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Challenges, Opportunities and Strategies for Integrating IIoT
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TEPCO Group and OSIsoft to Collaborate on IIoT
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In 1837, Australian Gas Light Energy (AGL) was founded in Sydney, Australia. At the time, Sydney was a small colonial outpost with less than 35,000 people, and “grid management” consisted of operating a few gas lamps. Today, AGL manages one third of the energy of Australia's eastern seaboard, where most of the nation's population lives. Acquistions and renewable adoption have been accelerating growth. In 2012, when David Bartolo, Head of Asset Performance, joined AGL, they had grown from 300 MW in 2005 to 5500 MW and were looking to further expand to 9000 MW. However, growth came at a price. “We were completely data blind,” said Bartolo at PI World San Francisco in 2018. “I had built a central asset management team. They were really clever people with years and years of experience, and they couldn't see a single piece of real-time data centrally… I had to ask one of the sites to print off a trend every ten seconds and send me the screenshots so I could understand what happened during an overflow incident. It doesn't get worse than this,” he said.
Something needed to change at Aurelia Metals. Gold recovery rates were less than 75 percent and throughput low at the end of the fourth quarter f 2015. If Aurelia was going to survive, its Perth processing plant needed to increase its recovery rate to 85 percent. It also needed to increase cash flow and capital. When Peter Smith, Metallurgy Superintendent at Aurelia Metals, started his role on February 1, 2016, he had no idea of the task at hand. Two days later, when he was briefed on the state of the plant, he knew one thing: he needed the PI System to remove manual processes and gain the necessary visibility to implement process control. By mid-March, the PI System was up and running, recovery rates and throughput were improving, and Aurelia's stock was rising.
Biogen is a leading developer of drug therapies for neurological and neurodegenerative diseases. Headquartered in Cambridge, MA, for nearly 40 years, the Biogen team has worked to combat the effects of diseases such as MS, Alzheimer's and spinal muscular atrophy. Biogen is in the process of rolling out its Aducanumab drug, which is designed to treat the symptoms of Alzheimer's. Phase 1b results noted that the drug significantly slowed the decline in Alzheimer's patients, giving hope to the over 25 million people around the world who suffer from the disease.
Around lunchtime on April 17, 2015, a massive power outage plunged the University of Maryland, College Park campus - a top-tier research facility that is home to 49,000 students, faculty and staff - into sudden darkness. The university was forced to close for several hours as the facilities management (FM) team rushed to restore steam and power to buildings.
For TraPac, automating its flagship operations at the Port of Los Angeles terminal enabled the company to cut costs, slash emissions, and move human operators out of harm's way. In order to fully realize the benefits of automation, however, TraPac also needed to harness their data. In 2017, the company implemented OSIsoft's PI System to organize and analyze the information generated by their operations. The result was a 10+% decrease in cycle time, improved maintenance, and faster issue resolution.
In 1895, Garant started manufacturing wagon wheels with a focus on craftsmanship. Today, they produce axes, shovels, snow removal equipment, gardening tools, and more. Their production line must be flexible enough to accommodate multiple work orders that vary in complexity and quantity, while maintaining quality craftsmanship and efficiency. However, in 2013, with employees regularly changing departments and disconnected systems slowing down production, Garant needed to optimize. They embarked on an Industry 4.0 initiative to establish a centralized data system to monitor the production process and optimize the performance of both machines and operators.