The manufacturing landscape is undergoing a seismic shift. The rise of Industry 4.0, characterized by increasing automation, interconnectivity, and data-driven decision-making, is forcing manufacturers to adapt and embrace new technologies. At the forefront of this transformation lies a powerful tool: industrial data analytics.

By effectively utilizing the vast amount of information generated by automated manufacturing processes, companies are unlocking a treasure trove of insights that are revolutionizing how they operate. This data-driven evolution is propelling manufacturers towards a future of unparalleled efficiency, innovation, adaptability, and competitiveness.

Understanding the Role of Data Analytics in Industry 4.0

“Industry 4.0” is engineering jargon for the 4^th industrial revolution, which is all about digitalization and AI. Enter the other current industry buzz word: digital transformation, which is all about mechanizing as many aspects of a business’ operations as possible. What do these have to do with industrial data analytics? Almost everything.

Industrial analytics refers to the process of gathering, organizing, culling, integrating, and translating raw data into understandable information that is able to be acted upon. Industry 4.0 and digital transformation would not be possible without it.

Consider an automated facility: every sensor, alarm, piece of equipment is constantly generating data. For that to be worth anything to the person standing at the control system panel, that ocean of stats and measures needs to make sense. That requires an integrated system that allows constant, clear, complex communication between devices across the network, and a central HMI that is able to access, affect and generate that information into a context the operator can utilize.

You need industrial analytics to assess, plan and design an automation system, and an automation system also requires analytics to perform all its functions correctly. You can’t have some without the others; Industry 4.0, digital transformation and industrial analytics are inextricably intertwined.

How Industrial Analytics Has Changed the Automation Ecosystem

Generally, there are four types of data analysis used in industrial automation solutions:

• Descriptive Analytics: This is the what-happened stage. It uses historical data to understand past performance, identify trends and get a general sense of how things have been operating.
• Diagnostic Analytics: This is the why-it-happened stage. Diagnostic analytics examines historical data to pinpoint root causes of issues or anomalies. It helps identify problems and malfunctions within the automated system.
• Predictive Analytics: This is the what-could-happen stage. It uses historical data and statistical models to forecast future events like equipment failure, production bottlenecks, or potential obsoletion.
• Prescriptive Analytics: This is the what-to-do stage. By analyzing all the previous data, prescriptive analytics recommends specific actions to optimize operations, prevent problems and/or improve outcomes. It suggests the best course of action based on the insights from all the other stages.

These data analytics happen in a continuous cycle where descriptive analytics sets the foundation, diagnostic analytics refines the understanding, predictive analytics forecasts future scenarios, and prescriptive analytics suggests actions to optimize those scenarios.

This is a distinct development from Industry 3.0, which was the first emergence of computers, robotics and automation. Data analytics were rudimentary and limited, which led to systems that were opaque, mysterious and problematic. What good is an automated process that generates raw data if, when something goes wrong, there’s no salient way to access a coherent report that tells you why?

Data analytics can be thought of as something of a Rosetta Stone of automation. Where we once had infinite spools of raw data we could barely piece together, leaving much of it unintelligible mess, we now have the technology to translate that data into a usable format, allowing us to unlock the full potential of the knowledge that data can provide. Now that we know how to build control systems that know how to use it, it would be a detriment not to.

Applications of Industrial Data Analytics in Automation

When you are able to understand the full picture of what is happening on the floor of your facility in real time, you ensure you truly do have control and oversight covering every detail of your operations. And with the hardware, software and automation services available, any industrial entity can transform their business with these analytical keys to success. Industrial analytics can be applied to virtually every facet of a company’s operations with functions like:

• Data-driven insights: Data analytics replaces guesswork with factual insights, enabling manufacturers to make informed decisions about production processes, resource allocation and investments.
• Identifying bottlenecks: Industrial analytics can pinpoint inefficiencies in production processes, allowing manufacturers to streamline operations and maximize output.
• Improved safety: By analyzing data on machine performance and worker activity, manufacturers can identify potential safety hazards and implement preventive measures.
• Improved scheduling: Data insights can help optimize production scheduling, ensuring on-time delivery and minimizing downtime.
• Innovation: Data analytics can provide valuable insights for developing new products and processes, fostering innovation and keeping manufacturers ahead of the curve.
• Optimized inventory management: Industrial analytics can help manufacturers optimize inventory levels, reducing storage costs and the risk of stockouts.
• Optimized resource allocation: By analyzing data on resource usage, manufacturers can allocate materials, labor, and equipment more effectively, reducing waste and cost.
• Predictive maintenance: By analyzing sensor data, manufacturers can predict equipment failures before they occur, allowing for proactive maintenance and preventing costly downtime.
• Real-time quality control: Data from sensors on the production line can be used to identify defects early in the process, improving overall product quality and reducing waste.
• Reduced downtime: Predictive maintenance and real-time quality control minimize unplanned equipment failures and production disruptions, leading to cost savings.

