#Emrex18: IIoT foundation for next generation digital workforce.

New mobility and decision-support technologies plus services for operations consulting and upskilling empower critical competencies for Top Quartile performance

As manufacturers accelerate digital transformation and workforce evolution, Emerson has unveiled significant enhancements to its Plantweb digital ecosystem, the industry’s most comprehensive Industrial IoT automation platform.


Peter Zornio

“Manufacturing jobs are rapidly becoming data-centric roles, requiring immediately actionable information for experts across the enterprise,” said Peter Zornio, chief technology officer for Emerson Automation Solutions. “Through a deep understanding of customers’ vision for organisational effectiveness and business performance improvement, Emerson is innovating breakthrough products and services to accelerate that organisational transformation.”


A 2017 Industry Week survey of manufacturing leaders revealed more than 60 percent of those surveyed indicated active pilot projects in IIoT, but only five percent identified clear business objectives at the heart of their programmes. Of the 205 industry executives responding, 34 percent stated that lack of clear technology strategy was a barrier while 61 percent confirmed that a scalable approach to investment is preferred.

“A clear message from the industry is that a one-size-fits-all, vendor-prescribed IIoT approach won’t work,” Zornio continued. “They want to identify specific business challenges, target technology to improve performance, then scale up their investment based on results achieved. That’s why we have architected Plantweb to enable companies to get started where they can gain the greatest near-term impact.”

Built on the foundation of best-in-class process control and safety systems, Plantweb expands on existing automation infrastructure to make the promise of Industrial IoT scalable and achievable, with a broad portfolio of Pervasive Sensing technologies, an extensive suite of analytical software tools, secure and robust data infrastructure devices and expert services.

During the 2017 Emerson Global Users Exchange event in Minneapolis, Emerson introduced extensive enhancements to the Plantweb digital ecosystem portfolio, including:

  • Pervasive Sensing™: Emerson’s Pervasive Sensing is the foundation of the Plantweb digital ecosystem, providing enhanced visibility into process performance and asset health, so experts have the information needed to drive operational improvements. This increasingly robust network of sensing, measuring and monitoring technologies features more than 50 wireless devices for temperature, pressure, corrosion, vibration, acoustic and more. The portfolio has been expanded to include the new wireless Rosemount 928 toxic gas and Therm-o-Disc Power Meter monitoring products.
  • Secure First Mile™: As global adoption of Industrial IoT increases demand for robust cybersecurity strategies, Emerson’s Secure First Mile provides secure transfer of actionable data from Operational Technology (OT) systems to authorised internet-based applications, services or mobile users. Emerson’s data-security portfolio has been enhanced through certification by ISA Secure, the industry standard for secure systems deployment. Additionally, to accelerate adoption of new service relationships like Emerson’s Connected Services, the Plantweb Secure First Mile works with a variety of standard security models to integrate with customer IT infrastructure to create a secure connection best suited to the existing technology architecture. This includes cloud-to-cloud or direct Edge connection to field level sensor and instruments via Azure IoT technology.
  • Plantweb Insight™: Emerson’s Plantweb Insight is a scalable and lightweight, web-based software platform that helps users instantly make sense of plant data by leveraging Pervasive Sensing technologies and pre-built analytics to provide relevant-time monitoring and identification of abnormal situations for specific asset classes.

Plantweb Insight now includes applications for air-cooled heat exchangers, corrosion, heat exchangers, network management and pressure relief devices.

