Scalable Process Software Solutions for Vertical Data Integration for the Smart Factory

COPA-DATA will present scalable software solutions with zenon for vertical data integration for the Smart Factory at the Microsoft booth at the Hannover Messe, between April 25 and 29, 2016

COPA-DATA will demonstrate how existing and new sensory systems can be integrated seamlessly into an overall solution, right up to the cloud. Existing production equipment is thereby also made available in the cloud for industrial IoT scenarios and for cross-site analyses according to local data protection rules.

Customised products and flexible sales markets with concurrent complex production processes characterise modern industrial production. The solutions of the independent software developer for industrial automation allow bi-directional networking from the field level, to HMI/SCADA, right up to the cloud.

The integration of zenon into the Microsoft Azure cloud platform enables access to all data from the individual production sites of a company in just one system, in real time. This allows companies to compare individual production lines with one another and substantiate qualitative analyses with quantitative data. This enables even existing equipment to generate a cost-effective value-added chain and a smart infrastructure, which thanks to zenon remains reliable, robust and scalable without restrictions. Based on zenon’s high level of connectivity, manufacturers implement applications to raise optimisation potential and advance business model innovation. Applications range from company-wide dashboards and benchmarking to energy data management, right up to predictive analytics for machine and production data.

Cross-site benchmarking with zenon

The integration of production data collected by zenon from one or more production sites with a cloud-based zenon application allows production managers to draw company-wide conclusions. Various sites and their equipment can be put in global comparison. This benchmarking has made previously untouched improvement potential in plant availability, efficiency and resource consumption possible. Additionally, the increased transparency of actual consumption offers improved quality management.

Optimisation of increasingly flexible production processes requires also varied data evaluations within the software. The sensor and production data gathered by zenon can be used for conclusive analyses from zenon in the Microsoft Azure cloud platform. zenon thereby uses technology components, such as the Azure Remote App, the Azure event hub, IoT hub, as well as the IoT suite or even Windows 10 IoT and the Microsoft SQL server 2016.

zenon can be integrated into existing, heterogeneous production environments and, thanks to its over 300 communication protocols, can be incorporated in an industrial IoT scenario,. “Industrial IoT, the main driver of Industry 4.0 and Smart Factories, now offers the possibility of developing substantial competitive advantages, and thereby leads the way to innovation. By using the Microsoft cloud platform, Azure, and its tailored IoT services, COPA-DATA has zenon in its portfolio as the innovative solution for manufacturers in the industrial automation area”, says Jürgen Mayrbäurl, Business Evangelist Azure & Business Manager at Microsoft Austria.

The zenon cloud solution integrates different systems, acts as a cockpit for key figures and allows analyses based on real-time and historical data. Evaluations of data from individual production sites are still possible. Additional Big Data tools supplement scenarios and can be used for further analyses.

New cloud framework for sensitive production data

Microsoft has set a new course for companies that have not yet considered the topic of cloud when it comes to their production data. In cooperation with a national data trustee of the Microsoft Cloud, all customer data can be made available in national data processing centres and thereby within the respective prevailing local legal system. Only customers and their data trustee can have access to their data.

Microsoft can now only retrieve customer data with consent and under supervision of the data trustee or the customer. The local cloud offering covers the high level of national demand for information security, compliance, server location and provider credibility. Companies that previously avoided the step to the cloud, due to data security or compliance issues, are now given new opportunities. Solutions with zenon in connection to cloud computing are thereby shifting – also legally – into the phase of feasibility for many mid-sized and large companies.

Energy Data Management with zenon

The zenon Energy Data Management System (EDMS) fulfils all necessary requirements for comprehensive energy management. With the solution companies can measure, record, collect, analyse and process all operational energy and consumption data. zenon also supports displaying different types of data – from key performance indicators, energy analyses, trend curves, alarm message lists and events, to complex graphical reports. Furthermore, the software offers industrially proven archiving technologies for storage and open interfaces for redistributing the information. zenon EDMS also conforms to the defined requirements of the TÜV SÜD Certified Energy Data Management standard. The software thereby fulfils important criteria for the international energy standard ISO 50001 and enables the end user to gain a certification. When zenon is used as an EDMS in combination with Microsoft Azure it also allows company-wide energy data management across numerous sites.

Predictive Analytics with zenon

Additionally, COPA-DATA can help companies find out more on the topic of Predictive Analytics at this year”s Hannover Messe. With the help of Predictive Analytics companies can foresee complex production synergies and use these findings to make well-founded decisions. In manufacturing environments, Predictive Analytics can be used in areas such as maintenance or production and consumption analyses. For maintenance issues, the goal is to minimise the number of machine downtimes and to reach maximum equipment availability. In correlation with Partner technologies, COPA-DATA”s solutions collect required data from production environments. These can then be interpreted using algorithms from the machine learning area. Patterns can thereby be identified and the learned knowledge returned to production management.