics
Energy Analytics
Siemens Offers
Control Performance Analytics
Drive Train Analytics
Customer
Siemens
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… only 50 % of control loops are well tuned1)
Optimized control loops save you money without newinvestments
Control Loop Monitoring of all control loops addsvalueto your PCS 7 system
Control Performance lies at the Heart of Your Process Plant
1) Source: Control Engineering
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Increased Product Quality
Optimized Process EfficiencyProcess Data Analytics
Minimize Equipment Utilization
Increased Throughput Reduced Work Load
Maximized process efficiencyProcess safety - Throughput - Quality - Raw Material - Energy - Equipment Utilization
Reduced variability in processimproves product quality
Improved set point limits increasesthroughput
Reduced variability in actors forminimized equipment utilization
Reduced alarms and fewer operatorinteraction reduce operators' workload
Production start
Pro
cess
-Ala
rms
Ope
rato
rIn
put
Nom
inal
Val
ues
Production start
Pro
cess
-Var
iabl
es
Production start
Act
uatin
gV
aria
ble
Production start
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Cost efficient through Managed Service ApproachProcess Data Analytics
Customer
Siemens
Visualization andrecommendations
Secureconnection
Data analytics andsimulation
Consulting andimplementation support
Secure connection
Data combinationand secure storage
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Control Performance Analytics
Energy Analytics
Our Portfolio
Industrial Network validation & Analytics
Drive Train Analytics
Customer
Siemens
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Industrial network as a critical assetWhat is your top current priority?
How can I maintain reliabilityand still be flexible?
How can I be more effectivein my network maintenance?
How do I identify network healthand anticipate network behavior?
How do I preventnetwork failures?
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Main failure scenarios within industrial networks
Failed robustness
Device misbehaviorat high load
Bad network communicationsquality
• Traffic overload
• Cycle time, jitter
Incorrect Planning andparameterization
Design problems of controller ordevice
Loss of transparency, loss of production and asset malfunctionConsequential losses
Ramp-up phase Operational phase
Sporadic failures
Sudden abnormalityin the network
Firmware problems
Increasing device mal-functions andsecurity incidents
Network changes(topology and use)
Increasing network load
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Services across the lifecycle of industrial networks
Check and certify roboustness ofPROFINET/PROFIBUS networksThrough hardware check, physicalnetwork build, data communicationcheck, compliance with PNOregulations
Supervise & diagnosestability in PROFINET/PROFIBUS networksContinuous, remote monitoringof status, KPIs (cycle time,network- load, events etc.)
Industrial Network Validation Industrial Network Analytics
Your Benefit – Smooth production ramp-upIdentify defects in planning – Rogue planning and parameterization defects in networksIdentify defects in HW – Such as cables, active and passive networks componentsCompare to PNO standards – Know to what extent approval standards of PNO are met
Your Benefit – Increase network availabilityCentralized monitoring – For quicker and efficient reaction by maintenance staffHighest transparency – Identifying bottlenecks in network communication beforehandImmediate expert support – For faster localization of root causes in networks
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Network Validation @ Saint Gobain Gyproc India Ltd, Bangalore
Challenge
Customerbenefit
• No shutdown time available.
• Having a failure-free network was still achallenge.
• Siemens provided answers to Saint Gobain’sproblems with Profibus Network validationservice.
• Network architecture - 7 different networkshaving 140 slaves.
• Improve network stability, availability &reliability, thereby avoiding production loss dueto network failures.
• Increase the signal strength throughout thenetwork by up to 100%.
Solution
Situation • SOx and NOx emissions reduced by more than 90%
• Availability and reliability of networkinfrastructure.
• Network installations done by differentvendors
• To achieve network stability, speed wasreduced in key areas
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Transforming data into actionable insights – from field equipment to userIndustrial Network Analytics
Siemensoperationcenter
Systemintegrator/OEM
Private cloud
OfficePlant
Internet
PlanningMaintenance
Network service station
SINEMA server
Bus analyzer agentsAsset
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Sample dashboards – Instant advice based on historic data and onlineanalyticsIndustrial Network Analytics
Overview of more plants andnetworks
Status about all sub-networks of onesite
Exact identificationof all notifications
Easy access to all current and historicaldevice data (switch load, port load…),trend views
Übersicht über Teilnetzwerke
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Industrial Network Validation and AnalyticsUSPs
Validation
Siemens is the only provider of simulated stress tests forindustrial networks
Analytics
Simple depiction of network diagnostic information
Proactive context feedback provided by Siemens experts
Reactive (on-demand) cRSP feedback provided by Siemensexperts (ad-hoc )
Decision-making support at all levels (from users to management)
Expertise in hardware, software and cloud-based services
Simple integration into existing automation systems
Exceeds requirements of PNO regulations regardingPROFINET telegram transmissions under stress loads
Field devices checked for availability under stress loadsonline
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Control Performance Analytics
Energy Analytics
Our Portfolio
Drive Train Analytics
Industrial Network validation & Analytics
Customer
Siemens
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A Managed Condition Monitoring Servicebased on Online Data Collection and Analytics
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Reduce forced outage downtimesDrive Train Analytics
• Reduce unplanned production losses• Accelerate issue resolution• Improve availability centered operation and maintenance
planning
Customer drivers and goals
• Accurate operation history for better root cause analysisenables reduced forced outage downtime
• Increasing operational efficiency in maintenance planning &execution through immediate asset transparency
• Optimize maintenance planning by early detection of patternsthat may cause anomalous behavior
Why it is worthwhile!
Siemens offering
• Trend-setting Managed Service Platform• Siemens Expert Network for fast problem analysis and
solving• Vast industry knowledge directly from the manufacturer
of drive train components up to whole plants• State-of-the-art IT security
Why Siemens?
Onlinedashboards
+ + +ReportsNotifications
and warningsData
assessment
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Sandeep BardeData ServicesSiemens LtdKalwa Works,Thane-Belapur Road,Airoli NodeNavi MumbaiPhone: +91 (22) 39663023Mobile: +91 9930765543
E-mail:[email protected]
Thank You!!
www.siemens.com/plantdataservices