  • Plantweb Advisor™: Emerson’s Plantweb Advisor Suite is a scalable set of software applications that utilise deeper analytics to provide reliability and energy specialists with critical information about equipment health and efficiency as well as energy consumption and emissions. Originally introduced as the Energy Advisor, Health Advisor and Performance Advisor applications, the Plantweb Advisor suite has been expanded to provide analytics applications for metrology and mining.
  • Always Aware™: Formerly known as Always Mobile, Emerson’s new Always Aware suite of solutions builds on previous mobility capabilities, expanding them to focus on delivering role-based, relevant-time information and alerts to plant personnel, regardless of locations, enabling more effective collaboration and driving actions to improve asset and process performance. Updates include RFID asset management tags and AMS ARES™ integration with various interfaces such as AMS Device Manager, AMS Machinery Manager, Plantweb Insight and Plantweb Advisor to streamline workflows, enhance collaboration and enable more effective response.
  • Services: Emerson is expanding its role as a trusted industry partner with consulting and service offerings that complement its leading portfolio of automation and IIoT-based technologies. These services provide companies with access to the information and engineering expertise needed to establish a successful path to Top Quartile performance as well as empower their personnel with the competencies and skillsets needed to become invaluable assets to their organisations. Services include:
    • Connected Services – offering remote assessment of a plant’s equipment and processes by Emerson experts to empower customers with the information needed to improve efficiency and avoid unplanned downtime. Updates include new capabilities for subscription-based services that require limited to no capital cost. These include industrial Wi-Fi network management for system health monitoring of Cisco Wi-Fi networks, and engineered Plantweb solutions such as management of Plantweb Insight and Advisor applications by Emerson personnel.
    • Software as a Service (SaaS) – leveraging the cloud to transform project engineering and a plant’s long-term operations by enabling engineering configuration and virtual testing online as well as virtualisation of a plant’s control systems for simulation, testing and operator training.
    • Operational Certainty Consulting – combining the business justification for investment with a scalable roadmap governed by business impact achieved is the mission of Emerson’s new Operational Consulting team…more than 100 industry experts helping deliver digitally enabled infrastructures with optimal organisational process approaches that generate significant financial returns.
    • Workforce Skills Development – focusing on enriching the skills of today’s workforce through the Control Performance Academy, the industry’s first comprehensive competency development programme, capable of equipping inexperienced engineers with the equivalent of 5-10 years’ worth of training in as little as 18 months; and Interactive Plant Environment, a fully-immersive, hands-on training experience for control systems personnel.
  • Foundational Solutions: The underpinning of modern plant automation, these technologies provide the core process control and safety systems critical to plant operations. Enhancements to Plantweb include the DeltaV Live Operator interface, which utilises Human Centered Design principles to integrate thousands of data points in the plant and improve control system functionality with a more efficient, intuitive interface that can be used in project design as well as daily operations.

To help customers understand the impact these new technologies can have on personnel productivity and organisational effectiveness, Emerson brought the next-generation digital workforce to life with the ‘Digital Workforce Experience’ during Emerson Exchange. The immersive, role-based simulation demonstrated first-hand how various manufacturing roles are evolving and the impact they have on business performance.

“The industry’s technology evolution over the past 30 years has delivered tremendous improvements in efficiency,” concluded Zornio . “Now it’s time to fuel the next-generation workforce with the actionable insights they need to become even more strategic assets in their companies.”

• See also: Five new easy-to-deploy apps to deliver actionable asset alerts!
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#Emrex18: Operations consulting group.

Emerson’s Operational Certainty consulting service helps manufacturers justify, design, execute and quantify value achieved by combining Industrial IoT technologies, proven methodologies and industry expertise

Reinforcing its commitment to help industry recover an estimated $1 trillion in lost operational performance annually, Emerson has announced a new Operational Certainty consulting business that helps manufacturers integrate Industrial Internet of Things (IoT) technologies and updated organisational work practices to achieve Top Quartile performance.

Operational-Certainty“Operational losses are the result of production downtime, increased safety incidents as well as excessive energy consumption, emissions and production costs,” said Thomas Waun, general manager, Operational Certainty Consulting, Emerson Automation Solutions. “We have quantified the opportunity in each industry and it is Emerson’s mission to help customers target these losses with scalable plans to recover what some call ‘dead money’ in their plants.”

In a recent Emerson and Industry Week survey of manufacturing executives, 60 percent acknowledged having active IoT pilot projects under way, yet only 5 percent had clear business case justification. Additionally, 61 percent stated a scalable approach based on business impact achieved was an important strategy to adopt. Respondents identified several barriers to progress, including:  47 percent cited company culture, 41 percent noted a lack of clear business case, while 34 percent pointed to a lack of clarity on which technology path to take. In response to this need, Emerson has developed the Operational Certainty consulting organisation.

