Industrial Internet of Things (I-IoT)

Lecture 03

Instructor: Dr. Farshid Najafi

School of Mechatronic Systems Engineering

Simon Fraser University

1
Outline

 Automation pyramid as the traditional model for enterprise modeling

 I-IoT model as the future model for manufacturing enterprises

 I-IoT example (case-study) in manufacturing

2
What is I-IoT?

Manufacturing enterprises want to:

 Increase efficiency of their operation

 Improve quality of products/services

 Be more competitive

3
What is I-IoT?

ERP
Level

MES
Level

Supervisory Level

Control Level
Manufacturing
Field Level Enterprise

Automation Pyramid
4
What is I-IoT?
Human Machine Interface
(HMI)

ERP
Level
Programmable Logic Controller (PLC)

MES
Level
Fieldbus
Communication
Supervisory Level
CNCs
Robots Actuators
Control Level

Sensors
Field Level
5
What is I-IoT?

ERP
Level

MES
Level
Enterprise Resource Planning
Supervisory Level
Project management, marketing, and accounting
Manufacturing Execution System
Control Level
Production planning from raw material to finished goods

Field Level
6
What is I-IoT?
I-IoT Model
MES ERP

ERP
Level

Consuming
MES Digital data
Level Transformation
Cloud
Supervisory Level
Publishing
data
Control Level

Field Level
PLC 1 PLC 2 PLC 1000
7
What is I-IoT?
I-IoT Concept
MES ERP
Getting all data or information
that any consumer needs in
their hand when they need it,
and where they need it. Consuming
data
Cloud

Publishing
data

PLC 1 PLC 2 PLC 1000

8
I-IoT example
Car Manufacturing Co.

Cloud

Factory 1 Factory 2
Press working Machining
9
I-IoT example ERP & MES Speed
PLC + Machine Controller HMI
Factory 1

Cloud

Fieldbus Communication
Press machine

Camera
vision system

Conveyor

10
 ERP & MES
I-IoT example PLC + Machine Controller
Factory 2
Cloud

Fieldbus Communication
CNC Mill
Camera
Vision system

Conveyor

11
I-IoT example

Cloud Subscribe for final

Publish final machining machining details
details for each barcode
PLC + Machine Controller Vision System
PLC + Machine Controller Vision System

Camera
Camera

Product

Conveyor
Conveyor
12
Benefits of I-IoT in Manufacturing

 Ensuring product quality

 Reducing equipment down-time

 Better Inventory control

 Just-in-time manufacturing

13
Digital Enterprise
Vertical integration – IT/OT convergence: data from
shop floor to top floor in a Digital Enterprise

• All field devices and control units operating on the

shop floor produce data.

• Industry 4.0 is dependent on the smart use of data

and communication.

• A vertical integration adds precisely these data

analytic capabilities, from the Information Technology
on the top floor to the Operational Technology on the
shop floor – for data-driven decision-making.
Digital Enterprise
IT/OT convergence

• Combining the real world of automation with the digital

world of information technology – as seamlessly and
completely as possible.

• Breaking up information silos by combining IT and OT helps

companies significantly boost their performance,
productivity, flexibility, and sustainability.
Case Study (Production of Running Shoes)
Digitalization Success Story
A model for other traditionally
Digitalization helps to bring sports shoe
manual industries
production back to France

• For many years now, sports shoes have been

synonymous with production in the Far East – and
subsequently a large carbon footprint due to long
transport routes. That’s changing.

• Textile manufacturer Chamatex Group is bringing sports shoe

manufacturing to France with its ASF 4.0 (Advanced Shoe
Factory 4.0).

• An example to demonstrate the possibility of automating and

digitalizing an industry that is traditionally very manual.
Digitalization Success Story
A model for other traditionally
manual industries
Full automation for ASF 4.0

• The machines have been equipped with Simatic S7-1500

controllers so that they can communicate among one
another via the OPC UA open protocol. The SCADA system is
based on Simatic WinCC OA (Simatic WinCC Open
Architecture), which gives users access to production
screens on browser-based clients.

