In this session, Automation Excellence gives viewers a simple approach to Industry 4.0, its principles, the components involved which include elements of both OT and IT, and the Ignition Platform.

2. Ramnath S Mani
Managing Director, Automation Excellence

3. Breaking the Myth of
Industry 4.0 with
Ignition

4. Industry 4.0 – What it means

5. Industry 4.0 – The OT – IT Divide

6. Industry 4.0 – Industrial Transformation
Industrial Transformation means something different for every organization, but
it always incorporates essential concepts, some of which include:
 Cross-disciplinary collaboration and shop-to-top engagement
 Thoughtful alignment of processes within functional groups throughout the organization
 More extensive sharing of enterprise data in and beyond the enterprise
 Managing data from device to Cloud
 Ability to use all sorts of data, structured to unstructured
 Advanced analytics from multiple sources, including third-party apps
 Open and secure communication
 First Step is Digitization of Factories

7. Industry 4.0 – Steps
1. All devices on the factory floor (regardless of manufacturer) seamlessly and instantly need to communicate.
2. All information from devices in various protocols and connectivity have to be brought to a common IT
understandable language and IT compatible protocol.
4. “Big Data” is able to enter the factory from the outside world, providing systems with statistics about consumer
buying habits and automatically increasing production at times of year when data trends indicate that demand for
a product is at its highest.
5. Tapped into a global data stream, the factory of the future can not only automate smart processes to meet its own
internal objectives, but can anticipate opportunities and failures based on external events before they occur.
6. Facilitates Multi-location sites to be inter-connected for overall visibility.
7. Fundamental steps manufacturer to prepare for seamless integration when the Internet reaches the factory:
Get Digital
Get Automated
Get Connected
Get Real-Time, Remote Access
Get Internet-Friendly Tools

8. Industry 4.0 – Smart Manufacturing (OT + IT)
 The Future of Manufacturing is in Industry 4.0 & IIoT.
 Industrial organizations see the value of uniting the factory floor with the executive
offices
 To implement needs mass Digitization
 New products addressing these challenges that will replace existing products
 Vision Document for the Company from Top Down – CEO the Architect
 Ensure that company’s management, including top management (e.g. CEO and CFO),
IT management (CIO) and OT management (production or unit management), commit
themselves to IT/OT convergence and actively support the initiative
 Your digital strategy must be driven by a clear understanding of the customer’s needs
and the way your products relate to them.
 Building IIOT from grounds Up - IIoT starts with Plant Floor & Field Devices

9. Industry 4.0 – Smart Manufacturing (OT + IT)
With Industry 4.0 being the buzzword on the industry’s lips right now,
 it’s easy for manufacturers to fall into the trap of believing that Digitisation requires a complete
overhaul.
 In contrast, taking small and strategic steps to digitisation can prove more beneficial for most
manufacturers. Remember, this is evolution, not revolution.
 Upgrading to Industry 4.0 in manageable steps not only allows businesses enough time to make well-
researched and considered decisions, but also gradually introduces employees to the new technology
around them.
 This step-by-step approach also enables manufacturers to see precisely how Digitisation is adding
value to their processes, and by reducing complexity, makes it possible to easily connect other
machinery down the line – saving time and money.

10. Industry 4.0 – Value Chain
Things
Gateways/ Networking
Infrastructure
Wireless/Wired
Communication
Services
Fast Data/ Big Data
Analytics
Enterprise Applications
Controllers,
transmitters, valves
Gateways, Routers,
Mobile Devices
Network Service
Provider
Data Centre, Servers,
storage
CRM, ERP, BI, HR
Light
Speed
Smoke
Vibration
Push button
Temperature
Water Level
Humidity
Pressure
Altitude
Motion
Speed
PLC
SCADA
MES
…
Sensors/ Devices
PROFINET
MODBUS
CANBUS
Others ..
IoT Concept ( Backend) IoT Concept ( Frontend)
Gateway
Edge
Cloud
Desktop
Tablet
Mobile