“Virtually all manufacturers are focused on some form of digital enablement, but very few have a clear plan to drive the culture change necessary to capitalise on the opportunity that digital transformation represents,” said Waun. “Automation is the highest impact lever to both accelerate and sustain behaviour change and deliver results. Emerson is marshalling the right resources, expertise and methodologies to help customers build a business case for investment, then make their vision a reality.”

With consulting experts specialising in disciplines including reliability, safety, energy and emissions, production and Industrial IoT architectures, Emerson’s new Operational Consulting practice includes more than 100 industry consultants with deep expertise in helping manufacturers achieve digital transformation. Through proven, flexible, yet repeatable methodologies, Emerson helps manufacturers quantify their business improvement opportunity and create a scalable, achievable roadmap. Emerson’s new consulting organisation is supported by more than 5,000 project and applications engineers to help customers execute plans. Emerson then helps manufacturers monitor progress with performance benchmarking in targeted operations areas.

“For years, customers have followed operational excellence programmes to drive incremental efficiencies, and those have been successful…to a point,” said Waun. “Diminishing returns in these programmes are driving industry leaders to look for bigger impact on their bottom line.”

Many organisations invest in systems to improve their operations. But they often fail to realise the expected return on those investments by not connecting their systems together, not effectively embedding them within their standard operating procedures, or underutilising the systems’ true capabilities because of a lack of expertise. Existing management consulting firms understand the broad opportunities the implementation of advanced technologies represents; however, they often lack the application and industry-specific expertise to develop a pragmatic solution architecture that leverages existing infrastructure and accelerates returns. Moreover, traditional consulting firms lack the specialisation and resources for end-to-end execution required to fully realise a successful digital transformation, frequently providing guidance without the ability to deliver.

Operational Certainty consultants understand the industry’s people and processes, putting them in a unique position to combine intuitive technologies and automated workflows to reduce complexity and empower more productive digital workers. Emerson will engage customers through proven methodologies that bridge visioning, change management, IT/OT convergence, and system architecture. This collaboration will result in a digital infrastructure that empowers workers with higher quality, faster decision-making capabilities to accelerate value creation.  Beyond the enabling infrastructure, Operational Certainty consultants will also develop a thorough assessment of the organisational changes that are required for full realisation of the benefits, ensuring best-in-class behaviours are adopted.

“Emerson’s Operational Certainty consulting team takes a total lifecycle approach to implementing digital transformation strategy,” said Waun. “Our consultants will methodically assess current operations and use the collected data to develop a future-state vision. Together, Emerson and its customers develop a digital blueprint that ensures the path from vision to measurable success is clear.”

• See also Jim Cahill’s “What is Operational Certainty?” (2016)
@EMR_Automation #EMrex #PAuto
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#Emrex18 Five essential competencies of digital transformation.

Following a period of what the company sees as the ‘efficiency era’ of manufacturing, Emerson opened its annual Emerson Global Users Exchange (#EmrEx) event with a focus on the resources that will enable manufacturers to drive greater business performance in the future:  people. Specifically, the ‘digital workforce.’


Mike Train explains the five essential competencies of digital transformation at EmrEx

“The past 30 years have brought us fantastic advances in the manufacturing sector, including greater operating efficiencies enabled by automation,” said Mike Train, executive president, Emerson Automation Solutions. “But the incremental benefits gained are diminishing. The pressure is on industry leaders to take the next step to the game-changing performance made possible by digitally empowering the workforce.”

By analysing the organisational behaviours of Top Quartile industry performers – those in the top 25 percent of performance among their peers – Emerson has identified five essential competencies as critical to realise the value of ‘digital transformation’:

  • Automated Workflow: Eliminate repetitive tasks and streamline standard operations to focus personnel on exceptions and other opportunities that require human intervention
  • Decision Support: Leverage analytics and embedded expertise to provide actionable insights that reduce complexity and enable higher quality, faster decision-making
  • Workforce Upskilling: Identify approaches that empower workers to acquire knowledge or experience faster and more effectively, to support higher-level and collaborative decision-making
  • Mobility: Provide secure, on-demand access to information and expertise regardless of location, enabling collaborative workflows
  • Change Management: Combine strategies, processes, tools and expertise that, in the right combination, simplify and accelerate the institutionalisation of operational best practices.