• Scalance – the communication solution for all the

technology in the factory – is at the heart of the OT
(operational technology), Where maintenance and
diagnostics operations can also be carried out remotely.
Digitalization Success Story
A model for other traditionally
manual industries
Transparency along the entire production chain

• Numerous sensors (including Simatic RFID chips) have

been installed throughout the production line, and the
information is fed into the automation to inform
operators about remaining steps in shoe production.

• Furthermore, they receive alerts in the case of malfunctions.

The generated data also provides information on the batches
– such as percentage of shoes correctly made – and the
achievement of key performance indicators.
Digitalization Success Story
A model for other traditionally
manual industries
Digital Enterprise
Horizontal integration – seamless data flow along the entire
value chain in a Digital Enterprise

The integrated Digital Enterprise approach enables the

horizontal integration and digitalization of the entire value
chain – from design, to production, service and recycling.
Seamless horizontal integration bridges the gaps between
information silos and connects everything from product
innovation to production through product in use.
Digital Enterprise
Integrating the lifecycle of product and production
Combining the real and the digital worlds makes it possible to
seamlessly integrate the entire value chain from design to
realization, while optimizing with a continuous flow of data.

A true Digital Enterprise is able to harness the unlimited power

of data by gaining valuable insights to make fast and confident
decisions – and to create best-in-class products through efficient
production.

Source: https://www.siemens.com/global/en/products/automation/topic-areas/digital-enterprise.html
Digital Enterprise

Make confident decisions with the Digital Twin

The comprehensive Digital Twin approach drives continuous
optimization throughout the product and production lifecycle,
enabling fast product introduction, flexible manufacturing, and
data-driven performance optimization.

By examining "what if" scenarios and predicting future

performance with the Digital Twin, you can be sure that your
product and production will work exactly as you designed and
planned.

Cybersecurity approach covers all levels simultaneously – from

the operational to the field level and from access control to copy Source: https://www.siemens.com/global/en/products/automation/topic-areas/digital-enterprise.html
protection. It is essential for comprehensively protecting
industrial facilities against internal and external cyberattacks.
 I-IoT Architecture of SIF-400
DB
HARDWARE CONTROL

SIF400-Station x SIF400-Transfer

Remote IO
Remote IO
ETH/IP //
ProfiNET
X2X // ProfiNET

Master
IOLink

Slave
PLC - Controller
COM ETH

RS-232
SMC

IOLink
EX260, ZSE20, ITV

Ethernet/IP // ProfiNET
BCR-NFC 3rd

Modbus/TCP // Ethernet
Printer Sensor
PRODUCTION MANAGER RFID
SMC
JXC_1

ROBOT

FQ VISION

SUPERVISORY STATION HMI Printer

I-IoT Architecture of SIF-400
I-IoT Architecture of SIF-400
I-IoT Architecture of SIF-400
SIFMES-400 Web
This web application makes it possible to perform,
from a graphic interface, many of the functions that
a Manufacturing Execution System (MES) provides.
These features include:

• Order management
• customer management
• manufacturing and expedition order management
• order launching
• warehouse management
• station monitoring
• physical and logical layout management
• order tracking
• component maintenance
• performance analytics
• statistical process control
• user management and role management
I-IoT Architecture of SIF-400
SIFMES-400 API
It is included with the web application. It offers
web services that facilitate data exchange and
can be used to create new applications or
connect SIFMES-400 software to existing
applications.
I-IoT Architecture of SIF-400
SIFMES-400 MovService
 This application manages the flow of movements
in the stations when operating in integrated mode
with the SIF-400 system. The OPC UA
communication protocol is used for the
communication. It also provides the SIFMES-400
software with real-time data on the status of the
stations.
I-IoT Architecture of SIF-400

SIFMES Delivery application

This application for smartphones with the Android
operating system makes it possible to finish the
production chain, making the delivery to the
customer and closing the order. It also offers the
possibility of storing products manually, using the
NFC reader that these phones usually have.