Computing: A Foundation for Faster Industry 4.0 Machine Design, Development, and Delivery
Engineering teams are turning to Edge Computing platforms to build resilient smart machines that meet a wide range of current and future end user requirements.
Edge Computing: A Foundation for Faster Industry 4.0
Machine Design, Development, and Delivery
Business as usual was upended for all industries due to the pandemic. For OEMs, Machine Builders, and Solution Builders, it has accelerated the requirement to design equipment with a new set of capabilities. They must not only match the ongoing backdrop of digital transformation, but also address the new operational needs of a pandemic world. These recent challenges have pressured OEMs to reimagine machine design. Leading engineering teams are able to outpace their competition in the current environment, while preparing for the future, by incorporating innovative solutions that accelerate the design cycle, ensure resilient operation, and offer future-proof capability backed by cybersecurity. This approach further provides the foundation for advanced capabilities like analytics, artificial intelligence (AI), machine learning (ML), and Machine-as-a-Service (MaaS) options that further improve performance and generate revenue.
The digitalization of machines is enabling Industry 4.0 across sectors such as Oil & Gas, Food & Beverage, and Life Sciences, while reducing TCO. Edge Computing is providing the foundation to enable engineering teams to build these resilient, smart machines and get to market faster.
The Challenges Facing OEMs and Machine Builders
From Machine Builders to skid manufacturers and Solution Builders, OEMs face acute pressures to design, develop, and deliver machines that are reliable and profitable; unplanned equipment downtime is unacceptable for customers.
OEMs also contend with increasingly complex compute requirements on the factory floor, where machines are running control software (HMI SCADA) as well as connected applications like historians, MES, APM, and condition-based monitoring. Traditional machine architectures can fall short in managing all of this, limiting engineers to simple designs and fixed functionalities.
The key characteristics of this architecture include:
1. Stand-alone devices for visualization and control.
2. Separate Engineering Workstation for engineering, programming and configuration.
3. Additional hardware for special functions.
4. Simple design and fixed functionality.
OEMs using older automation architectures are facing challenges on the journey to the connected enterprise
With the introduction of artificial intelligence and autonomy, machines need to support an increasingly greater variety and number of sensors that allow for interrogation, fault detection, failure prediction, and more performance analysis.
Edge Computing is an essential Industry 4.0 technology to enable Machine Builders to deliver these key characteristics of smart machines such as fault detection, failure prediction, performance analysis, greater autonomy, artificial intelligence and develop the most competitive offerings. Doing so is a differentiator for engineering teams facing pandemic-related challenges.
EWS PLC
3rd Party Apps
The Traditional Machine Builder Architecture Panel Displays Control Network
ARC Advisory Group
Automation Expenditures for Production Machinery Report
Edge Computing: A Foundation for Faster Industry 4.0
Machine Design, Development, and Delivery
What Is Edge Computing?
Edge Computing provides the answer to today’s machine-building challenges. An Edge Computing platform should offer scalable, modular technology that supports the development of standardized, compartmentalized software components and applications. The right edge solution should also allow OEMs to consolidate existing control and automation applications within a single, fault-tolerant platform.
Edge Computing broadly refers to any computing done outside the data center at the edge of corporate networks. Importantly, this data acquisition and processing occurs in close proximity to where the data is generated from critical equipment and processes.
Modern Edge Computing architectures, of which smart machines are a key part of the network, enable edge-to-enterprise connectivity and data management. The availability of Edge Computing platforms with smart machines further includes the ability to add functionality down the road, re-task equipment with software, and extend the equipment lifecycle. Edge Computing presents OEMs with multiple cost-savings and fast payback in addition to avoiding having to rip and replace legacy equipment to implement upgrades. With the ability to consolidate tasks done on multiple platforms into an Edge Computing-powered machine, OEMs can save hardware costs and speed commissioning time.
The digitalization of factories and production environments requires data from the edge where machines are the foundation of operations. OEM equipment holds a wealth of critical operational data, and the availability of Edge Computing is essential for the difficult challenges of organizing, analyzing, and protecting that data.
To effectively capture and process data from machines and skids to gain insight from edge locations, Machine Builders require Edge Computing platforms that are purpose-built for the rigors of the operational edge. They must provide simple, protected, and autonomous operation while allowing OEMs to consolidate existing control and automation applications.
