Showing posts with label smart devices. Show all posts
Showing posts with label smart devices. Show all posts

Sunday, September 14, 2014

The Steps on the Operational Journey from Siloed to Optimized to achieve Operational Excellence

We have all seen the debate on how do we go from todays manufacturing to an effective operational landscape, across the full valued supply chain. The increased urgency of this debate has become  recent discussions, I have with different companies; people are trying understand how they going stay competitive delivering the correct products, to the correct markets, locations, in the correct time, at the correct price and margin. All this with increasing costs in labor, energy, transport and regulation compliance.  
The common thread across the discussions was:
·         Real time transparency across all sites, and “cogs” in the supply chain.
·         Shift from “traditional reporting” to “actionable decisions”
·         Shift from operators to “Operational Teams” that align operations, planning and expertise
·         Shift from Siloed process on a plant or across plants to optimized and aligned.
·         Shift from experience in people to experience in the system
·         Alignment and consistency across the operational decisions and action for a product no matter location. 
Providing the foundation for optimizing and continuous improvement, not just of assets but process, assets, product production, and workforce.

Sunday, September 7, 2014

Industrial Internet of Things: What does it mean to me?

I must have sat through 3 to four presentations of IoT in the last 2 weeks from different vendors, different industries. Combine this active strategic discussions within our development teams, you see many angles and thought approaches.

ARC’s definition:
“The industrial internet of things is a collection of technologies that can come together in a targeted  solution to improve business performance and machine availability”.

The key is the transition to information driven system has begun and it is about alignment of devices, process and people, to be effective in real-time agile production. Extending across the plant, and the whole value supply chain, providing transparency in end to end operations.


All are valid, but the question was asked on a site visit last week " what does it mean to us?". So I stood up and went to white board and drew three circles and intersected them, to represent the opportunity.

Sunday, August 10, 2014

Can you have Smart Cities without Smart Citizens?

For the last couple of weeks I have been engaged in smart cities investigation, interviews and understanding the landscape. While I keep abreast of this developing and over crowded market, we have a focused team in this area that requested my input on investigations and defined strategies.
Enjoyment in these exercises is the interviewing and learning. It was clear that many of the initiatives we seen in the industrial sector apply to here but differently in smart cities. So in a visit to Singapore I had the opportunity spend time with a number of “city authorities” involved in their smart city vision.
The head of the Urban Planning   made some very interesting comments, around what a Smart City is! Too often we read about the efficiencies of smart devices, and management of energy across a city, the transparency across a city to systems.
But he raised the point that a “smart city requires smart citizens, and smart service workers”, this took my interest as the concept aligned with my thoughts on empowerment. On digging deeper he broke up his thoughts into:
  • Workers: Workers being the people who work in different jobs in the city, but use the services of the city to get to and from work, and to execute their job each day.

