news for process automation news for process automation 1/2017 a flash of inspiration the new plug-in surge protection system protects plants from lightning strike damages. hmi to go mobile devices for explosion hazardous areas extend the pepperl+fuchs product portfolio. people make the diference three experts discuss the working world of tomorrow.

contents technologies+ products applications+ knowledge markets+ trends 04 focus: a flash of inspiration the new plug-in surge protection system protects plants from lightning strike damages. 09 hmi to go mobile devices for explosion-hazardous areas extend the pepperl+fuchs product portfolio. 12 melting pot in the indian ocean the production site in chennai complements the pepperl+fuchs group. 20 people make the diference three experts discuss the working world of tomorrow. 16 looking at the bigger picture together together with strong partners, pepperl+fuchs has developed an overall solution for the process industry. 24 lateral thinking required what makes an innovation team? 27 material flow with vision how products from mannheim, singapore, and houston make their way all over the world. s t n e t n o c 12091620042427

focus technologies+products | news for process automation 1/2017 5 “it is the sum of the additional functions that makes the new surge protection module so special.” friedrich füß, product portfolio manager interface technology it’s hard to believe but true—roy c. sullivan, a former ranger at an american national park, was struck by lightning an incredible eight times during his life- time and walked away each time with only minor injuries. this earned him an entry in guinness world records. statistics on the international occurrence of thunderstorms are equally incredible: experts estimate that, at any given point in time, there are 2,000 to 3,000 thunderstorms worldwide accompanied by up to 30 million lashes of lightning each day. most lightning strikes occur in regions in south america, along the equator in africa, and in asia. “so it’s no surprise that the irst impulses to work on the subject of lightning and surge protection came from asia,” says friedrich füß, product portfolio manager for interface technology at pepperl+fuchs in mannheim. “initial spark” after lightning strikes one of his irst research trips led him to asia, to the institute for surge protection in shanghai. “the institute is a leading authority in china,” explains füß. “there, damage caused by surges from large lighting strikes is well known because people have personal experience with strong storms and have to deal with the consequences.” he also got a taste of this himself: his appointment at the institute was canceled because the director he was supposed to meet with was called to investigate a lightning strike on a soccer ield that had fatal conse- quences. despite this, or indeed because of it, füß was undeterred in his pursuit of the topic, and he dedicated himself to assembling a team that came to be true experts in surge protection. “the features that we have developed in minimal space for the new m-lb-5000 (modular lightning barrier) surge protection system were only possible thanks to the wealth of ideas from a highly motivated group. the ive-man core team, along with about 25 colleagues from production, purchasing, engineering, and service, has achieved great things,” sums up füß. left to right: friedrich füß, thomas lebkücher and thomas ofenloch

focus technologies+products | news for process automation 1/2017 7 creativity was also required, so key issues were worked out in a series of brain- storming sessions, particularly with regard to integrating the required functions into a module that is just 6.2 mm wide. “based on 20 years of experience, we have built up extensive expertise in surge protection complemented by long- standing expertise in explosion protection, analog technology, and interface modules,” says lebkücher. what’s more, all the stops were pulled out: “even during the design phase, we made video recordings with high-speed cameras to analyze the behavior of high-current contacts during a surge,” reports project manager ofenloch. “with 50,000 images per second, it was possible to precisely identify every little detail, so we could build on this to optimize the number and arrangement of contacts.” close collaboration with colleagues at the production site in singapore also played a key role in the successful development. “this was immensely important for the production-optimized development of the surge protection system,” emphasizes ofenloch. and lebkücher enthusiastically adds: “this module is one of the most sophisticated and innovative products that i have ever helped develop.” “this module is one of the most sophisticated and innovative products that i have ever helped develop.” thomas lebkücher, head of the mechanical design product group, process automation take a look behind the scenes at this exciting product development.