And the benefits don’t stop there. Consider how improved efficiency can reduce energy waste; how increased consistency can lead to better quality; how better visibility can improve network security. It’s the technological incarnation of the old adage, “The more you know”.

E Tech Group: Helping Clients Reach Industry 4.0 & Beyond

Is there such a thing as too much data? Not if you know how to handle it. E Tech Group partners closely with our clients to create comprehensive automation systems that optimize the present and prepare for the future. Our advanced control system solutions utilize automation software that constantly collects, organizes, analyzes and translates usable raw data into information that’s easy to understand and also applicable. Let us help you transform your business with automation system design that won’t leave valuable data resources to waste when they could be used for actionable insights.

E Tech Group prioritizes building and maintaining partnerships with the global leaders in automation products. Not only does this help us implement the best control system solutions for our clients, but it also keeps us at the forefront of automation advancement while keeping a solid hold in the history of the automation movement.

Siemens Automation Group (Siemens Global) is one of the longest-standing leaders in the field of process engineering, pioneering automation for well over 150 years. With that kind of heritage, it’s easy to infer they are committed to advancing manufacturing and industry. That’s just one of the reasons they develop some of the most adaptable and flexible automation products around – which is just one of the reason E Tech Group maintains a close partnership with this giant in engineering.

Siemens Global: From Pointer Telegraphs to Process Control & PLCs

The story of Siemens begins as a small company trying to improve upon the original electric telegraph design in the mid-19^th century. Founded in 1847, within twenty years, their product, called the pointer telegraph, was all over Europe as a result of multiple government contracts. By the 1880’s, they faced numerous startups that would pose competition in the rapidly-expanding energy technology market.

They went public in 1899 – over 125 years ago! By this time, Siemens had already proliferated its engineering capabilities, including inventing the first elevator motor in 1880 and the first crane drive in 1891. Shortly after going public, they developed the world’s first reversing electric drive in 1907.

In 1958, Siemens came out with SIMATIC, the first modular system for contactless control. It was basically the progenitor to PLCs, which emerged less than 20 years later. SIMATIC is still regarded as one of the world’s most successful automation systems. In 1960, they developed the first industrial numerical control system, and by 1996, the availability of mini computers and moving hardware controls to software allowed them to truly achieve a totally integrated automation system.

The next major movement in automation was decentralizing controls, and Siemens was at the head with the Simodrive Posmo A in 1999. It allowed different machines to communicate and coordinate with each other, as it was integrated with the motor on each piece of equipment. And if this concept is starting to sound familiar, it’s because this was the tipping point in gaining the ability to build and implement complex, integrated control systems on large scales.

Why We Use Siemens Products in Our Custom Automation Solutions

It’s impossible to detail the myriad and significant developments in Siemens products that have occurred over the last 25+ years. Today, Siemens Global is a leader in automation and system integration products across the spectrum of industries, worldwide. And it’s a combination of who they are and what they do that keeps them there. We value Siemens AG as a partner and resource because:

Siemens Automation Products are Reliable

Siemens has a long-standing reputation for building dependable and high-quality automation products. This translates to less downtime, lower maintenance costs and a longer lifespan for equipment. Their products go through rigorous testing procedures to ensure they meet strict quality standards. This gives users confidence in the performance and reliability of Siemens-built control systems.

Coupled with their extensive domain experience across many industrial contexts, users can rely on Siemens automation products being designed by engineers and developers with deep understanding of the contexts in which they’ll later be applied.

They Provide Comprehensive Automation Solutions

Siemens offers a vast portfolio of automation products, from PLCs and HMIs to sensors, drives, and communication networks. This allows system integrators to source everything they need for their automation project from a single vendor, simplifying procurement and integration.

Siemens’ core concept of Totally Integrated Automation emphasizes seamless communication and interoperability between all their automation components. This simplifies control system design, reduces project time and ensures smooth operation of the entire automation system.

They’re Focused on Innovation & Future-Proofing

Siemens continuously invests in research and development, keeping their automation products at the forefront of technology. This ensures users have access to the latest advancements and can benefit from improved efficiency, productivity, and performance.

Their automation products are also designed to be modular and scalable. This allows Siemens system integrators to start with a basic system and expand it as their needs evolve, without the need for a major control system retrofit, future-proofing their investment.

