Aum Universal

Valued Solutions

Digital Transformation and IIoT for Titan

High Level Agenda
➢ Introduction to IoT
○ Industries
○ Applications
○ Architecture
○ Technologies
○ Comm. Protocols
➢ IT-OT convergence
➢ Cloud
○ IaaS
○ PaaS
○ SaaS
➢ Cyber Security
➢ Case Studies
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Transformation – some definitions

Digital Transformation

Use of
techniques,
methodologies
Digitalization
and technologies,
categorized as
digital in nature, Digitization
that help
companies
transform their
when applied
to a larger unit
of work like a
Digitization
manufacturing,
production, and process or
Converting manual data collection to use of digital tools. Use of a
business procedure spreadsheet, manual input to an application, automation of tasks
operations and yielding higher and activities. Applicable to lower level work hierarchy
services benefits

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Why Transform
Disrupt
the
industry

Grow
your
company

Survive
the
market

Gain
competitive
advantage

Safety and
Compliance

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Transformation – Basic view

Transformati • Business Resulting in • Customers

Leverage • Tools
on methods • Digital outcomes • Employees
appropriate • Technologies
like • Industrial for • Company

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 Transformation – Concepts, Technologies and Use
Cases

• Business
Umbrella Concepts

• Sensors •

Use Cases
Technologies
Safety & Compliance
Transformation • CM & D • Remote Monitoring
• Digital • Automation • Asset Reliability
Transformation (PLC/SCADA/HMI) • Process Optimization
• Asset Performance • Robotics • Energy & Water
Monitoring • Cloud/Edge Management
• Industry 4.0 • Data lake, Big Data • Feedback to product
• Smart Manufacturing • IoT engineering
• Smart City • Analytics (D, P, P) • Environmental
• AI/ML Control
• AR/VR • Quality
• Digital Twins • Sustainability
• Blockchain • Supply Chain
• KPIs & Reporting

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IIoT Communication - Protocols and Technologies

Protocols Technologies

MQTT 4G/5G

Bluetooth WiFi
LoRaWAN Z-Wave

TinyOS Zigbee

MQTT is amongst the most popular protocols. Always choose standards!!

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 IoT Technology Perspective

Connectivity
(Hardware)

Better Insights Data Analysis

(Software) (Computers)

The complete deployment architecture enables better decision making!!

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Application Sectors

Industrial Consumer
O&G Home Automation
Power Utilities Appliances
Transportation Home Monitoring
Heavy Machinery Phones
Logistics Wireless
Healthcare TVs
Manufacturing

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IIoT Applications
Manufacturing Efficiency Track and Trace
Minimize downtime in factories
Self-driving tractors for mining
Connected Robotics in manufacturing
Labor reduction for material handling
Decoupled operations eliminate conveyors
Intelligent routing
Intelligent Logistics
Smart automotive manufacturing: worker safety
Smart Oil Field
Construction
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IT OT Convergence

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Typical Architectural Blocks

Application and
Tools
Analytics

Data Conditioning
Hosting (On-
premise, edge, (Cleansing,
cloud) aggregation,
anomaly detection)

Connectivity with
Security

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Sample IIoT Architecture

Wired and wireless connectivity

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IoT Common use cases
Single source Common Knowledge Decision Operational
of Truth Visualization Management Making Efficiency
Data Visualization Sharing of Digitize Visibility to
aggregation platform best manual events,
across plants across practices process to status, and
and enterprise – across the collect data reports.
enterprise to anytime, enterprise to from Complete set
build a single anywhere improve additional of Persona
source of visibility productivity. sources based
truth Capture and resulting in dashboards
platform. use in-house better and KPIs
Avoids data knowledge to insights and using
silos and build custom decision analytics for
conflicts KPIs - to making increased
avoid efficiency of
problems operations
around skilled
workforce
depletion
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Manufacturing specific Use cases and benefits
Smart Production Planning and Scheduling

Optimize process and help improve production time, cost. Effective production planning and Scheduling by
Increase production efficiency and capacity leveraging data lake

Maintenance Optimization OEE

Better visualization and management of quality issues and calculating and monitoring overall equipment
work orders - by integrating with EAM/ ERP systems (E.g. effectiveness based on quality, performance and
SAP) availability

Supply Chain Management Equipment Reliability

Track and trace inventory on a global scale and estimates
of available resources to reduce costs and improve calculate MTBF and MTTR
resource utilization

Asset Health Monitoring Utilization

Condition Monitoring of critical assets and their health

instead of preventive or time based maintenance (%) Equipment Utilization

Predictive Maintenance Asset Strategy

based on anomaly detection can be a future step. This Risk based inspection and management of asset
helps manage equipment downtime and maintenance
costs.
lifecycle