Key architecture features:
1. Edge Platform configured as a pair for redundancy.
2. Inherent Virtual Machines: thin client, engineering and configuration, custom applications.
3. Flexible functionality accommodates extra features.
4. Edge to Enterprise: Big Data, Historians, Enterprise to Enterprise and Cloud, Digital Twin, AI, Analytics.
5. Extends control and monitoring into newer devices.
Edge Computing-enabled machine solutions also eliminate concerns with data loss, networking, and information or access not being available when required. Edge Computing helps eliminate bandwidth and latency issues at the device and gateway edge and reliably transmits information from the field to the enterprise and the cloud. For OEMs responsible for supporting mission-critical industries where downtime is expensive and unacceptable, Edge Computing offers not only peace of mind, but also competitive advantages.
Smart Machines using Edge Computing Platforms
Edge Computing: A Foundation for Faster Industry 4.0
Machine Design, Development, and Delivery
The Benefits of Edge Computing for Machine Builders
Reliability: It is expensive to maintain solutions that require frequent maintenance, not to mention exhausting. No supplier wants to get a phone call in the middle of the night from an angry customer asking to come over to the plant and troubleshoot their equipment. Machine Builders want solutions that they can embed into their machines, knowing everything will run smoothly.
That’s where Edge Computing comes in. Modern Edge Computing platforms operate in extreme conditions, while offering downtime prevention and numerous other benefits for both OEMs and their clients.
Repeatability and Scalability: It is important for Machine Builders to remove complexity and frequently replicate their designs as they scale their sales and business. Part of a good solution includes ease of duplicating software, solutions, and applications. Edge Computing does not require an OT professional to become a software programmer — any Machine Builder technician can leverage these modern computers with ease to create repeatable solutions for multiple clients.
With Edge Computing solutions that offer built-in virtualization, users can simply drop pre-tested, characterized, and validated software applications into a virtual machine (VM).
Edge Computing allows Machine Builders to scale their solutions based on the requirements of their customers, so they can grow their business without reinventing the wheel. Implementing analytics and Industry 4.0 is transformational and is not daunting when using the right technology.
Machine Builders can start with Edge Computing deployments that simplify implementation starting small and increasing features and capabilities over time to fuel advanced applications with VMs and this can be done without requiring a complete tech refresh in order to expand.
To improve their competitive edge in the crowded OEM space, engineers must mass produce machines in a way that is easy to repeat. They should be able to create, test, characterize, validate, and deploy applications many times over.
Machine Builders can develop their software applications with solutions from familiar partners like AVEVA, Schneider Electric, or Rockwell Automation. Once the applications are tested, characterized, and validated, they can easily be added to an Edge Computing server’s virtual machine, repeating this standardized process for any and all customers.
Edge Computing provides engineers the flexibility to build machines that meet a variety of requirements in a manner that is reliable, repeatable, scalable, flexible, secure, and most importantly—profitable.
Flexibility of Zero-touch Remote Operation and Management:
Edge Computing facilitates a design strategy that readily enables mix and match applications on one system based on the requirements of end customers. Machine Builders can create solutions from basic HMI SCADA, to historian, MES, AI/ML, APM, and other advanced applications. They can then offer these to customers as options ready for Industry 4.0.
To implement one or an infinite number of applications, OEMs can host the software in multiple Edge Computing virtual machines.
Machine Builders need solutions that are designed to allow for the addition of new capabilities or functionality for example, empowering customers by giving them the ability to use mobile devices for monitoring and control, in addition to the normal panel and control room computer displays.
Remote monitoring alerts have recently become increasingly important. Operators don’t have to be in front of their machines to be able to see what’s happening—they’re able to remotely perform actions to address alarms and events.
Remote desktop services managers are easily deployed as a virtual machine, which in turn enables customers to monitor and control their machines from remote locations using mobile devices such as smart phones, tablets, and laptops.
Security: Machine Builders need to address the cybersecurity concerns of their customers by creating solutions that contain security features inherent to equipment and hardware and that are compatible with requisite third-party security solutions. Edge platforms provide these features, and help secure machines from cyber-threats in several critical ways:
Host-based firewall blacklist and whitelist IP addresses or domain names
Restricted USB ports help prevent spread of malware
Role-based access controls authorize specific users and groups
Secure communications protocols and trusted boot helps prevent cyber-attacks
Ability to run cybersecurity software from third parties
As cybersecurity regulatory requirements become more stringent in Power, Water & Wastewater, and Oil & Gas, Machine Builders will need to keep these considerations top of mind during the product design process through to deployment and support.