  • Service Workers: These are the people who provide the services to keep the city running, from bus drivers, to city clerks, to maintenance electricians, to firemen, and the other 1000s of job roles in the city.
  • Citizens These are the above and everyone else enjoying and living in the city, no matter if they in the park, at a concert, at a football game, shopping, or out to dinner, or just living at home. All the time they using services of the city.
In my discussions with the planning authority, and then with one of the universities, and others it became clear that they faced a similar problem we have in Industry, but on different scale and angle with the empowerment of people, and processes. In order to change the culture for them to use the services of the city in a more efficient way, and allow people more enjoyment time.  Remembering that the average age in most cities is going up, and we do not have transition of population, but yet we require an “operational change in culture” in the way they use their city services.
When discussing this concept I was reminded of a concept of the modern wealthy: “today’s wealthy been wealthy in enjoyment time, not necessary money.”   A reflection on our current times where we are always connected, always working, and not disconnecting and really enjoying. The modern wealthy have learnt how to execute work effectively while maximizing their time to enjoy.
This came up in a conversation in Singapore around “smart work” when asked the answer related to “worker” category of person above. To the way they need to change the way they work from being able to work anywhere, not a new concept called “activity based” work. He went on to talk about a worker not wasting time in travel, or in a train, but to use that time effectively, giving increased output, and giving back time to enjoyment.
The real area that caught my interest and debates were around the “changing of the culture” in all the citizens in the city to use services efficiently and turnoff lights, use less water, change habits. Like we have changed over the last 20 years to wear seat belts naturally in the car, how can we evolve the way people operate their house, their work environment, and their enjoyment environment.
I reflected on how my family’s culture had changed when we lived our yacht for ten years, both in California and travelling, as the boat is a small micro grid for power generation storage and usage, and we make our water from seawater or capture water. But we set the boat up with LED lights, and taps that force turn off, installed efficient shower heads, and on goes the list. My sons turnoff lights; they watch the power; it becomes a core part of daily KPIs, similar to weather.
When discussing this required cultural change the real concept of “smart Citizens” came into play. It was not just about the app on my phone to understand how to order taxi’s or understand the transport system. Tt was also about the applications that embed best living practices on how to operate the house, etc. So that through the natural use of these applications in the house, on the phone, etc. the user inherently executes the best-operational practice and increases efficiency. As that operational practice in tuned and improved, the embedded procedure is updated and effecting 1000s, to millions of people, without them realizing, but with significant impact to cities use of services and therefore improved efficiency.
This discussion does not take away from much of the focus today in smart cities around empowering the “service worker” and the associated services provided to citizens to attract them to live in the city. How a smart city will make these “service workers” situationally aware of conditions in the city not as they happen, but in the future detecting conditions from historical patterns bringing awareness of situations before they occur.
A “smart City” is about the city systems, services status, and capability being intelligent, and empowering right decisions faster to bring service satisfaction higher in the city. But all of this must happen while significantly reducing the impact on the environment, with goals of 50% reduction in energy usage and carbon footprint from cities by 2030, if not more, not counting waste and water usage. A lot more than just the systems must change, or the efficiency of the services and people are operating them. The way in which we as citizens go about daily life must change, so we enjoy more, but execute in the most efficient and natural way to increase the efficiency of the city.

It is certainly an interesting opportunity, but draws on many parallels whit the “operational Transformation” in the industrial space, and merging of concepts can only help accelerate the transformation in both landscapes.  

Monday, July 14, 2014

Asset Management / Optimization Stands to Take Significant Leaps of Value with the Internet of Things

Last week I talked about the “smart plant”, one of the key areas that is changing and opportunity for a step level of output value is in the “Asset Reliability” / “Operational Continuity”.




The real opportunity in is increasing capacity of through :

  • Increased flexibility in the existing assets to run more products, and we understand asset condition through pattern recognition
  •  Improved preventive, and “awareness” of asset condition and capability of performing at optimum. The devices / assets are “self aware” and self learning on improvement and conditions so early detection of conditions are seen and corrected in a timely manner.
  •  Improved planning and asset utilization through transparency across assets on a site and across sites,
There is a lot of talk around the internet of things (IoT) in the general world but in the industrial world there is huge opportunity just due to the significant number of devices.
Industry pundits predict that by 2020 over 50 billion everyday objects will be connected to the Internet. This does not even include the Industrial IoT and the entire M2M environment, much of which is already in place in our factories, plants, and infrastructure.The initial trend will be to establish one-way communication, ultimately migrating to "many-to-many" communications as more physical objects be-come connected. Connecting all the assets and devices in communities of active tuning, decisions and optimization, requiring a significant rethink and change to current operational management/ supervisory systems and information systems to take advantage, but it aligns with the workforce operational transformation.So if we look at the clear steps that can happen in Asset Efficiency:


1/ Increased information, data in a one way capture of asset information.
This step is the first one and is well under way where increased intelligent devices are monitoring / calculating their performance and the information is logged to an historian. As stated in past blogs we seeing the I/O count between control systems and historians increasing by over a factor of 10. (example a pump use to be 5 to 10 variables, now is 120 to 200, a well head was planned to 50 points now logging 690 points).
Once you have this data companies like Pattern Discovery Technologies (http://www.patterndiscovery.com/) produce solutions that used defined events to investigate through Big Data Techniques asset condition patterns, from this vast historical data, so that better prediction is possible of conditions earlier.
2/ Is by direction, and communities of devices “learning” together and tuning their performance.
So instead of a device/ asset just learning on it’s own, imagine a community or similar type devices learning and sharing their learnings between them. This is not a linear learning of optimization but an exponential learning. So the conditions for a type can be immediately picked up and used by a new device / asset of the same type. Machine learning and community “hub” learning is a powerful predictive capability coming into the market.
Companies like MTELL (http://www.mtell.com/) have introduced some powerful “Machine Learning” capabilities, that combine with their “Transfer Learning” capability. Key is this does not have to wait to new devices/ assets on the plant it can be applied to existing assets, and the “learning” will begin.