Automation Products are Designed with Critical Logistics in Mind

Siemens automation software is known for its intuitive interface and ease of use. This reduces programming complexity and training time for operators, but it also ensures that the control system panel design is able to be integrated in a way that users can access, analyze and control their automated processes at a high availability.

And we can’t forget about industrial cybersecurity, which is an ever-growing concern. Siemens prioritizes security features in their automation products, giving users peace of mind about their systems’ vulnerability.

E Tech Group: A System Integrator & Trusted Siemens Solution Partner

E Tech Group is a North American leader in industrial automation and control system integration services. We are committed to disrupting and advancing the world of automation and engineering – to create a world where industrial operations are safe, efficient, scalable, and able to adapt to changing circumstances, whether they be expansions, regulations, labor shortages, or anything else.

We bring our deep domain expertise, creative approach and diverse skill set of our automation and IT teams to design the ideal, custom automation solution for every project and every client. Whether a small upgrade or a complete turnkey system build, our clients and industry partners know that an E Tech Group automation system uses the best practices and the best products.

Siemens AG’s combination of extensive experience, comprehensive solutions, commitment to innovation, and global reach solidifies their position as a leader in automation technology. As far as industry partners, we value our relationship as a Siemens system integrator and the opportunities their innovative products provide us with regard to providing the most advanced, elegant process control and integration solutions for our clients.

No question – automation is the future of the industrial sector. From OEM machine builders and metals production to pharmaceutical entities and alternative protein startups, automation and system integration will soon become a necessity to succeed in any given sector.

However, savvy businesses know that manufacturing automation solutions are already integral to success in the present. Automating previously manual processes and integrating control systems across facilities reaps real returns – it can completely transform a business from one that’s struggling to keep up to one that’s always a leg up on the competition.

But engineering quality automation systems for industrial facilities requires anything but an off-the-shelf, one-size-fits-all approach. CSIA control system integrators offer manufacturers a fast-track through automation present and into the future with performance-driven automation and integration tailored to each client’s unique needs. 

Why Tailored Process Automation Solutions Matter in Industry

During the first wave of automation, standard industrial automation solutions made sense. It was a new field of engineering and technology – there were scarce product options and strategic system design was in its infancy. The manufacturing and automation sectors needed time to gain their footing.

Fast-forward a couple decades, and many manufacturers are weighed down with piecemeal automation systems that carry stark limitations on capability, adaptability and scale. And with the rapid development of new process automation technology and engineers who have now had decades to gain expertise in the area, these aging systems are simply not a viable option anymore.

In today’s market, adaptability and scalability is key. Standard automation solutions aren’t going to get you there.

Benefits of Custom Machine Automation Solutions for Businesses

Certified control system integrators like E Tech Group design, implement and support custom process automation systems that significantly impact a business’ success in any sector:

Precision & Efficiency

• Increased productivity: Custom automation is fine-tuned to your specific production processes, materials, and workflow, minimizing bottlenecks and optimizing output.
• Enhanced product quality: Exact control over parameters and processes leads to consistent, high-quality products with fewer defects.
• Reduced waste and rework: Accurate automation minimizes material waste and the need for rework due to errors, saving time and money.

Flexibility & Scalability

• Adaptability to changing needs: Custom process automation solutions can be easily modified and upgraded to accommodate new products, processes, or production volume shifts.
• Integration with existing equipment: A precisely designed system can seamlessly integrate with your existing infrastructure, avoiding compatibility issues and costly retrofits.
• Future-proofed for technological advancements: Tailored control systems can incorporate cutting-edge automation technologies like AI and IIoT, keeping your facility competitive.

Cost-Effectiveness

• Long-term ROI: While the initial investment might be higher, custom automation often delivers significant cost savings over time through increased efficiency, reduced waste, and lower maintenance needs.
• Improved resource utilization: Precise process automation optimizes energy consumption and minimizes material usage, leading to cost reductions.
• Competitive advantage: Increased efficiency, agility and product quality can enhance your competitiveness in the market, increasing profitability.

Logistical Benefits

• Improved data collection and analysis: Custom systems often provide valuable data on production processes, enabling data-driven decision-making and continuous improvement.
• Enhanced employee satisfaction: Automation can free up workers for more skilled and creative tasks, leading to better job satisfaction and morale.
• Improved worker safety: Performance-driven systems can automate risky tasks, reducing the risk of workplace injuries and improving overall safety.

These benefits culminate in the two overarching advantages of a custom-built manufacturing automation solution: the ability to compete, and the ability to grow.