hmi to go mobile devices for explosion-hazardous areas extend the pepperl+fuchs product portfolio. hmi to go with mobile devices from ecom instruments gmbh and stationary hmi solutions, pepperl+fuchs is now making end-to-end process visualization and control possible virtually anywhere in hazardous environments—opening up more process applications to industry 4.0. 9

technologies+products | news for process automation 1/2017 11 digital system solutions for all scenarios the key to new, more lexible applications lies in the synergy between stationary remote monitors from pepperl+fuchs and mobile devices from ecom instru- ments. “it is an enormous beneit to customers that we can leverage our broad portfolio of technologies and interfaces to meet a wide range of industry demands, for instance when it comes to monitoring and control. stationary terminals from pepperl+fuchs bring thin-client technology and sophisticated remote monitoring mechanisms into process plants. we complement this with mobile devices which make all the beneits of technologies such as 4g, bluetooth, or gps available in hazardous areas,” explains uhl. “our product lines ofer the user the same ‘look and feel’ in hardware and operation, allowing seamless integration into the digital network of the overall system. the function- ality of the terminals, smartphones, and tablets can be used fully. and customers receive a complete solution from a single vendor—with absolutely no risks in terms of compatibility or availability.” “mobile worker” puts hmi system concepts in motion ecom instruments developed the “mobile worker” concept for its digital mobile computing and communications solutions that are now joining the pepperl+fuchs portfolio. “it bundles explosion-protected smartphones and tablets, peripheral hardware such as headsets and docking stations, as well as intelligent soft- ware, applications, and service packages into comprehensive solutions for a variety of situations where lexibility is required,” says uhl. typical applications include data collection for incoming goods, mobile control and monitoring, and the identiication and veriication of raw materials and formulas in storage and production. providing work instructions to employees in the ield or decentralized access to production data and process procedures are also part of the mobile worker concept. this all points to the digital future of process automation—people, processes, and systems will tap into networks to discover new dimensions of industrial value, in hazardous areas and beyond. “with industry 4.0 in mind, we can now map and establish comprehensive and eicient condition monitoring through stationary clients and mobile devices,” says wessels. “so the world of hmi is in motion, in every way.” www.ecom-ex.com explosion-proof smartphones and tablets roll of the assembly line in assamstadt, germany.

applications+knowledge | news for process automation 1/2017 13 “with the new production site in chennai, we are also implementing our stringent quality standards in the production of enclosures.” hermann best, vice president of global sales processes www.explosionprotection.com exotic curry, the impressive taj mahal, colorful bollywood: anyone who has not yet visited india only has a vague idea of the second largest country in asia. and yet, india has long been one of the most important business locations in the world. with a growth rate of 7.6%, the country was among the fastest expanding economies in the world in the 2015/2016 iscal year. although the majority of the population is still employed in the agricultural sector, a number of large industrial centers have developed in the land of colors and spices within the last few decades—such as chennai, formerly madras. situated on the indian ocean, the city is dominated by the automotive sector, yet other important sectors such as the chemical and petrochemical industry have estab- lished themselves there, too. “chennai is very industrial. a large number of metal processing plants and foundries that supply large local businesses have been set up in the city,” is how hermann best, vice president of global sales processes at pepperl+fuchs, describes the local environment. in 2016, after the acquisition of former petroleum safety products industries (psp) in chennai, pepperl+fuchs thoroughly integrated one of these plants into its own group, and is now also implementing its stringent quality standards in the production of enclosures.

applications+knowledge | news for process automation 1/2017 15 all work and processes are subject to the high internal standards that apply to all facilities within the group. “this means that our customers can rely on the quality and safety they are accustomed to in our electrical explosion protection solutions,” sums up best. more for the customer with its new facility, pepperl+fuchs is transferring not only its quality standards but also its in-depth explosion protection knowledge relating to the production and processing of ex d empty enclosures. “the acquisition allows us to increase our vertical integration and develop additional capacity for the electrical explosion protection equipment business segment. this means that, in the future, we will be able to handle the needs and requirements of our customers with greater speed and with a more systematic approach.” a manufacturing facility with its own foundry was the missing piece of the puzzle for pepperl+fuchs in terms of production: “now the entire value chain for complete solutions in electrical explosion protection is in our hands. we provide customers everything from a single source, from the foundry to the inished solution,” says best. discover lameproof enclosures that will be manufactured in chennai.

