Key Ingredients for Smart Machines
Learn what OEMs need to meet end users’ needs for integrated machines that provide production intelligence and improve responsiveness to changing market demands.
Original equipment manufacturers (OEMs) always have been expected to innovate and keep pace with end users’ requirements. Yet, today in the era of smart manufacturing, users want to optimise their production and supply chain by bringing together islands of information — and they want OEMs to help. Delivering on the promise of smart manufacturing is vital.
The Connected Enterprise is at the heart of a smart operation, which consists of converged IT and operations technology (OT) systems into a single network architecture. It also uses smart machines and Industrial Internet of Things (IIoT) technologies for seamless connectivity and information sharing across people, plants and supply chains.
As a result, users need smart machines and equipment designed to thrive in The Connected Enterprise and provide nearly endless opportunities to improve their operations. It also can help them address their most pressing needs, such as:
- Remaining globally competitive by keeping business models relevant and moving from mass production to mass customisation
- Addressing workforce issues, including retaining the skills of retiring workers, and helping IT and OT workers prepare for the influx of new smart technologies
- Addressing risks, including security threats and increasingly complex regulations
- Making the most of Internet- and Ethernet-enabled technologies
This all may be daunting for industrial OEMs. However, they can meet customers’ needs and simplify design of smart systems by focusing on three key elements: processes, technology and people.
Processes: Meet End Users on Their Journey
An end user’s journey to The Connected Enterprise generally follows four stages (see sidebar). Still, every journey will be distinct. Factors such as operational needs, available resources and workforce availability will be unique to each organisation and influence their Connected Enterprise path.
OEMs will encounter end users at different points in their journey. Some will be in the early planning stages. Others may be in the midst of IT/OT convergence, and still others may be ready to integrate smart machines or equipment.
It’s important for OEMs to communicate with users to understand their needs and stage in the journey. Those conversations also can help OEMs identify opportunities to innovate with their customers, such as using remote monitoring to monitor assets and maximise uptime.
Ultimately, OEMs always must be ready to equip users with smart machines or equipment, regardless of where they are in their journey.
Technology: Deliver Systems That Match Needs
OEMs that want to support smart manufacturing and industrial operations should rethink traditional, machinery-design approaches. As they consider different design aspects to change and update, five key technology areas are important:
- Integrated Safety: Combining standard and safety control into a single platform enables the use of intelligent, machine-safety-system designs. This can improve productivity while still achieving compliance. Machines can also collect safety-system data to alert operators where safety-related issues are occurring for faster downtime resolutions and long-term improvements.
- Accessible and Secure Information: End users develop goals for securely accessing and capitalising on their operational, business and transactional data. OEMs can support and fulfill those goals by connecting control systems and using performance dashboards that make information available and actionable.
- Simplified Integration: Replacing a multi-tiered networking strategy with a single, open EtherNet/IP™ network can simplify the network infrastructure and reduce integration risks. Likewise, a single, Logix-based control and information platform can ease the collection, transfer and analysis of real-time operations data.
- Real-Time Diagnostics and Analysis: Embedded-intelligence devices can deliver real-time data for predictive maintenance to help users more quickly troubleshoot and repair problems. Remote monitoring also can monitor critical parameters and address issues before they reach a point of failure.
- Operational Efficiency: Design tools and scalable automation technology help OEMs deliver flexible equipment for multiple purposes to improve efficiency. For example, modular programming and re-usable code can help reduce system complexity and support faster design, commissioning and installation times. Motion-sizing tools also can help make mechatronic designs faster and easier to analyse, and help optimise, simulate and select motion-control systems.
People: Secure the Right Skills
Engineers and programmers must understand the blend of IT/OT technologies used in connected plants and enterprises. They also must know how to configure, operate and sustain their customers’ networked industrial control systems.
Providing training for existing workers can be critical to achieving this, especially because skilled workers are increasingly hard to find. OEMs should consider using training and certification courses developed specifically to help bridge the IT/OT gap in smart operations.
OEMs don’t need to go it alone. Look to use vendors’ consultative, design, integration and support services to help fill areas of need, such as to help design a more secure control system in a connected operation, help smart machines and equipment comply with the latest standards, or analyse trends and recommend actions to help prevent downtime.
Keeping Up With Expectations
End users still expect machines and equipment to help them optimise processes, achieve compliance, maximise quality and protect workers. But they also now expect those same systems to easily integrate into their operations, offer production intelligence and improve their responsiveness to changing market demands.
With the right mix of processes, technology and people, OEMs can develop smart machines and equipment that meet these higher expectations.
OEMs can explore smart machine solutions available from Rockwell Automation at PACK EXPO International, 6-9 November 2016 in Chicago, USA.
Also, OEMs exhibiting machines and equipment at interpack 2017 with Rockwell Automation products and solutions can enter by 31 October 2016 to win the Best Future Machine Award.
Learn about our OEM Solutions.
Four Stages of The Connected Enterprise
While every end user’s journey to The Connected Enterprise is different, they generally follow these four primary stages:
- Assess and Plan: Conduct assessments to understand the culture and to evaluate the IT/OT infrastructure in place, including controls, networks, information and policies.
- Secure and Upgrade Network Controls: Securely upgrade the network and controls to prepare for future configurations and technologies, such as mobility, big-data analytics and cloud computing.
- Leverage Data and Analytics: Define data, identify how to turn it into actionable information to support better business decisions, and use it to drive continuous improvements.
- Optimise and Collaborate: Optimise operations, and engage with internal teams, suppliers and customers to better respond to internal and external events.
How Rockwell Automation Partners Support OEMs
Rockwell Automation Encompass™ Product Partners support OEMs in The Connected Enterprise journey. Here’s how:
Encompass Partner products are aligned with Rockwell Automation configuration tools; ProposalWorks™ includes 622,000 partner products, Integrated Architecture Builder — 763 partner products; and Motion Analyzer — 25,000 partner products.
- Hundreds of products are designed solely for the Logix-based platforms
- More than 110 Custom Add On Profiles (AOPs) ease configuration with Rockwell Automation control systems
- Partner sample code and HMI face plates save development costs and provide key user diagnostic information
- More than 240 Encompass products are tied to EtherNet/IPTM networks
More than 1,000 referenced products from 130 market leading companies help to expand Rockwell Automation Solutions. The total years of experience and collaboration in the Encompass program is 1,375 years from these 130 companies.
Learn about Encompass referenced products.