Integrations That Matter for The Success of Your IIOT Solution
- By /
Mr. Pradip Pawar, Senior Manager - Product Engineering
14 Feb 2019
Imagine if you knew the state of the equipment on your shop floor to the minute and could take action based on that knowledge – the value you could create for your customers is unimaginable. Industrial IoT or IIoT that successfully integrates the various elements inside the manufacturing value chain has the capability to create incredible opportunities for new revenue streams and customer relationships. Yet, for many organizations, embracing new business models created by connected systems is often challenging due to problems with data management and system integration, lack of which is often a cause for IIoT project failure.
Let’s take a look at 5 such systems, integration with which can reap substantial benefits from your IIoT investment:
1. Integration with ERP
Linking IIoT with your existing ERP system is the gateway to digital transformation; yet, according to a recent IFS survey, only 16% of manufacturers consume IIoT data in their ERP systems. Enabling seamless access to IIoT data by ERP systems like SAP will unlock the true value of the data generated by connected things. Significant improvements in business and financial performance can be achieved: you can capture master data details like asset information, user information, downtime reasons as well as project rejection reasons. Unlike traditional ERP systems that are incapable of identifying operational anomalies and uncovering the root cause of issues, real-time IIoT data can help identify anomalies and drive decisions that can have an immediate impact on business processes. What’s more, your ERP system can also export master data in CSV format to your IIoT solution – either on demand, at a given time interval or on a specific event like project is rejected – and process real-time data of machine health parameters like temperature, speed etc. and processed data like OEE, machine utilization, production count, product rejection etc., for improved efficiency.
2. Integration with Enterprise Asset Management
EAM systems have evolved from basic asset tracking to managing millions of components and devices throughout the enterprise. By integrating your IIoT solution with EAM like Maximo, you can attain operational insights from massive amounts of data and drive enhanced synergy between devices, components, and people. Such visibility eliminates inconsistencies and errors that result from manual tracking and drives higher reliability, operational effectiveness, asset planning and scheduling for all your supply chain operations. Your IIoT solution can optimize EAM by bringing disparate systems, sensors, and information together, and driving top-class after-sales support and service. You can seamlessly import master data details around asset ID and asset name from your IIoT solution to your EAM, as well send downtime details such as equipment number, downtime duration, downtime reason and more. Your EAM can then generate a ticket that is sent to the maintenance team for resolving the issue on priority.
3. Integration with Production Scheduling
Most often than not, production decisions are made with partial information; although at the micro-level, the decision may seem optimal, at the macro-level, they could create costly disruptions. For instance, manufacturing equipment often needs preventative maintenance, but production schedules typically do not include machine downtime because of the absence of operational insights. If maintenance is delayed, the equipment may fail, and bring the entire manufacturing process to a halt. By integrating your IIoT solution to production scheduling, you can have immediate visibility to sales, product design, supply chain, maintenance personnel availability as well as customer issues. You can seamlessly enable transfer of master data such as product name, product cycle time, overall cycle time etc. between the two systems, create production schedules accordingly, and drive higher production efficiency.
4. Integration with Regulatory Board Monitoring
In today’s highly regulated manufacturing environment, production plants have to regularly send pollutants/emission data like NO, SO2, PH, water quality, ambient air quality etc. to regulatory boards. For this, API is provided by the regulatory board monitoring system. However, with no access to real-time IIoT data, there is no way your monitoring system can identify emission sources and calculate emission data. With no knowledge of the ‘when’ and ‘where’ of emissions, you cannot determine ‘how’ to control it. Integrating your IIoT solution with your regulatory board monitoring system can help in accurately measuring emission levels and facilitate compliance with the required regulatory standards. By feeding data from related equipment like weather stations, flow meters, level sensors, etc. into your monitoring system, you can achieve real-time insight and visibility across your supply chain.
5. Integration with Distributed Control System
In addition to sending important pollutant/emission data to regulatory boards, production plants also need to send data of environmental parameters to the plant DCS. IIoT provides for a new generation of control systems that have unparalleled capability and extensibility; as each connected device has sufficient memory, it can hold all of your control strategy programs and execute backup strategies in case of device failure. By integrating IIoT with DCS, you can build an efficient redundancy and backup model, where controlling tasks are divided among multiple distributed systems. In case of failure of a single part, you can still ensure uninterrupted production Such an approach to manufacturing can drive higher flexibility, system availability, and reliability.
Drive your business forward
In a world that thrives on connectivity, industries need to acquire a strategic approach to integrating connected device data with their existing environments to drive higher efficiency. Hence, now, more than ever, manufacturers are in quest of integration to harness the power of IIoT and realize operational and competitive benefits for their business. IIoT can bring together people and systems on the plant floor with those at the enterprise level, and enable manufacturers to get the most value from their systems. However, to ensure successful deployment of IIoT across the manufacturing landscape, it is important that your IIoT solution integrates with various enterprise systems that play a big role in driving your business forward.