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ISA 95 manufacturing - A quick glance

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ROI – Measurement Parameters

Cost Savings Enhanced Usability

Increased Enhanced Market

Efficiency/Productivity Share

New Business
Stay Ahead of
Models/Revenue
Competition
Streams

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Stakeholder Goals, Departmental concerns

• Align with overall strategy

Business • Business case
• Process impacted
Perspective • ROI

• Technology
• Security
IT • In-house expertise
• Maintainability

• Operations impact
• Process change
OT •
•
Ease of use
Training
• Job security

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Digital Projects - Challenges
Cost Uncertainties
Ambiguous ROI
Take-off
Technology Choice
hiccups
Fit for purpose
Customization
Time to completion
Internal expertise
Budget overruns
Incomplete preparedness
Lack of clear requirements
Failure Causes Cyber Security
Invalid assumptions
Third party integration
Scope creep
Planning and coordination for third party
POC to production discovery and surprises

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Key to IoT project success
Management approval, buy-in

Business Case

Involving the right people

In-house, External, Partnership, Ecosystem

Technology
Platform, Components (HW and SW)

Strong Execution
Project Management

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Cloud Technologies
Basis Of IAAS PAAS SAAS

Stands for Infrastructure as a services. Platform as a services. Software as a services.

IAAS is used by network SAAS is used by end

Uses PAAS is used by developer.
architects. user.

IAAS give access to the PAAS give access to run time

resources like virtual environment to deployment SAAS give access to the
Access
machines and virtual and development tools for end user.
storage. application.

It is service model that It is a cloud computing It is a service model in

provide visualized model that delivers tools cloud computing that
Model
computing resources over that is used for development host software make
internet. of application. available for client.

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Ref: geeksforgeeks.org
Cloud Technologies continued..
IAAS PAAS SAAS

In which you required knowledge There is no requirement about

It required technical
Technical understanding. of subject to understand basic technicalities company handle
knowledge.
setup. everything.

It popular between developer It is popular between consumer and

It is popular between
Popularity. who focus on the development of company.such as file sharing, email
developer and researchers.
apps and scripts. and networking.

Amazon web services, sun, Facebook, and google search M.S office web, Facebook and
Cloud services.
vcloud express. engine. google apps.

Enterprise services. AWS virtual private cloud. Microsoft azure. IBM cloud analysis.

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Ref: geeksforgeeks.org
IT vs OT security – A look in

● Dynamic Vs Deterministic
● Data vs Process
● Multiple gateways vs fewer
● Confidentiality vs Control
● Frequent vs infrequent patch

Confidentiality, Integrity and Availability – CIA Triad is the foundation

of security

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IIC & IEC Standards
● Waterfall Security Solutions contributes regularly to IIoT,
ISA, IIC, NIST and IEC standards
● Unidirectional Gateways feature prominently in standards
including:
○ NIST 800-82 R2,
○ IIC Security Framework,
○ ISA/IEC 62443-3-3
○ ANSSI Industrial Control System Security
IEC 2443-3-3 in particular positions
unidirectional gateways as optional
protection for even the most sensitive
industrial networks

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IEC 62443

24-07-2019 Aum Universal 25

Security in IoT – common concerns

● Data Privacy (sovereignty) (on premise, cloud, in country, global)

● Data availability (online, API, dump, anytime)
● Data confidentiality (access to third party, or solution provider, or other
tenants from the same service provider)
● Hardcoded and default passwords
● Set it and forget it – no patch/update (Legacy devices/systems)

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 Case Study: Digital Transformation and Industry 4.0
Goal: Requirement:
• Organization (discrete manufacturing) • Conduct site and plant level
wants to embark on implementing assessment from a digital maturity
Industry 4.0 practices and realize perspective
value from deploying the latest digital • Understand current operations, goals
technologies and challenges
• Interact with key stakeholders to
ferret out individual /departmental
short term and long term plans
Methodology:
Assessment, review and
recommendations

Solution: Benefits:
• Conducted a survey of two plants • Continuous visibility to health of all
• Provided a digital roadmap consisting monitored machines and processes
of deploying multiple solutions • Insights to manufacturing data in real
including machine monitoring, energy time enabling better control
management, MES, OEE, and others • Optimized O&M costs and improved
quality

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Case Study – OEM IoT based Performance Monitoring
Goal: Requirement:
• Organization wants to provide value • Measure key parameters of machines
added services to its customers by and processes in real time
implementing IIoT for continuous • Show periodic averages and calculated
measurements, and fine tuning of the values of the plant processes based on
various processes in chemicals and measurements
other industries • Provide a dashboard to plant
personnel for monitoring and control
of process performance

Technology: IIoT,
and Analytics
Solution: Benefits:
• Pressure, Temperature and Flow • Continuous visibility to health of all
Sensors and Energy Meters monitored machines and processes
• Data Acquisition system and • Insights to process data enabling
communication equipment better control of the overall plant
• Purpose-built web application operations.

