News for Factory Automation 1/2016

platform consolidates both data sources. With the help of downstream

processing, process parameter deviations can already be detected

by using a simple comparison. This not only creates informative

transparency throughout the production process but, at the same

time, also identifies the points with the greatest potential for increased

effectiveness,” explains Bozek. “In this way, we can detect delays or

micro-downtimes that are not so obvious and optimize the preliminary

processes and target processes, taking into consideration the order

situation and current stock levels.”

The Path to the Networked Future Starts Today

The aggregated data is essential to improve the availability of machines

and systems. “The recorded notes and warnings from the sensors

allow you to determine the current status of not only the component

itself, but often even the machine or plant. Historical values that

correlate with the actual machine runtimes and maintenance recom-

mendations of the manufacturer provide an excellent picture of the

current status of the machine or plant. This helps detect impending

failures at an early stage and reduces downtime,” explains Bozek.

“Even today, industrial components provide information on contami-

nation or wear, but in practice they are rarely used. There is a large

amount of untapped potential: With the help of SmartBridge

, this

data can be extracted by smart sensors and transferred wirelessly

to a service platform via an Internet gateway. There this status data

is evaluated and, if necessary, a service contract can be triggered in

the company’s maintenance department or with an external service

provider,” explains Bozek. “Our demo model thus impressively illus

trates how easily and efficiently future production processes can be

optimized.”

These examples show that continuous communication from the field

level to the IT level is essential to ensure that intelligent sensors are

used to their full potential. Cost-intensive modifications of machines

and plants are not always necessary to achieve this – sometimes

an investment in a few additional components is sufficient to make

production processes economical and to optimize them in line with

the concept behind Industry 4.0. Comprehensive, barrier-free com-

munication in automation is not merely a vision anymore – we have

already taken the first few steps along the path towards it.