Strength in numbers: How the Industrial Internet of Things applies to fabricators

How is continuous improvement achieved after the best manufacturing processes and practices are implemented? It comes by harnessing the strength of numbers, enabling machine-to-machine (M2M) communication, and automating activities previously performed manually. Welcome to the Industrial Internet of Things (IIoT), or Industry 4.0.

From a historical perspective, the four phases of industry are:

Industry 1.0: Water/steam power
Industry 2.0: Electric power
Industry 3.0: Computer power
Industry 4.0: IIoT power

Conceived by the German government in an effort to promote the computerization of manufacturing, the term Industry 4.0 was first used at the Hanover Fair in 2011. Numerous consulting groups offer white papers with further details, including Accenture, Boston Consulting Group and Deloitte.

Note that the IIoT terminology seems to be more popular in the U.S., whereas Europeans often use Industry 4.0. No matter what you call it, the adoption of IIoT practices by leading companies will explode in the next decade, driving the next round of productivity and quality improvements. While larger fabricators and manufacturers are leading the way, smaller companies that supply parts and subassemblies will likely need to implement IIoT practices to retain their customers.

Online Data Management Software

At the heart of IIoT in the fabricating industry are welding power sources and cutting systems that incorporate built-in data-gathering capabilities and web servers that enable remote access from a wide range of external devices, including robotic controllers. These power sources then integrate with online data management platforms via Wi-Fi, mobile cellular, or hard-wired Ethernet communication.

The more advanced systems, many of which were introduced at FABTECH® 2015, now offer "cloud" capabilities. With these systems, fabricators can automate many of the activities that surround the welding and cutting processes. With an IIoT platform, they can:

• Enable bidirectional communication to pull in welding procedures and schedules, verify operator qualifications, and confirm machine setup.
• Develop schedules on a single machine, move them into the cloud, and then push them out to other systems, whether that's one machine, a group of machines, or groups of machines in multiple locations.
• Remotely manage parameters, set limits, and set alarms for deviations.
• Facilitate traceability, from single welds to the complete product, because the core of a data-gathering system provides a comprehensive database containing key information of every seam. Automated documentation of every step in the process chain (for example, filler metals, consumables, operator qualifications, and welding parameters) is becoming essential for structural steel construction, ship, offshore, pressure vessel, military, automotive, crane, and fabrication in many other industries.
• Monitor job status and facilitate real-time response to production situations, such as alerts when consumable levels run low, generation of a predictive maintenance schedule, or pushing out a restocking text to suppliers.
• Share and analyze data by teams across multiple data collection sites, using any computer, tablet, or smartphone connected to the same internal network as the welding systems and database.
• Connect remotely to experts for process optimization, updates, and troubleshooting.
• Access web-based reporting that provides up-to-the-second status information that highlights production and quality concerns to increase overall quality and production performance.
• Integrate with enterprise resource planning systems like Oracle®, SAP®, IBM, and SharePoint, plus analytics and reporting tools such as ClickView, Qlik®, SAS®, and Tableau®.

Even if an IIoT platform offered only the functions noted above, a fabricator could make a quantum leap in productivity, quality, and machine efficiency. For example, think of all the hours spent manually inputting information into production processes and recording results. Transferring data automatically not only saves hours, it also generates better reports because automated reports are not subject to human error or intentionally tampering with data to "improve" results.

Selecting a System

For the fabricators who feel that they lack advanced computer skills, there's no need for concern. IIoT platforms provide applications and dashboards with functionality tailored for the job needs of different personnel, such as operations managers, quality managers, engineers, welders, maintenance staff, and training supervisors. Customized displays eliminate extraneous data, so employees make smarter and faster decisions.

In addition to verifying ease of use, fabricators examining an IIoT platform for the first time should look for systems that take just a few hours to install. Ideally, the company should be able to install a software package on a laptop or server, configure the network using a communications module, and automatically link the welding system to the cloud platform.

Rather than start with a fleetwide deployment, many companies want to start with just a single system to familiarize themselves with the IIoT platform and the power of its data. As a side note, starting small can eliminate the need for a large capital request or the CIO's involvement at the exploratory stage. After confirming the software's value, the company then can deploy the platform enterprisewide.

System Security

In an era in which data theft is rampant, security often tops the list of concerns. With some IIoT systems, data can be stored securely in one comprehensive database located within the user's firewalls, or it can be stored remotely. When examining systems, manufacturers should look for those that ensure optimal security from all angles: data storage, access, user control, and remote diagnostics.

Systems also should be "future-proof," meaning that they use open-source messaging instead of proprietary software. Open-source protocols enable connectivity between machines and systems from many manufacturers.

Fabricators should look for systems that use a communication protocol with a proven ability to run in a fabrication environment. With the addition of 3G cellular and GPS on top of Wi-Fi, wired LAN, and Bluetooth®, even the hardware is future-proof.

Actionable Insight

IIoT platforms enable data-driven decision-making so that fabricators can move the true levers of productivity and quality, as well as make better use of working capital. Easy to install, use, and maintain, the IIoT applications let companies access information on any web-enabled device, as well as automatically receive software update notifications and download updates.

Because web-based reporting speeds information flow, manufacturers obtain a clearer picture of plant operation. They can eliminate equipment downtime, unscheduled maintenance, and process bottlenecks, as well as improve overall equipment effectiveness, speed time-to-market, and streamline schedules. Significant ROI typically can be expected in six to 12 months.