Maximize profitability through actionable insights from your data. Data FACE -23 to 24 th Jun2016

Transcription

1 Maximize profitability through actionable insights from your data. Data FACE -23 to 24 th Jun2016 Restricted Siemens Ltd 2016 Siemens.com/ds

2 Digitalization : The future of Manufacturing From Industry 1.0 to Industry 4.0 First Industrial Revolution Second Industrial Revolution Third Industrial Revolution Fourth Industrial Revolution Degree of complexity based on the introduction of mechanical production equipment driven by water and steam power based on mass production achieved by division of labor concept and the use of electrical energy based on the use of electronics and IT to further automate production based on the use of cyber-physical systems Data Driven Services Repair shops Standardization / Process knowledge Software Updates First mechanical loom, 1784 First conveyor belt, Cincinnati slaughterhouse, 1870 First programmable logic controller (PLC) Modicon 084, Time Page 2

3 Data is the key to the future of manufacturing Really Big Data The volume of data is increasing exponentially The data collected can be used to create valuable insights Page 3

4 Internet of Things (IoT) technology is being widely adopted By 2020 estimated 5.4 Billion Source: Gartner Devices will be connected to IoT. Page 4

5 Industry 4.0 is set to revolutionize manufacturing Main pursuits of Industry 4.0 are Product Innovation Increased Collaboration Operational Process Enhancement Cyber-Physical Production Page 5

6 Data Services- Intelligent, Simple & Economic Get a running start on the future of industry with Siemens Plant Data Services With data Siemens can help you to.. Master asset uptime Maximize process efficiency Enhance industrial security Optimize energy performance We understand: monitoring and analytics capability for critical applications plant-wide We know: expertise in core systems / components of critical industrial applications. We integrate: technical integration of monitoringfunctionality in sub-systems and OEMequipment. We act: reliability and up-time-centered customer care. We protect: ensured industrial IT security standards. Page 6

7 Siemens Offers Customer Energy Analytics Control Performance Analytics Industrial Network validation & Analytics Drive Train Analytics Siemens Page 7

8 Energy Analytics at a glance Achieve transparency Realize savings Enhance efficiency Assess energy data at your fingertips Improve transparency of your energy consumption via basic analytics and dashboard views Monitoring Consumption 7th 14th Wasted energy 21th 28th Identify hidden savings potential with advanced analytics Improve energy efficiency and reduce energy costs Action Production Measurement Line 1 Line 2 Production Enhance business results by reducing operation costs Improve process efficiency, quality and output by implementing measures based on advanced data analytics Optimization Your Benefits Page 8

9 Siemens Answer to Industry -Energy Analytics Simple, intelligent & economic solution Page 9

10 Energy Analytics addresses all levels of metering Page 10

11 Real solution -Switching from time-based to efficiency-based controls Analytic Workflow: Controls Optimization 1 Identify current control scheme to meet target production 2 Identify regions of economically efficient operation 3 Optimization: Identify economical optimal control scheme Average Energy Consumption Energy Consumption Average Energy Consumption Current Time of day Compressed Air Production Time of day Compressor 1 Compressor 2 Optimized Compressor 1 Compressor 2 4 Verify savings and identify how operations can be optimized into the future Past consumption Estimated consumption Saving Potential% Page 11

12 Case Study 3 - Paint Shop Energy Management 1* 3* 1* Gas or HSD 3* Water Page 12

13 Siemens Offers Energy Analytics Customer Control Performance Analytics Industrial Network validation & Analytics Drive Train Analytics Siemens Page 13

14 Control Performance lies at the Heart of Your Process Plant only 50 % of control loops are well tuned 1) Optimized control loops save you money without new investments Control Loop Monitoring of all control loops adds value to your PCS 7 system 1) Source: Control Engineering Page 14

15 Optimized Process Efficiency Process Data Analytics Increased Product Quality Minimize Equipment Utilization Process-Variables Reduced variability in process improves product quality Actuating Variable Reduced variability in actors for minimized equipment utilization Production start Production start Increased Throughput Reduced Work Load Nominal Values Production start Improved set point limits increases throughput Process-Alarms Operator Input Production start Reduced alarms and fewer operator interaction reduce operators' work load Maximized process efficiency Process safety - Throughput - Quality - Raw Material - Energy - Equipment Utilization Page 15