While these themes are not necessarily new, Industrial Internet of Things (IoT) innovations are bringing unprecedented opportunities to evolve performance in each area of organisational transformations. To make these opportunities attainable, Emerson will expand its Plantweb™ digital ecosystem with a wide range of new digital technologies and services, including a consulting practice with the expertise, methodologies and personnel to bring predictable success to digital transformation.

“By mastering these competencies, manufacturing organisations can fully leverage the digital technologies of today and those just around the corner,” continued Train. “Emerson uses the organisational insights we gain through customer collaboration to focus our product and service portfolio development in areas that create bottom-line impact.”

In a 2017 study conducted by Industry Week and Emerson, manufacturing leaders from a variety of industries confirmed the Industrial IoT will bring new possibilities fuelled by increased real-time information, a more tightly connected enterprise and improved analytical tools. However, the group consistently pointed to personnel as the most important factor for success. Namely, the need for companies to adopt effective change management methodologies to drive an increased focus on education and upskilling along with improved organisational workflows to effectively leverage their technology investments.

“There is an increasing number of reports suggesting that technology is displacing manufacturing jobs, yet they routinely miss the big picture,” said Train. “History has taught us time and again that, while technology can unsettle the current or traditional nature of work, disruption consistently brings new opportunities and net employment growth, not loss.”

During the 2017 Emerson Global Users Exchange event, held in Minneapolis, Emerson introduced significant enhancements to its Plantweb digital ecosystem portfolio, with new technologies and services targeting workforce productivity and organisational effectiveness. To bring the ideas to life, Emerson will help industry leaders see the near-future of how a digitally enhanced workforce behaves differently through its ‘Digital Workforce Experience’, an immersive experiential environment demonstrating how new and emerging technologies are fundamentally transforming organisations by helping them accelerate, institutionalise, and sustain Top Quartile behaviours.

“Companies and employees who embrace the rapidly transforming digital landscape stand to achieve the greatest success,” said Train. “But everyone has skin in the game. Employers need to provide education and upskilling opportunities, and employees need the confidence and commitment to learn new skills and competencies to manage their careers into the information age.”

@EMR_Automation #Pauto #Emrex
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#Emrex18: Making project engineering & operations more intuitive, flexible, accessible and secure.

Emerson’s Latest Control System Transforms Projects and Helps Bridge IT/OT Divide for Operational Performance

DeltaV_InterfaceEmerson has expanded its Plantweb™ digital ecosystem with the launch of DeltaV version 14, a cybersecurity-certified control system designed to deliver new value in capital projects and make plant operations more connected and productive. The latest release provides significant innovations to the entire DeltaV architecture and was built with customers’ digital transformation initiatives in mind.

This major update to the DeltaV automation system includes several meaningful enhancements to eliminate costs and reduce complexity in capital projects, plus improve productivity during operations through enhanced access to production and equipment data, improved usability and greater security.

“More than ever, an integrated plant data environment is essential to achieve digital transformation. With DeltaV, we’re reducing the engineering effort required to securely connect plant, operational and information systems,” said Jamie Froedge, president of Process Systems and Solutions, Emerson Automation Solutions. “Our customers will have more capabilities in their distributed control and safety systems to help them successfully execute capital projects and optimise operations.”

Capital Project Flexibility
Continuing to advance the impact of DeltaV Electronic Marshalling with CHARMs on capital project engineering, CHARM I/O Block takes CHARMs – which achieved more than one million deployments at more than 1100 sites in only five years – closer to the field. Small enclosures with up to 12 CHARMs can now be installed closer to field devices, significantly reducing wiring and overall installation costs by as much as 60 percent and providing more engineering flexibility.

Smart Commissioning software


Smart Commissioning Software


Smart Commissioning, launched in 2016, took one of most engineering-intensive operations off a project’s critical path. Traditionally, commissioning has been a manual task that requires more than two hours per device for thousands of devices. Smart Commissioning reduced commissioning time to 25 minutes. Emerson is now expanding these capabilities and reducing device commissioning time to as little as 10 minutes, a nearly 93 percent reduction in costly commissioning time that could save several hundred-thousand dollars in engineering costs.