applications+knowledge | news for process automation 1/2017 17 temperatures, fill levels, flow rates—this is typical information that ield devices in process plants generate every second. these devices also produce endless additional data about their environment and condition, but such data has previously gone virtually unused. that’s because, until now, most commonly used interface technology has not allowed such information to be transferred to the control room. how helpful would it be if all of this data were available centrally, and if it were used to automatically monitor ield devices and plan condition-based predictive maintenance? in collaboration with four other companies, pepperl+fuchs is making this scenario a reality. together with sap, hilscher, endress+hauser, and samson, the company is paving the way for the internet of things (iot) in the process industry. the aim is to improve the availability of plants with pre- dictive maintenance and condition monitoring. greater plant availability with the internet of things “in the process industry in particular, plant monitoring is associated with demanding requirements since this industry is already complex to begin with,” explains benedikt rauscher, head of global iot projects at pepperl+fuchs. “take for example explo- sion-hazardous areas or non-interruptible production processes. unplanned outages can be fatal.” the five companies are working together to counteract this with their joint development eforts: the interaction between the components and systems means that defects and impending failures can be detected before they arise, and the need for preventive action can be automatically signaled. the basis of the solution is comprehensive networking both within the plant and beyond. sap, endress+hauser, samson, hilscher, and pepperl+fuchs: the ive partner companies talk about the joint develop- ment project in a video. left to right: benedikt rauscher, head of global iot projects, pepperl+fuchs guido könig, senior technology manager business innovation, samson michael bückel, product manager platforms, endress+hauser armin pühringer, business development manager, hilscher timothy kaufmann, business development manager internet of things, sap

applications+knowledge | news for process automation 1/2017 19 more data and more paths mean added value to make this possible, pepperl+fuchs equips ield devices with the bullet wirelesshart adapter, enabling wireless com- munication parallel to the 4 ... 20 ma current loop. the beneit for the process industry is that the bullet in a robust ex d enclosure is also suitable for explosion-hazardous areas. so it enables continuous communication through to the hazardous area. the adapter transfers the recorded data wirelessly to a wirelesshart gateway which in turn communicates directly with the sap cloud via an mqtt protocol. the valuable additional data is therefore also transferred reliably to ain and is available there centrally. alternatively, the data can be transferred to the cloud using a wired connection via the netiot edge gateway from hilscher. ain processes all the information clearly and signals a possible need for action to the user. based on this, further applications can be added that process the data for other pur- poses, as required. limitless networking in addition to continuous communication from the ield level through to the cloud, the developed solution ofers the particu- lar beneit of networking beyond the physical boundaries of the company. this is because not only the plant operator but also manufacturers and service providers can access certain areas of ain. this enables new service models that could be used to better plan maintenance and inspection schedules or optimize delivery dates. at the same time, manufacturers can supply all the relevant information for the operator about the individual components within the network. minimum work, maximum beneit the joint solution its seamlessly into the processes, with mini- mal installation work required. existing plants can easily be ret- roitted with the bullet wirelesshart adapter without having to completely shut down the system. the particular beneit for customers in the process industry is clear: “the use of innovative industrial iot technologies such as this enables predictive maintenance and condition monitoring so that impending failures can be identiied in time and appropriate preventive action can be taken,” sums up rauscher. “this not only improves plant availability but also ultimately saves costs.” the comprehensive solution from sap, endress+hauser, samson, hilscher, and pepperl+fuchs thus makes data continuously available and helps improve eiciency in process plants. find out more about the bullet wirelesshart adapter. www.pepperl-fuchs.com/news-bullet

