Industrial automation falls within a broad technological framework and benefits significantly from industrial networks and mobile computing technologies. This combination of technologies will help transform the "connected factory," "Industry 4.0," and the Industrial Internet of Things (IIoT) from concept to reality. However, implementing these concepts one by one can be confusing and leave organizations feeling overwhelmed. This article introduces these concepts, outlines key factors organizations should consider when developing an effective implementation strategy, and explores the operational advantages of connecting, monitoring, and controlling operations.
Over the past two decades, science and technology have advanced rapidly. Among these advancements, industrial networking and mobile computing have continued to impact manufacturing. These technologies have helped manufacturers and organizations worldwide turn visions such as the “connected factory,” “Industry 4.0,” and the Industrial Internet of Things (IIoT) into reality. But what are the differences between these concepts? This white paper will first define these concepts and then explain the key elements organizations need to consider when designing an effective implementation strategy, while illustrating the benefits of achieving connected, monitored, and controlled operations.
Concept Definition
What is a connected factory?
The connected factory is a concept for a manufacturing environment in which every machine can communicate with all other machines and equipment within the factory and in other remote locations. The connected factory aims to connect, monitor, and control any equipment in virtually any location, improving operational productivity and profitability.
What is Industry 4.0?
According to Wikipedia, Industry 4.0 is "a collective term for technologies and concepts used by value chain organizations." The term first appeared in the German government's high-tech strategic plan for the Fourth Industrial Revolution, which is based on the dynamic optimization of production resources within and between highly interconnected factories.
What is the Industrial Internet of Things (IIoT)?
Similar to the connected factory and Industry 4.0, IIoT means that organizations can connect multiple different devices, including legacy equipment, and enable them to "talk" to each other. By collecting, analyzing, and utilizing data from both new and legacy devices, organizations can improve efficiency and gain a competitive advantage.
Design an effective implementation strategy
Many organizations today are eager to implement the concepts of connected factories, Industry 4.0, and IIoT to achieve numerous benefits, such as reduced operating costs and improved visibility and control. However, for most organizations, building entirely new facilities or "tearing everything down and starting over" is neither practical nor cost-effective. Therefore, many solutions leverage existing equipment and cleverly deploy components to achieve expanded monitoring and control without disrupting daily operations. It is crucial to set expectations early when upgrading facilities. While every device in the network has an IP address, this does not mean you can log into every panel meter, pump, and inverter using a mobile device. Several core fundamental principles ensure a smooth transition and provide the ability to access, monitor, and control information from all locations for facilities to enter the 21st century.
The first step in designing an effective implementation strategy is to gain a deep understanding of the organization's operating environment and the devices, applications, and processes that constitute it. Before taking action, organizations should consider the following five key factors:
1. Existing equipment
Connecting existing equipment to the network. What is the lifespan of these devices? Do they need upgrading? Can the older equipment communicate with the newer equipment? How much time and cost will this take? What cost-effective solutions can properly handle the existing infrastructure?
2. Protocol/Communication
What communication protocols are being used by the network devices in the equipment? How many are being used? Is it necessary to change the communication protocol so that the equipment can communicate with other devices in the environment? What type of transmission medium is used in your workplace? Is it fiber optic cable? Serial communication (RS-232/422/485)? Or a copper port?
3. Location/Environment
Where is your facility located? If your equipment is in a remote location, can it be monitored via a cellular network? Is your location accessible via 3G or 4G/LTE networks? If not, are broadband or fiber optic connections allowed? Furthermore, what is the overall environment like inside the building? Is it hot and dusty, or is it a controlled temperature environment? Is there frequent vibration? Does the industrial-grade equipment you are using have environmental ratings and industrial certifications?
4. Security
A recent Business Insider Intelligence survey reveals that 39% of senior executives consider privacy and security the biggest obstacles to IoT investment. Security was the most frequently cited concern. While the survey covered all IoT projects, security is equally important for the Industrial Internet of Things (IIoT). How can sensitive data be protected when it is collected and disseminated? What security measures are in place for systems that collect, monitor, process, and store IIoT data? What regulations related to data and information protection do you need to know?
5. Employees
As more technologically advanced devices are added to your network, do you have the right IT staff and other skilled personnel to help you with installation and monitoring tasks in your facility? Do you need software or remote monitoring devices to monitor the devices in other locations?
Once everything is in place, the organization should gradually achieve the following three points:
Enables communication between devices
Ensure the operational efficiency of the entire facility.
Provides a secure platform that enables devices to communicate.
Enables communication between devices
In some factories, drives, sensors, programmable logic controllers (PLCs), panel instruments, and other automation equipment may have been in use for years, even decades. A key challenge in achieving a connected factory lies in enabling these devices to communicate via proprietary communication protocols using RS232/422/485 serial cables. While these serial protocols are efficient, they have historically been designed for specific applications. Many of these applications do not include 24/7 monitoring capabilities via TCP/IP networks. To integrate these devices into the framework of connected factories, Industry 4.0, and IIoT, an organization's engineers must first ensure that these devices can communicate with other equipment within the factory. Now, companies can choose to use advanced HMIs, protocol converters, and other automation products in the field that support different protocols to connect devices from different manufacturers. These protocols offer seamless industrial transmission and multi-protocol support without regard to the physical medium during communication.
Ensure the operational efficiency of the entire facility.
There are many ways to achieve operational efficiency, one of which is using data collected from monitoring points on the production line to minimize waste and downtime. As technology continues to improve, these status points will include more information from a wider range of sources. Managed Ethernet switches will be able to report data flows throughout the facility in the same way that sensors on the production line report product status. This expanded approach to collecting operational data enables organizations to access readily available data through visualization management solutions, allowing them to collect, record, and display critical Key Performance Indicators (KPIs) and Andon information. Real-time display of this KPI data helps improve productivity and increase output. This concept extends beyond connectivity, communication, and monitoring within the organization to the supply and distribution chain, providing a comprehensive view of operations.
Provides a secure platform that enables devices to communicate.
Routers are deployed in a network to limit specific types of network traffic or traffic destined for specific users, minimizing the risk of network attacks. Another technique is to implement NAT (Network Address Translation). NAT is a technique that masks network devices for inbound access but does not affect traffic within the network. Finally, VPN devices also ensure secure communication between factories, supply chains, or distributors by creating virtual "tunnels" for transmitting sensitive data.
Overall Implementation Advantages
The efficiency of connected factories, Industry 4.0, and/or IIoT models does not derive from the absolute number of connections, but rather from the competitive advantage derived from high-value connections and harmonious dialogue between devices and people. Seamless communication with operators, control systems, and software applications, coupled with practical networking options and support for local functions and protocols, provides exceptional value for extracting data from industrial equipment. These capabilities elevate automation and remote management to new heights, making this vision a reality. Organizations employ specially designed support components to precisely integrate all facilities into a unified network, enabling connectivity, monitoring, and control capabilities to achieve the following advantages:
Extend equipment lifespan: Enhance the value of existing equipment through powerful protocol conversion capabilities.
Improve process transparency: Gain insights into equipment status and increase productivity through data logging and communication capabilities.
Extending control functionality to the network edge: System management is expanded through device-level control functions, replacing the original control room-based approach.
These advantages not only significantly reduce total cost of ownership and accelerate equipment deployment, but also provide more stable end-to-end functionality for a variety of applications.
For more information, please visit the Industrial Ethernet channel.