Profitability: Organizations that modernize their compute infrastructure can reap competitive advantages. On a high level, the capabilities discussed in this whitepaper translate into increased profitability in several ways:
Time-savings in design, engineering, testing, deployment, and maintenance
Less personnel needed to implement projects
OT-friendly products that meet IT requirements but don’t require IT professionals or programmers to leverage their capability
Ability to consolidate applications into a single edge device
New or enhanced revenue streams from support and services
Some edge solutions help Machine Builders reap these benefits as well as augment support offerings that OEMs can in turn provide to their customers.
Three Critical Edge Computing Capabilities for OEMs to Pursue
While the potential capabilities that Edge Computing unlocks are endless, a few specific applications are leading the way for OEMs on their digital transformation journeys today. These include advanced analytics and predictive maintenance driven by artificial intelligence and machine learning, remote monitoring applications, and emerging revenue models around service and support.
Advanced Analytics: To stay competitive, it’s essential to connect and leverage operational data from the edge. With emerging technologies like AI and ML, OEMs are improving operational efficiency and resilience with real-time data insights and advanced analytics.
Increased Automation and Remote Monitoring: Organizations seeking to scale edge automation increasingly turn to OEMs and Solution Builders to provide monitoring and support for sustained value. Modern Edge Computing platforms allow OEMs to easily deliver this support for fielded customer units by enabling 24/7 system support, proactive health monitoring, and service.
Such remote support combined with on-premises service adds value for end users while creating new recurring revenue opportunity for Machine Builders in deploying and supporting Edge Computing-powered solutions.
Edge Computing: A Foundation for Faster Industry 4.0
Machine Design, Development, and Delivery
Machine-as-a-Service: Many OEMs look to Machine-as-a-Service models to generate predictable, subscription-based revenue including service and/or consumables. This model is increasingly appealing to end users, as preference continues to grow to rely on OEMs for equipment expertise and technical service. Edge Computing with zero-touch operation and industry-leading availability aligns well with OEMs’ ability to deliver this as-a-service business model.
Choosing an Edge Computing Solution Provider
The digital transformation of machine building will accelerate globally, but will become particularly critical for OEMs serving Oil & Gas, Food & Beverage, and Life Sciences. To build solutions that meet the needs of today while remaining flexible for the future, OEMs should select a partner who is in it for the long run.
With robust services and support that accommodate Machine Builders’ growing needs, while allowing them to focus on what they’re good at.
Edge Computing Platforms Must Be Simple, Protected, and Autonomous
While Edge Computing presents transformative potential for Machine Builders, it is imperative to get the implementation right, and include ground-level considerations around installation and support from the get-go. Engineers building smart machines and skids at the edge should consider the following tenets of Edge Computing solutions: They must be simple, protected, and autonomous.
Simple: Edge Computing solutions provide simplicity for OT and IT staff alike, unburdening Machine Builders from demands that detract from their core skillsets. With an Edge Computing server, mechanical engineers are not charged with becoming IT software coders. Edge-based solutions are easy to set up, easy to maintain, and easy to support.
Protected: Designing a modern Machine Builder architecture is a low-risk proposition with a high probability of success. Owner-operators can enter and exit a pilot program with Stratus to explore the needs and potential of their plant’s specific compute environment.
Autonomous: Edge Computing solutions must operate autonomously in industrial environments, without the need for dedicated IT staff on site. OEMs should expect global services and support teams are always on demand 24/7 to troubleshoot any issues before they occur.
Summary
The pace of digitalization in the OEM market is accelerating rapidly as new challenges force out old ways of doing business and spur engineers to reimagine machine building from the design stage. As Industry 4.0 unfolds, engineering teams are being asked to provide capabilities like analytics, artificial intelligence (AI), and machine learning (ML), and equipment that can meet Machine-as-a-Service (MaaS) requirements. In order to outpace their competition in the current environment, while preparing for the future, best-in-class OEMs are adopting Edge Computing platforms to simplify, protect, and automate their digital transformation journeys.
More information
For more equipment and machine manufacturer information, visit: https://www.stratus.com/oem/
For more information on the Stratus ztC Edge product line visit: https://www.stratus.com/solutions/platforms/ztc-edge/
Explore Stratus Edge Computing use cases and environment visit: https://www.stratus.com/ecx/