markets+trends | news for process automation 1/2017 21 everyone is talking about the “digital revolution.” what does this mean for the workplace and what is hidden behind the big keyword “digitization”? christian schwöbel: first of all, it must be said that we already live in a digitized world. think of video conferencing: that we are able to see colleagues in production facilities on the other side of the world on a screen, is only possible thanks to digital technology. in the same way, processes such as vacation requests take place electronically in companies today—this is also digitization. such digitized worklows are also found in production. for example, there is increasingly the possibility to make status and process results available and able to be evaluated in digital form. for us in-house, this is actually already commonplace. so it is not the case that yesterday everything was analog and today it is digital. we only notice it more, simply because more and more is being digitized, and digital technologies are penetrating more and more areas. till hofmeyer-zlotnik: in sales, this is shown by the simple example of how we communicate with custom- ers today. in the past, a written request arrived by mail that was electronically recorded and edited by an employee, and then a written quotation was sent. today, the request itself is digitized, and you do not need to be in direct contact with people but rather with soft- ware. continuing along this line, the person in such processes perhaps has at some point taken more of a supervisory function. think of orders for large online retailers: from receipt to shipping, today, all information and interactions run through software and systems— the process is not controlled by people. in future sce- narios in the industry, one machine will place the order of your spare part directly with another machine. benedikt rauscher: exactly, an important change in the industry is coming our way—provided that we are creating the technological basis for it. today, we have a kind of “internet of people”. this means that a person provides information on the internet. in the “internet of things”, it is no longer the person that provides the information, but the machine itself—and for another machine. naturally, this has an efect on the way we work. how does the vision of industry 4.0 it into this? benedikt rauscher: industry 4.0 uses the internet of things to make processes and worklows more efficient. machines should be able to communicate with each other in a plant and even beyond the walls of a company. processes such as ordering a spare part don’t then need to “detour” via a third point, which saves a lot of time. such a message could be “i am almost inished with component a and am sending it to you for further processing.” this will speed up the processes because employees do not need to irst record and enter a status and initiate or control further steps, but instead much more is automated. does this mean that, at some point, we will no longer need people in production? christian schwöbel: the scenario of the human-free factory is raised again and again but has still not occurred, and i don’t believe that it will. of course, the topic of digitization in production is also about auto- mation. steps and processes should be linked together so that machines work independently or communicate with each other, because people will most likely play a diferent role in the future. but this does not mean that people will no longer be needed. on the contrary: tasks are, in my opinion, much rather complex. the cognitive abilities of people will be essential in the future, because you must also be able to deal with the systems. “machines should be able to communicate with each other in a plant and even beyond the walls of a company.” benedikt rauscher head of global iot projects

markets+trends | news for process automation 1/2017 23 “as individual as the customers’ wishes in the context of the digital transformation are, the sales approaches must be equally individual and unique.” till hofmeyer-zlotnik new business development sales engineer ... and for the individual workers? benedikt rauscher: undoubtedly, more lexibility will be required of us in the future with regard to what the tasks are and the way we work. we need to be open to new things. “lifelong learning” is a good keyword here, because it will probably not be the case that you can perform the same task for your whole career. job tasks are also changing alongside technological advances. christian schwöbel: but one thing is certain: people are and remain important, and are in fact more important than ever. because after all, it is people that address, implement, and then maintain developments such as those needed for industry 4.0 scenarios. it should also be borne in mind that a complex develop- ment lies behind all of the simplicity that so much technology ofers. right now, we can only speculate about the jobs of tomorrow. till hoffmeyer-zlotnik: digitization can also create more lexibility for the individual, when, for example, it is no longer necessary to be on-site, because the work can be accomplished from anywhere via the internet. however, the existing rules in the company must be reconsidered for this, starting with the workspace and concluding with the time model. so digitization not only afects production and sales, but the whole company. benedikt rauscher: digitization is actually also a change process. it is not just about developing digital technologies. learning to deal with more and more digital technology and using it to our advantage is ulti- mately the big change facing us all.

