Especially in the manufacturing sector, companies have had to face extremely dynamic changes in recent years. In addition, topics such as Industry 4.0, automation and mobility have become an integral part of IT roadmaps and are already an integral part of corporate strategy. Various areas of work in the industrial environment, which for a long time were completely analogue and did not require software-supported processes, are now firmly reliant on digitalization. However, in order to ensure holistic digitalization, all IT systems, machines and control systems must be seamlessly networked with one another. This requires a universal Industry 4.0 platform (IoT platform) as a communication data hub. The corresponding strategic approach can best be described using the automation pyramid, which represents the conceptual structure of a manufacturing company in its hierarchical structures(Figure 1).

Figure 2: Flexible Industry 4.0 approach - resolving point-to-point connections.

© Membrain

As a counter-concept, the Industry 4.0 approach aims to eliminate point-to-point connections and link all levels of the entire automation pyramid independently and flexibly. This is achieved with the help of a universal Industry 4.0 platform that provides relevant data where it is needed. In architectural terms, this means that the individual components of the automation pyramid are broken down into their individual parts. The structure is thus softened and a new one is created(Figure 2).

At the center of this new structure is a universal platform (Industry 4.0 platform) that directly links the individual systems and hierarchical levels. This approach has clear advantages. First of all, the system can be expanded easily and as required. For example, mobile applications can be easily and quickly integrated into this Industry 4.0 structure. SQL databases, time series databases, etc. can also be integrated as required. Algorithms, machine learning and artificial intelligence, for example, can also be easily applied on the basis of this data. Communication between the individual components in this eco-system and the central Industry 4.0 platform is bidirectional. This means that it is possible to both read and write data. For example, decisions can be made with the help of AI modules and made directly available to the relevant systems such as MES or PLC.

This architecture offers companies maximum flexibility and complete scalability. For example, new systems can be introduced and replaced or different protocols or sensors can be added. The aim of this structure is to achieve optimum data availability: data producers and data consumers need to be connected directly with each other and without delay. Relevant data should be made available directly to specialist departments, taking into account the factors of what data they need, when they need the data and in what form they need the data.

Process automation thanks to Industry 4.0

The following describes the architectural structure of a Membrain customer scenario and shows how easy it is to avoid point-to-point connections thanks to the Industry 4.0 approach (Membrain IoT). The core of the Industry 4.0 platform is the flexible connection of different components, such as mobility, controllers (OPC UA), dashboards and the leading ERP system (SAP). The diagram shows the architectural structure and communication via OPC UA and, for example, a Wago PLC with the Membrain IoT Industry 4.0 platform(Fig. 3). Other connected components are the leading SAP system, a time series database (TIMSCALE), the mobile applications and the maintenance dashboard for visualizing machine status, messages and relevant KPIs

Figure 3: Architectural structure of an Industry 4.0 architecture with IoT platform.

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A recorded data point is read out via OPC UA and communicated directly to the IoT platform. This information is immediately available to all modules in the eco-system. A corresponding visualization is immediately displayed in the dashboard. Other supplementary actions such as task and resource planning can be triggered immediately or published automatically in the database (configurable recording of machine data, quantities, machine status, etc.). Automatic notifications directly in SAP are also possible and can be pushed to mobile devices and processed in real time. The user has the option of reacting directly to "events" in real time. Possible SAP PP and SP PM scenarios include the automated recording and processing of fault messages based on trigger points, push messages or reading out a production status.

Membrain's solution supplements the SAP system with a mobile component. This allows various departments (production, logistics, maintenance, etc.) to work with SAP in a very intuitive and mobile way, reduced to the essentials. Documentation or data entries or transactions are carried out automatically in the background. Further add-ons expand the solution and bring more productivity to the store floor.

Mobile working for more productivity

Especially in the industrial environment, native applications have prevailed over browser solutions in recent years due to their many advantages. The performance of powerful applications plays a key role here. In addition, native apps guarantee uninterrupted, transaction-safe working thanks to offline mode. If the connection to the leading system (SAP) fails or is unavailable, the recorded data is buffered (temporarily stored in the app). As soon as an online connection to the system is re-established, the data is automatically synchronized in the background. Furthermore, native apps meet a clear security standard, as communication is encrypted and paths into the leading system are secured thanks to certified interfaces.

The modularity of the platform enables connection to subsystems and expandability. This facilitates the integration of third-party systems such as quality assurance, PDA and MES. These are areas that are not traditionally among SAP's strengths. A particular focus here is on usability. This significantly increases productivity and user acceptance. When it comes to operating an Industry 4.0 platform, cyber security plays an important role, as it does in all IT projects. This is because many projects fail as early as the PoC (proof of concept) due to unpredictable project costs and insufficiently secure interfaces to subsystems.

Critical systems live in view

Christian Jeske is Marketing Director at Membrain in Unterhaching.

© Membrain

Thanks to the Industry 4.0 platform and apps, processes can also be automated and factories digitized in the production area. Dedicated apps inform plant managers about critical machine statuses via push notifications on their smartphones in real time. Dashboards, for example, graphically display the live status of individual machines and thus monitor production. The app automatically reports as soon as a predefined event occurs, for example if limit values are exceeded or undercut. This can be a message or an email notification to the production manager or lead to an autonomous machine stop. The distributed messages contain further information and reasons for the fault. These must be defined and specified in advance for each machine or machine group in the leading system. Real-time data from the store floor thus provides significantly more transparency and makes machine data, for example production times, downtimes, process data such as temperature and pressure or energy data, for example electricity and water consumption, available systemically. Mobile working not only speeds up processes, but also ensures automatic and seamless documentation of workflows.