Mobility and User Experience
DeltaV Live Operator Interface is a modern, built-for-purpose operations experience that is easy to understand and modify. The HMI comes pre-engineered with the industry’s best practices for user experience including ISA 101.01 and is based on research with the Centre for Operator Performance, a consortium of vendors and academia focused on human factors engineering. The HTML5 interface enables scalable graphics and gives operators the flexibility to adjust their displays to focus on process data that is most important for each situation. The new operator interface helps improve overall situational awareness and decision-making speed. Emerson is helping companies prepare for the shift to mobility with DeltaV Live by building a foundation for graphics to be transferrable across desktops, laptops, and mobile devices – all without additional engineering or custom scripting.

A Secure, Connected Plant
DeltaV will offer its users a new level of confidence and protection from cybersecurity threats by being one of the only systems to have a top-to-bottom cybersecurity certification. DeltaV v14 will be certified ISASecure SSA Level 1 by the International Society of Automation (ISA), signifying that Emerson developers are trained to write secure code and the system as a whole is hardened against cyber threats.

Emerson is making connecting a plant’s OT systems with IT systems seamless by expanding OPC UA access in its DeltaV hardware and software offerings. DeltaV is the pathway for most plant data and now using the IIoT’s most prevalent protocol, OPC UA, DeltaV applications and servers can securely share data to cloud analytics applications, remote monitoring solutions, and third-party technologies.

Emerson announced the first two additions of its new DeltaV system last year with the DeltaV PK Controller and DeltaV Mobile. The DeltaV PK Controller enables plants to control skids and applications typically managed by PLCs with a standalone DeltaV controller or connect into an integrated full-scale DCS automation architecture or the cloud via embedded OPC UA. The DeltaV Mobile platform natively connects into DeltaV – securely and without additional engineering – to enable managers, engineers, operators and subject matter experts to monitor operations and have critical data and alarms at their fingertips, whenever and wherever they need it.

#PAuto #Emrex @EMR_Automation
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#Emrex18 Five new easy-to-deploy apps to deliver actionable asset alerts!

Emerson Extends Plantweb™ Insight Application Portfolio to Simplify Asset Health Monitoring and Maintenance

With the demand to implement the Internet of Things, the challenge is knowing where to start. Plants generate more data than ever before without meaningful analytics to guide expert decisions and actions. Plantweb enables customers a scalable, easy path into Industrial IoT benefits that will transform data into truly actionable information – information that plant personnel can use to dramatically improve the safety, reliability and efficiency of assets, people and processes.

Deployable via traditional workstation, tablet or smartphone, Emerson’s Plantweb Insight apps provide specific asset alerts which enables companies to see a quick return on investment in months by avoiding slowdowns and shutdowns. Instead of having to rely on an asset expert, these affordable, easy-to-use apps can be quickly deployed and easily accessed anytime, anywhere in real-time by maintenance staff to improve asset operations in chemical, oil and gas and refining. A user can begin with one or more assets, such as pumps or heat exchangers, and then expand as they achieve measurable benefits.

The built-in domain expertise of the analytics helps resolve asset issues that were formerly solved by periodic, time-consuming manual rounds or unexpected failures. Pre-built analytics require minimal configuration, and its flexible software is operating system-independent, easily installing and integrating with existing infrastructures.

Plantweb Insight Heat Exchanger

Heat Exchanger Insight

Using Plantweb Insight, users can improve asset reliability and energy usage by identifying abnormal situations and inefficiencies, recognising optimum maintenance times, and tracking asset health to identify and prevent failures before they occur. They also can avoid potential safety incidents and ensure regulatory compliance, reducing fines and environmental impact though the real-time identification of leaks and other hazards. Plantweb Insight is currently available with applications for steam trap monitoring, pump monitoring and pressure gauge monitoring. The newest apps in the suite include:

  • Heat Exchanger Insight – This Plantweb Insight app provides an overview of heat exchanger status and diagnostics from all the instruments on the network. Based on an algorithm, it provides directions to maintenance on where to focus action for issues, and provides a detail of the issue to guide them in efficient resolution, thereby avoiding slowdowns and shutdowns.