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 Case Study – Manufacturing Productivity
Goal Requirement:
Leverage IIoT technology for improving • Monitor and track asset position and
the safety and productivity of utilization
manufacturing operations • Decision on buy/lease of equipment
• Collision detection and avoidance of
material handling equipment

Technology: IIoT
and Asset
Tracking software

Solution: Benefits:
• Vibration and temperature sensors, • Optimize operational costs
local gateways, GPS/GPRS devices, • Improved safety
and web application deployed in cloud
• Monitor and improve productivity

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 Case Study – OEM Value Added Services
Goal: Requirement:
• OEM wants to implement IIoT and • Monitor and track ~2500 turbines
Analytics for providing value added installed across the globe
services to its customers • Provide real time status on turbine
• OEM wants continuous feedback on health, anomalies, and maintenance
their machine performance recommendation
• Collect turbine performance data for
improved product design

Technology: IIoT,
APM, and Analytics

Solution: Benefits:
• Existing condition monitoring and • Optimize O&M costs
automation equipment - PLCs and • Real-time visibility to health of
SCADA. equipment installed across the globe
• Industrial Gateway and APM Software • Data driven analysis and decision
making

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Engagement and Execution Cycle

Foundation
Show Value
Discovery
Sessions Quantify
Technology
Demonstrator Maximize Benefits
Pilot
Full
Implementation

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Sample of a Digital Transformation Report
About Customer
About Aum Universal
Background for digital transformation at XXXX
Industrie 4.0 Overview
Technologies and Evolution
Maturity Index: acatech-STUDY
Site Survey Report – Observations, Challenges and Recommendations
Machining Plant
Casting Plant
Chrome Plant
Foundry Plant
IT Systems
How Aum Universal Can Help

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Sample of a Digital Transformation Report Continued..
Recommended new systems/software across the plants and shop floors–

Automated OEE monitoring (OT)

Manufacturing Execution Systems MES (OT/IT)
Condition/Machine Monitoring System CMS (OT)
Energy Management System EMS (OT/IT)
Product Lifecycle Management PLM (IT/OT)

How Aum Universal Can Help and Why?

✔Vendor-neutral independent consulting services company providing technology guidance to end users with
focus on customer success.
✔We have tie-ups with multiple products and solution companies – both in India and Abroad.
✔For every project/initiative, we give a multiple choice or options in products and solutions keeping in mind the
end user requirements, cost, quality, service, etc.
✔We also undertake customizing existing solutions or build a new one for the enterprise.
✔We act as single point of contact and take full ownership for the project management and execution. Right
from conceptualization to execution and coordinating with multiple suppliers, vendors, third parties and
customer.
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 Specialized Solutions for the Industry
Aum universal has partnerships across the globe and some key solutions we provide are -

Major focus:
✔IIoT Platform for various types of requirements and industries –
▪ Generic, Manufacturing (production, quality, OEE), asset tracking and utilization, Lighting,
Energy mgmt.
✔Condition Monitoring solutions (vibration, temperature, and others)
✔Transformer monitoring system
✔Earth pit monitoring system
✔EHSS (Environment, Health, Safety, and Sustainability) software solution
✔Software solution for shutdown, turnaround, outage for managing operations and maintenance
✔IT/OT solutions for Manufacturing

Other advanced areas:

⮚ Gateways and data diodes – cyber security solution for the industry
⮚ Digital Twin software solution
⮚ Asset Performance Management (APM) software solution
⮚ Predictive Analytics including anomaly detection software
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External References

● https://www.mckinsey.com/business-functions/operations/our-insights/industrial-
iot-generates-real-value-if-businesses-overcome-six-myths?cid=other-eml-alt-mip-
mck&hlkid=8b9c471de59e4493bb9a7d00d2f9e9fd&hctky=11771855&hdpid=d61
3e8f4-82b2-4bd1-8f5e-e28c5aba8d08

● https://www.isa.org/intech/20190405/#:~:text=RAMI%204.0%20definition,4.0%2
0in%20a%20structured%20manner.

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Thank You!!

M +91 9867613415
girisharalikatti@aumuniversal.com
aumuniversal@gmail.com

www.aumuniversal.com

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