11. Industry 4.0 – New IIoT Architecture
What do companies need to move to an IIoT architecture?
There are 6 core success factors …
1. Decouple Devices
From Applications
2. Superior OT
Solution
3. Single Source
of Truth
4. Plug-and-Play
Functionality
5. Eliminate
Cutovers
6. Scale with
Unlimited Licensing

12. Industry 4.0 – New Architecture (OT + IT)
 Fundamental concept to IIoT and IT-OT convergence is to decouple Devices from Applications
 Open architecture that decouples applications from devices enable enterprise to get
needed data without interrupting operations at plants
 Conventional System architecture : intelligent devices such as PLCs coupled to applications
through proprietary protocols
Conventional Architecture IIoT New Architecture

13. Industry 4.0 – IIoT Architecture
What do companies need to move to an IIoT architecture?
There are 6 core success factors …
1. Decouple Devices
From Applications
2. Superior OT
Solution
3. Single Source
of Truth
4. Plug-and-Play
Functionality
5. Eliminate
Cutovers
6. Scale with
Unlimited Licensing

14. Industry 4.0 – Ignition Platform supports
The Ignition platform supports those features.
That’s why Ignition is perfect for positioning your company for IIoT,
Perfect for converging OT & IT,
And perfect for shifting to the Pull economy.
It lets you pull the modules & tools you need,
It’s a superior OT solution that leverages proven IT technologies
And it addresses the goals of the Open Process Automation initiative for an open, standards-
based, secure, and interoperable control system.

15. Industry 4.0 – Ignition - Universal Platform
One Universal Platform for IIoT, SCADA and More
Ignition is the only IIoT Platform
1. With built-in tools for creating full featured SCADA systems
2. Ignition is modular, so you can easily add fully integrated software modules for building
industrial applications such a SCADA, Alarming, Reporting software and more ..
3. With Ignition you can connect to all your IIoT Data, rapidly develop any kind of industrial
application and instantly web-launch clients to virtually any device – all without limits

16. Industry 4.0 – Platform and Ecosystem
What is an ecosystem?
• Open networks of strategic business partners
• A company’s competitiveness network of cooperators,
suppliers, institutions, customers and other stakeholders
• “Typically ecosystems are built around intellectual property
stemming from one core partner.” – Eric Schaeffer, Industry X.0

17. Industry 4.0 – Ignition for Industry 4.0
Level 4
Level 1
Level 2
Level 3
Business Planning
& Logistics
Control
Sense & Manipulate
Level 0 Actual Production Process
Ignition MES Add In
• OEE
• SPC
• Scheduling
• Recipe
• Track and Trace
Ignition Standard
Capabilities
• Connect to PLCs
• SQL bridge module for tracking
and historical data logging
• Real time data display via charts
and graphs
• Reporting module
• Alarm module

18. Industry 4.0 – Use Cases – Customer 1
 Global Manufacturer 6 Business Units with more than 950 plants worldwide.
 Vision to achieve Industry 4.0 driven by Central of Industrial Excellence Centre
 Made comparative studies and chose Ignition as the Platform
 Selected by 1 business unit in India and executed on a line
 On successful execution executed in other business units successfully
 Found it very useful as being an Enterprise Level Licence with unlimited Users and Tags
which makes the Total Cost of Operation low.

19. Industry 4.0 – Use Cases - Customer 2
 Working through a partner in South East Asia
 Global Electronic Manufacturer with plants in US, Asia, China
 Connected 127 machines with PLCs from Allen Bradley, GE Fanuc etc. and Industrial PCs.
 Able to connect some of the machines that are 40+ years old
 Collecting Real-time Data of availability, Performance and Quality, system providing accurate
OEE numbers in the dashboard with drill down capabilties
 “We have seen 7% improvement in our backend equipment OEE and 17% improvement in
MTTR. We have seen at least 15% reduction in downtimes in the front end equipment. Overall
it has been a positive experience”
“