markets+trends | news for process automation 1/2017 25 “creativity isn’t something that you can switch on and then of again after an hour,” says michael bozek when asked if his activities still leave time for creativity. together with the team leader benedikt rauscher, he is working on approaches for future industry 4.0 scenarios. his work rarely focuses on a single product; to the contrary, much more holistic solutions are in demand today. with this in mind, pepperl+fuchs has created an overarching “industrial internet solutions” team that operates outside of the business units and draws on expertise from each of the product areas. but how do they develop innovative approaches? the ideas for new applications come from a wide variety of situations. when, for instance, rauscher and bozek exchange views with industry experts and market competitors through activities in organizations such as the vdi or the zvei, it always inspires new ideas. “when we meet with like-minded people who are working on the same future scenarios as us, we get an ever-increasing picture of where the journey can go and what solutions will be needed,” says bozek. “sometimes, you have an idea in mind, but sometimes a concrete concept only comes after a discussion with colleagues.” that is why cooperating closely with the product groups at pepperl+fuchs is just as important. product development itself is not one of the tasks of the innovation teams; instead, they look at technologies across the board and consider how they can be used innovatively in new applications. benedikt rauscher head of global iot projects michael bozek product and business development manager for industry 4.0

material flow with vision how products from mannheim, singapore, and houston make their way all over the world. material flow with vision the stacker cranes are constantly in motion. they lit back and forth non-stop between the racks, where the constant stream of boxes briely comes to a stop. the tireless machines in the global distribution center (gdc), which opened in 2016 in singapore, are more than just technical assistants.

markets+trends | news for process automation 1/2017 29 ideal conditions in singapore the amount of time saved just by automatic storage is explained by the director of the gdc in singapore, han thanh hong: “previously, when a 40-foot container was delivered, we needed two days to inventory the goods and transport it to the racks. today, we can do it in three hours.” the structure and technology of the mannheim logistics center was not applied one-to-one in the gdc. “we used the experiences from germany and developed the system further. the updated version was then transferred back to mannheim after the introduction in singapore, so that we are now at the same, improved level.” join us on a video tour through the european distribution center! the starting position in singapore was similar to mannheim. the old logistics center was bursting at the seams, and accelerating the processes was becoming more and more urgent. 80 percent of pepperl+fuchs products come from locations in the city-state as well as vietnam and indonesia. so it was obvious that the new global distribution center should be built in the southeast asian region. “singapore, with its modern infrastructure and traic connections, business-friendly regulations, and good conditions for import and export transactions, ofered the best environment,” said han thanh hong. reining what has been tried and tested structure, technology, and the “operating system” in houston are in line with the other two centers. the new udc there will irst serve the north and also later the south american market. “we can also use it as a regional showroom for our logistics products,” says külken. “we can demonstrate the performance of our sensors in operation to interested customers there.” what will beneit customers most, however, will be quicker, more reliable delivery, which will be made possible by the optimized, high-quality logistics pro- cesses. incidentally, these are subject to a continuous improvement process, known within the company as loop (lean operation and organization in processes). “this process may reveal that an additional tool at a specific workspace can save a lot of time,” explains külken. the storage facilities have also been able to take the next steps toward digital transformation. “thanks to the high level of automation, ‘digital logistics’ is tangible and can be integrated into ongoing processes. with con- stant access to all data and different possibilities for ine-tuning, the processes in our distribution centers also conform to the principles of vertical and horizontal networking. the dynamic maintenance management is already making real-time data available to intelligent systems—be it the information from motors and brakes on the stacker cranes or the photoelectric sensors on shuttle cars. these forecast models allow machine learning and thus pave the way for predictive mainte- nance, which will signiicantly reduce sudden failures,” says külken.

imprint impint publisher pepperl+fuchs gmbh lilienthalstrasse 200 68307 mannheim · germany phone: +49 621 776-2222 e-mail: pa-info@pepperl-fuchs.com year of publication: 2017 © pepperl+fuchs gmbh editorship global marketing newsletter@pepperl-fuchs.com editorial support zsolt pekker, dirk heyden design: www.ultrabold.com pictures: shutterstock news for process automation is published twice a year. all rights are reserved. the reprinting or electronic distribution of articles or excerpts of articles is prohibited without the express permission of the publisher. links to third-party websites if you choose to visit external websites via links printed in the newsletter to other non-pepperl+fuchs group websites, the company is not responsible for the privacy policies and terms of use of those sites. the company has no control over such websites and resources; it does not endorse and is not responsible for the availability of external sites. www.pepperl-fuchs.com