16 Cost efficient through Managed Service Approach Process Data Analytics Customer Visualization and recommendations Siemens Secure connection Data analytics and simulation Consulting and implementation support Secure connection Data combination and secure storage Page 16

17 Our Portfolio Energy Analytics Customer Control Performance Analytics Industrial Network validation & Analytics Drive Train Analytics Siemens Page 17

18 Industrial network as a critical asset What is your top current priority? How do I identify network health and anticipate network behavior? How can I maintain reliability and still be flexible? How can I be more effective in my network maintenance? How do I prevent network failures? Page 18

19 Main failure scenarios within industrial networks Ramp-up phase Incorrect Planning and parameterization Design problems of controller or device Network changes (topology and use) Increasing network load Operational phase Bad network communications quality Traffic overload Cycle time, jitter Firmware problems Increasing device mal-functions and security incidents Failed robustness Device misbehavior at high load Sporadic failures Sudden abnormality in the network Consequential losses Loss of transparency, loss of production and asset malfunction Page 19

20 Services across the lifecycle of industrial networks Industrial Network Validation Industrial Network Analytics Check and certify roboustness of PROFINET/PROFIBUS networks Through hardware check, physical network build, data communication check, compliance with PNO regulations Supervise & diagnose stability in PROFINET/ PROFIBUS networks Continuous, remote monitoring of status, KPIs (cycle time, network- load, events etc.) Your Benefit Smooth production ramp-up Identify defects in planning Rogue planning and parameterization defects in networks Identify defects in HW Such as cables, active and passive networks components Compare to PNO standards Know to what extent approval standards of PNO are met Your Benefit Increase network availability Centralized monitoring For quicker and efficient reaction by maintenance staff Highest transparency Identifying bottlenecks in network communication beforehand Immediate expert support For faster localization of root causes in networks Page 20

21 Network Saint Gobain Gyproc India Ltd, Bangalore Challenge No shutdown time available. Having a failure-free network was still a challenge. Availability and reliability of network infrastructure. Network installations done by different Situation SO x and NO x emissions reduced by more than 90% vendors To achieve network stability, speed was reduced in key areas Solution Customer benefit Siemens provided answers to Saint Gobain s problems with Profibus Network validation service. Network architecture - 7 different networks having 140 slaves. Improve network stability, availability & reliability, thereby avoiding production loss due to network failures. Increase the signal strength throughout the network by up to 100%. Page 21

22 Transforming data into actionable insights from field equipment to user Industrial Network Analytics System integrator/ OEM Private cloud Siemens operation center Internet Plant Asset Bus analyzer agents Network service station Office SINEMA server Maintenance Planning Page 22

23 Sample dashboards Instant advice based on historic data and online analytics Industrial Network Analytics Overview of more plants and networks Übersicht über Teilnetzwerke Status about all sub-networks of one site Exact identification of all notifications Easy access to all current and historical device data (switch load, port load ), trend views Page 23

24 Industrial Network Validation and Analytics USPs Validation Analytics Siemens is the only provider of simulated stress tests for industrial networks Simple depiction of network diagnostic information Exceeds requirements of PNO regulations regarding PROFINET telegram transmissions under stress loads Proactive context feedback provided by Siemens experts Field devices checked for availability under stress loads online Reactive (on-demand) crsp feedback provided by Siemens experts (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 Page 24

25 Our Portfolio Customer Energy Analytics Control Performance Analytics Industrial Network validation & Analytics Drive Train Analytics Siemens Page 25

26 A Managed Condition Monitoring Service based on Online Data Collection and Analytics Page 26

27 Reduce forced outage downtimes Drive Train Analytics Customer drivers and goals Reduce unplanned production losses Accelerate issue resolution Improve availability centered operation and maintenance planning Why it is worthwhile! Accurate operation history for better root cause analysis enables reduced forced outage downtime Increasing operational efficiency in maintenance planning & execution through immediate asset transparency Optimize maintenance planning by early detection of patterns that may cause anomalous behavior Siemens offering Why Siemens? Online dashboards Notifications and warnings Reports Data assessment 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 Page 27

28 Thank You!! Sandeep Barde Data Services Siemens Ltd Kalwa Works, Thane-Belapur Road,Airoli Node Navi Mumbai Phone: +91 (22) Mobile: Page 28