Future Plantweb Insight applications launching in the next year include:

  • Air-Cooled Heat Exchanger – This Plantweb Insight app recognises abnormal situations in the Air-Cooled Heat Exchanger pertaining to fan vibration, reduced cooling, louver defects and fouling. The app provides the user with instant visibility into asset status and alerts as well as guidance on how to resolve the issue.
  • Pressure Relief Device Insight –  Plantweb Insight for Pressure Relief Devices (PRDs) identifies failures in relief devices such as simmering and leaking and alerts staff on actions to take to guide resolution. The Insight app also logs all release events to assist with regulatory compliance, and tracks production and emission impact in relation to goals and regulations.
  • Network Management Insight – Plantweb Insight for network management manages up to 100 Wireless Gateways in one easy-to-use application that quickly identifies network status and any abnormal conditions, and recognises network issues pertaining to reliability, pinch points, network load, etc. then guides users to resolve any issues.
  • Corrosion Insight –  Plantweb Insight for corrosion gathers insight into pipe integrity and health, and identifies safety and reliability events before they cause shutdowns. The app tracks and trends corrosion rates to proactively address issues and provides guidance in how to correct any issues.
@EMR_Automation #Pauto #Emrex @Emerson_News


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#Emrex18 Improving enterprise-wide visibility.

Plantweb Optics helps companies visualise and take action on their most important plant assets with mobile-ready collaboration software that transforms business processes

Plantweb Optics is a new mobile-ready collaboration software platform announced by Emerson.  It provides an unprecedented view of plant reliability and operational performance. Connecting technicians, engineers and plant management through Plantweb Optics transforms decades-old work processes, providing cross-functional collaboration and decision-making to help plants operate safely and profitably.

plantwebopticsWith access to data across an organisation, Plantweb Optics translates equipment health data into a user-friendly format and instantly and securely delivers it to relevant personnel so they can make more informed decisions impacting production. The collaboration software improves the user experience with intuitive visualisation and customised alerts to reduce or eliminate irrelevant data. On mobile devices, personnel can quickly access equipment health scores any time, from anywhere, and can combine multiple views for easier monitoring of facilities across multiple locations.

“Getting the right data into the hands of the right people is paramount for our customers, and Plantweb Optics aggregates asset health information from various sources and not only prioritises the most important and relevant asset data, but easily targets actionable data to the people responsible for acting on it,” said Jim Nyquist, group president of Emerson’s Systems and Solutions business. “It transforms how companies have traditionally managed data and puts companies on the right path to digitally enable their workforce.” 

As a part of Emerson’s Plantweb digital ecosystem, the industry’s most comprehensive Industrial IoT platform, Plantweb Optics delivers higher-level collaboration, better insights and priority decision-making, all behaviors of Top Quartile performance. Research shows Top Quartile performers spend two to four times less on maintenance costs than poorer performers—a potential savings of $24 to $80 million annually for a $1 billion plant.

Today, plant management is unable to see critical data from various siloed systems and its impact on broader operations. Solutions exist to connect plant data to other users through complicated mapping processes, but those solutions deliver only raw data, leaving behind the rich information available from asset management systems. Using industry-standard, embedded communications protocols, Plantweb Optics can share data with big data machine learning and analytics software to create new strategies for asset management and reliability. The software provides a platform to integrate more enterprise applications in the future for better reliability and operational performance. 

@EMR_Automation #PAuto
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#HM18 Clever sensor cable.

This intelligent sensor cable with SmartCore Technology from Leuze electronic improves machine and system availability.

Smart_Core_EN_23 11.jpg_ico500

With the new SmartCore cable, the company presents an interesting highlight at the Hannover Messe 2018 trade fair especially for applications with moving cables, e.g., in robots or with handling axes. The cable contains an additional, special sacrificial cable that fails at approximately 80% of the possible movement cycles.

To evaluate, the sacrificial cable is bridged with the supply voltage and, if the core breaks, gives early warning of the impending end of the cable’s service life. Unplanned system downtime caused by cable breakage can thus be effectively prevented, and the sensor cable at risk of breaking can be replaced during the next scheduled maintenance cycle. The SmartCore Technology thereby contributes to increased system availability.

@LeuzeUK #PAuto
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