E Tech Group: Advanced Industrial Automation Services Across Sectors

As a leader in industrial automation and engineering, E Tech Group partners with clients across North America to create an automation system and integrated controls that fits their unique specifications and preferences. Open communication, the best in automation products, and a growth-focused approach define our brand of process automation solutions.

The benefits of an automation system that fits your businesses needs cannot be understated – streamlined operations, improved quality, less errors and downtime. Implementing an advanced, integrated control system now can ensure you stay competitive, adaptable and scalable in even in fast-paced markets.

In 2020, AVEVA, a global leader in engineering and industrial software, announced its intent to acquire OSIsoft, a forerunner in industrial data management. This strategic move served to merge two giants in the field of industrial intelligence, combining each company’s complementary abilities.

Completed in 2021, this new partnership between AVEVA and OSIsoft would have an almost immediate impact on the automation industry at-large. Control system integrators partnered with AVEVA had an opportunity to expand their expertise to support OSIsoft PI as well, adding yet another tool to our control system design belt, if you will.

Who are AVEVA and OSIsoft? And how does this acquisition affect manufacturers looking for bleeding-edge process automation solutions? Let’s take a look:

About AVEVA

AVEVA launched in 1967 under the name CADcentre. They quickly became the game-changers on the frontier of CAD applications in industrial processes. They were the first engineering firm to create a 3D computer plant model in 1976.

AVEVA has led the charge in collaborative automation system design and cloud-based applications. Today, as a global leader in industrial intelligence, AVEVA strives to innovate sustainable automation solutions. They’re renowned for:

• Basic engineering design: Conceptualizing and designing industrial facilities.
• Detailed engineering: Creating detailed plans for construction and equipment installation.
• Operations and asset management: Monitoring and optimizing production processes, ensuring asset performance and safety.

About OSIsoft

OSIsoft was founded in 1980 as Oil Systems Inc. where they initially focused on real-time data acquisition and analysis for the oil and gas industry. They developed PI System, which revolutionized the management and utilization of industrial process data.

By the early aughts, OSIsoft had expanded their PI System capabilities for other sectors like chemical and power, and launched PI Server, an internet-based platform for accessing data. A pioneer in real-time industrial data management, OSIsoft’s PI System is a powerful automation system platform that collects, contextualizes, and analyzes data from industrial assets, providing crucial insights for:

• Process optimization: Identifying inefficiencies and improving production performance.
• Predictive maintenance: Anticipating equipment failures and scheduling preventive maintenance.
• Compliance and safety: Ensuring adherence to regulations and maintaining safe operating conditions.

Acquired by AVEVA in 2021, OSIsoft operates as a distinct brand within the company.

Impact of the AVEVA’s Acquisition of OSIsoft

The recent acquisition of OSIsoft was a genius strategic move on the part of AVEVA, and according to both industrial trailblazers, was driven by 3 main factors:

• Complementary strengths: AVEVA’s engineering expertise combined with OSIsoft’s data management prowess created a comprehensive solution for managing the entire industrial lifecycle, from design to implementation.
• Market opportunity: The demand for industrial intelligence was rapidly growing, driven by factors like digital transformation initiatives and the increasing adoption of IIoT.
• Synergy potential: The combined entity aimed to achieve significant cost savings, cross-selling opportunities and accelerated innovation in the automation and control system software market.

And they were right. Adding OSIsoft PI to AVEVA’s portfolio of automation software has had a significant impact on the landscape of industrial automation applications:

• Creation of AVEVA PI System: This combined offering leverages OSIsoft’s real-time data with AVEVA’s engineering and operational software, enabling enhanced process visibility, improved decision-making, and optimized performance across the industrial value chain.
• Strengthened market position: AVEVA has emerged as a major player in the industrial intelligence market, competing with established players in automation software, like Siemens and GE Digital.
• New innovations: The merger has spurred the development of new automation solutions and services that capitalize on the combined expertise of both companies.

Automation happens in two contexts. In the industrial sector, the integration of AVEVA and OSIsoft has driven innovation in automation applications and industrial intelligence. And in the engineering sector, this merger has driven automation companies to integrate their expertise in both to offer a new brand of OSIsoft support.

E Tech Group Supports OSIsoft PI as an Endorsed AVEVA System Integrator

As an endorsed system integrator with AVEVA and a leader in North American industrial automation, E Tech Group engineers leverage these companies’ complementary technology to support OSIsoft and AVEVA-based automation systems. And because we are dedicated to providing high-value automation and IT services, we will continue to expand our expertise as these products evolve.