Digital technologies are changing manufacturing

Industry 4.0 describes “connecting autonomous, self-regulating, self-configuring, knowledge-based, sensor-supported and spatially distributed production resources (production machines, robots, conveyor and storage systems, operating resources)” (source: Fraunhofer Institute, Arbeitskreis Industrie 4.0).

But how high is the monetary potential of industry 4.0?

The value added in manufacturing worldwide amounts to more than $ 3 trillion annually (source: VDMA). And while digitization has the highest priority in Ø 68% of all industrial companies worldwide (in China even in 87% of all industrial companies), the real-world implementation lags behind: Only 21% of German companies use the most important industry 4.0 technologies on an fully-operational base (source: McKinsey).

This means that there is still an enormous amount of potential in the digitization of the manufacturing industry.

IoT: The key technology for industry 4.0

“Internet of Things” technology is the necessary platform to tap into this potential. But the great opportunity for manufacturers of manufacturing machines lies elsewhere: in the creation of product-accompanying services (servitization).

Services are made possible by the product.For example: service / uptime contracts, pay-per-use models or IoT-enabled consulting offerings.

With these new services, manufacturers of industrial machines can be on the forefront of innovation (and reap the commercial benefits), create higher margins, generate recurring revenues and react flexibly to economic fluctuations.

Increased sales through the introduction of digital services

Rolls Royce, for example, was able to increase its service sales from around £2 billion in 2000 to more than £6 billion in 2011 with product-related services such as the famous “Power-by-the-Hour” model. Now more than 65% of Rolls Royce’s turnover comes from the high margin service business.

In addition to these benefits, Rolls Royce has also been able to increase customer satisfaction and retention through increased flexibility, availability and reduced operating costs.

These results are creating attention: More than 60% of machine builders now assume that the most important service strategy over the next 3 years will be the introduction of service contracts.

The enormous potential of digitization

That brings some advantages: For the customer, the maintenance costs of the machine can be reduced by 10 – 15% annually and the productivity of the machine can be increased by 8%. For the manufacturer of the industrial machine, an increase in the total service turnover of approx. 12% per year is possible. (Source: European Commission, Business Innovation Observatory.) An exciting model that many other companies have already recognized and are working on.

Easy integration into your machine

In the first step, the machine is digitized with a “ToolSense IOT” unit, so that machine data can be generated.

You can connect the “ToolSense IOT” unit in each machine to a power supply between 5 – 520V and integrate it to the existing data interface.

If IoT hardware already exists, it also can be integrated (e.g. SIMATIC IOT2000).

ToolSense IOT gets the data from your machine

The data can be collected from existing control systems using common protocols such as OPC-UA or MODBUS. With “ToolSense IOT” all hardware interfaces such as RS485/RS232, Ethernet or CAN bus can be covered.

Using the “ToolSense IOT” unit, it is also possible to access the machine with WRITE operations and control it remotely.

Furthermore, “ToolSense KEY” can be added as authorization management, “ToolSense AMP” as current measurement sensor or you can also add additional sensors.

“ToolSense NOW”: scalable, solid and secure

The collected data can be transmitted via a variety of options using “ToolSense IOT”, e.g. wireless connections (3G, 4G) or, if available, WLAN or Bluetooth Low Energy.

The data is 100% encrypted and GDPR-compliant stored in Germany and Belgium.

If desired, ToolSense can also run in your own infrastructure or in the infrastructure of your customer – thanks to the “containerized” infrastructure of “ToolSense NOW”.

Your machine’s digital twin with “ToolSense NOW”

Now you can work with the digital twins of your machines with the “ToolSense NOW” IIoT platform.

Of course, you can also make this platform available to your customers and service partners – the broader the use, the greater the benefit.

A new world of data with “ToolSense NOW”

With the Data Analyzer on “ToolSense NOW” platform you can access all data parameters – be it from the machine interface, external sensors or “ToolSense IOT” unit.

Industry 4.0 creates a big advantage for R&D and product development

You can use the Data Analyzer to compare different parameters (e.g. motor frequency and motor temperature).

You can also use the data analyzer to uncover correlations or anomalies using statistical methods.

Security is at the core of “ToolSense NOW”

VPN protocols such as OpenVPN or WireGuard are already integrated into “ToolSense NOW” platform.

Using the VNC Viewer you can access the HMIs of your machine in real time and perform READ or WRITE operations – always available and encrypted end-to-end.

“ToolSense NOW” can be integrated into all your of systems

“ToolSense NOW” is developed on the basis of state-of-the-art IT infrastructure technologies.

The “ToolSense NOW” IIoT platform is “Cloud-Native” and the server capacities used adapt automatically to the number of users and machines.

Thus it makes no difference whether 100 or 100,000 machines are digitized.

“ToolSense NOW” is GDPR compliant, your data is 100% encrypted and stored in the EU.

In addition you can integrate “ToolSense NOW” into any system (e.g. MES systems, ERP systems, etc.) using the ToolSense GraphQL / REST API.