Retrofitting Legacy Systems for Data-Rich Industrial IoT. Allen Tubbs Product Manager

Transcription

1 Retrofitting Legacy Systems for Data-Rich Industrial IoT Allen Tubbs Product Manager 1

2 The problem with legacy machinery - Limited Intelligence - Mechanical Machines - No Sensors - R&D = $$$ - Replacement = $$$ - Risk to process = $$$ Robert Bosch s lathe circa Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, aswell as in the event of applications for industrial property rights.

3 Enterprise problems make it worse - Machines age range - Many vendors - Different functions - Protocol variety 3

4 Why Bosch listens it s our problem too Lead Provider of Automation & Manufacturing Solutions Lead User Product manufacturer Drive and Control Technology Industrial Sensor Solutions Bosch Software Innovations Bosch Sensortec Packaging Technology Assembly Systems and Special Machinery Bosch Connected Devices & Solutions plus Consumer-goods e.g. - Power Tools - Home Appliances - Thermotechnology - Innovations in Logistics Management Machine Platforms Data Mining, Big Data Center of Competence RFID@BOSCH 250+ Bosch plants worldwide Manufacturer of products Machine user Plant management and optimization Interface to customers/suppliers 100s of Industry 4.0 Pilot projects 4

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6 IoT Gateway links existing legacy machines with the infrastructure of the IT + IoT world. WLAN IO/Sensors Proprietary PLC Data Streams Fieldbus IO/Sensors Direct IO/Sensors Open Core Interface 6

7 IoT Gateway links existing legacy machines with the infrastructure of the IT + IoT world, without programming, in one device Overview Dashboard 7

8 Industry 1.0 to 4.0 Add Speed sensor: - Immediate operator feedback - Correlate to product quality - Detect tool wear Add Tension sensor: - Machine health indicator - Predictive maintenance - Improve operator efficiency Data Analysis Visualization 8

9 IoT Gateway Success Story: Hydraulic Test Bosch Homburg Monitoring oil quality and filters and compliance with the ISO cleanliness level Maintenance Support System -25% Maintenance costs -20% Complexity for manual testing Existing test facility + + IoT Gateway Software Production Performance Manager (secondary system) +5% OEE ROI < 1,5 years 9

10 Connected Forming Machines - Wear parts - Failure - Quality - Replacement Parts - Environmental Effects - Production Monitoring / OEE Hydraulic Control Electric Servo Control Less Mess Better Control Motor as a Sensor 10 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, aswell as in the event of applications for industrial property rights.

11 Getting the right data 11

12 Applying analytics to mine value 12

13 But what about that enterprise problem?? 13

14 ? - Immediate Quality Score - Maintenance Prediction - Wear Part Prediction Leads to: -Better Parts, Efficiency/Up-time and Customer contact 13 Bosch Rexroth AG All rights reserved, also regarding any disposal, exploitation, reproduction, editing, distribution, aswell as in the event of applications for industrial property rights.

15 Get everyone on the same page ActiveCockpit Present solutions Before After Digital solution 15 High manual effort for boards No interactive solutions No consistent action High surface requirements Connected with MES, ERP, DB Paperless communication Moderation, escalation, whiteboard Open system via app platform

16 Connecting people to the data and results 16

17 Retrofitting Legacy Systems for Data-Rich Industrial IoT Allen Tubbs Product Manager 17