The concept of going to “Smart Machines/ assets” that are:
  • Self-Aware”
  •  Self and Tribal Learning, so improving in predictive understanding of behavior

  Notification and increased analysis capability through powerful tools for asset analysis from the dramatic increase in data available.Now that devices can be connected through wireless to internet, and therefore a “cloud historian that is managed” and these analysis tools can executed centrally, or devices discover each other and learn together provides the breakthrough in the Asset world from predictive to prescriptive.



Sunday, June 8, 2014

"Smart, intelligent, brilliant devices" what is key is "self aware" devices

As I listen to “Youtubes," lectures on the Internet of Things, and in industry forums, I hear the terms of " smart, intelligent, and now brilliant" devices, as we move to smart cities, smart farms, smart airports, and smart industrial sites. I asked myself what is the core value and difference?

There is a significant leap and a significant switch from monitoring devices from a high application or humans, to " self aware" devices that monitor their own health and capability. Next you ask the difference between "smart" to " brilliant" devices and interestingly there is even amongst the marketing hype! The level of capabilities associated to the device that takes them from simple "self awareness" of asset health, to predictive and "machine learning" capability to move from the " as is" alarm to "to be " state."

However, it is all increased levels of embedded "self awareness" capability as close to the device or in the device to monitor, and understand it is effective condition to the "golden" operating condition, with the intent to sustain "operational continuity." The key is device level " awareness" and the connection of these devices to the Internet apart of a  holistic system( site, enterprise), raising exception conditions automatically, and acted on in a consistent, and “best practice procedure." With many of the same types of devices can now be aware of each other, learn from each other and grow in "self awareness" capability. Increasing the ability to shift to the "to be " state where exception conditions seen early,  corrective action can be taken fast and early to maintain " operational continuity."

As we go forward the " future" will also be incorporated into the device, eg high fidelity simulation models will be available for common devices, and will learn relative to the particular device setup and situation. Enabling not just the current condition but the future condition window to be seen, and " what if" to be played out but inexperienced operational staff to make well informed and correct decisions. This simulation model will either run locally or be called upon by the device to a remote simulation environment with discrete device models.

All of this device awareness is what I see as a paradigm shift the "Internet of things" brings and the opportunity to the industrial operational space for the next jump in productivity.

I have heard many times, and agree with the Internet of things, "self aware"devices that leverage their "brothers and sister devices" and other intelligence not applications, brings the next step change in output growth and GDP output. Called the "third industrial revolution" where and industrial revolution is when a significant step change in GDP productivity output is achieved, the first two been:

1/ the first industrial revolution with the steam engine, and then self pro population capability for production and transport.

2/ the Internet in 1992 to 2000, and beyond where human communication, collaboration and the " flat world was introduced" switching us from regional to global effectiveness.

3/ the Internet of things" self aware devices, and collaboration between devices, applications and people to address the fast moving world we live in and the requirement of “Now” decisions and satisfaction.

Too often all of this is associated with larger companies and utilities, but last week I visited a small food plant in rural Australia, to discuss their next step in operational change, and competitiveness. Two thought leaders where present, and it was great to have a very active and productive discussion around not problems, but opportunities. Leading to a powerful discussion on discovery investigations around these opportunities, and the key opportunities were again:

1/ People cost, therefore effectiveness

2/People efficiency in a dynamic and changing workforce

3/Brand integrity, and quality

4/Variable costs in materials but now energy

The discussion took us to the operational work space of the future the need for not data, but effective information that enables exception based operational management, supervisory control of the plant, and process.  Shift from process management to product production management, spanning all the processes and production units required to produce a product. A shift to activities that are required in order make the product and enable operational continuity.

The concept of "self aware plant” made up " self aware devices” and " self aware process" with embedded operational procedures was a reality, and not just for big companies, but even more critical for small to medium companies/sites that have fewer resources.


Maybe the new world is not that far away!