How to Digitize Industrial Manufacturing with Azure IoT Edge, InfluxDB, and MAJiK
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Majik Systems provides real-time data solutions for manufacturers to optimize their operations by integrating directly with capital equipment and industrial data systems. Their platform offers actionable insights, predictive maintenance suggestions, and performance analytics, supporting continuous improvement and lean management practices. The technology facilitates real-time monitoring of production processes while also enabling device connectivity and maintenance management across various industrial environments.
How to Digitize Industrial Manufacturing with Azure IoT Edge, InfluxDB, and MAJiK
- 1. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Jared Evans – MAJiK Systems jevans@majik.io 1 833 MAJIK-IO www.majik.io Delivering Actionable Factory Information to Decision Makers in Real Time Provide clients with real-time information to monitor, analyze, and optimize their manufacturing operations by connecting directly to capital equipment in the plant
- 2. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Jared Evans COO - MAJiK Systems Experienced Co-Founder with a demonstrated history of working in the information technology and manufacturing industries. Focused on Product Management, Customer Delivery, and Partner Enablement. Member of the MTConnect & OPC UA Technical Advisory Group. Strong operations professional with a Bachelor of Applied Science (B.A.Sc.) in Industrial Eng & Systems Design from University of Waterloo. Previously roles include Engineering Manager at Apple Inc and Program Management at Broadcom Corporation.
- 3. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Azure Kubernetes Service Factory Azure IoT Hub Visual Manufacturing Architecture 3 Operations HumanContext Downtime Classification Work Instructions Scrap Tracking Production-to-Plan PLC CNC OPC UA MQTT SQL “Autonomated” Manufacturing Processes Maintenance Process Engineers IoT Edge Runtime I I o T C o n n e c t Industrial Protocol Translation Secure Edge-to- Cloud Connectivity Device Connectivity Monitoring OT Network Health VisualWorkcell Asset Health Monitoring Real-Time KPIs Production Tracking Shift Targets Downtime Notifications Real-Time Data Streams VisualFactory Operational Data Review Process Flow Tracking OEE Shift Reporting Downtime Analysis Text/Email/Push Notifications Data Integrity Scorecards Analytical Data Storage VisualEnterprise Common Data Model Data Consistency Scoring Cross-Site Comparison Data Lake / Data Bricks OEE Performance Trending Issue Drilldowns Mobile Access Industry 4.0 Platform Integrations Process Connect ScheduleConnect MaintenanceConnect + Any API-Based CMMS Asset ID Consistency Predictive Maintenance API Service Monitoring ScheduleConnect Corporate Data Consistency Smart Scheduling Integration Health Monitoring Process Connect Manufacturing Data Summary Schemas Enable AI-Based Process Control Data Stream Monitoring Enterprise Executives OpEx AdministrationTools Active Directory Integration Enterprise Data Management Standard Operating Procedures Enterprise-Level Device Management Data Integrity & Contextualization Predictive Actions & Feedback Loop of Best Practices Cloud - Feature Highlights - Industry 4.0 Success Tools - MS Azure IoT Reference Architecture Equipment-Specific Visualizations
- 4. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. MAJiK IIoT Connect 4 IIoT Connect integrates directly with capital equipment and other plant-floor assets to capture industrial data in real-time, enabling Manufacturers to use MAJiK Visual Manufacturing Tools to monitor, analyze, and optimize their operations Out-of-the-box connectivity 95% + of controls & sensors in market Sensor Networks IoT Clients SCADA SCADA Historian MES
- 5. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. What is a PLC? 5
- 6. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Industries that Use PLCs 6
- 7. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Value Proposition of PLCs: Digitization of Relay Systems 7
- 8. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. HOW PLCs Function 8 Outputs Inputs Power Supply Memory Data Program CPU Comms Sensors Contacts Switches Buttons Relays Relays Starters Valves Solenoids Lights/ Displays PC for Programming Facility Ethernet Network: Gateway to other PLCs, SCADA, etc.
- 9. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Supported Protocols & Applications 9 Protocol Example Control Brands & Models Ethernet/IP Allen-Bradley Logix Series Controls (ControlLogix, CompactLogix, MicroLogix) Omron CJ2M-based models, modern Keyence PLCs DeviceNet Allen-Bradley Logix Series Controls PCCC Allen Bradley Legacy Controls (SLC series, PLC5 series, MicroLogix Controls) S7 Protocol Siemens S-Series Controls TIA Protocol Modern Siemens Controls OPC UA Multiple Industrial Devices/SCADA Systems (Ignition, Wonderware, Rockwell Software, etc), GE Controls, Beckhoff Controls FINS Legacy Omron Devices Melsec Protocol (MNet) Mitsubishi Controls Modbus TCP/IP Many Legacy Devices, Schneider Electric Controls, ABB Controls, Keyence and other Automation Direct PLCs, Camera Vision Systems, Advantech ADAM Modules (Analog-to-Digital signalling) MQTT Multiple IIoT Sensor Platforms and Smart Devices, including IFM IO-Link Platform AMQP Multiple IIoT Sensor Platforms and Smart Devices HTTPS Local Web Servers and APIs (HVAC Systems, local Web Services) IoT Hub Integration Microsoft Azure Eco-System (PowerBI, PowerApps, etc) SQL Local SQL Databases, SCADA Historians, and traditional Manufacturing Execution Systems (MES)
- 10. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Co nnect +20 % Improvement in OEE Extrusion Assembly IndustryHighlights 8 Day Standardized Implementation Packages Visual Factory provides information such as the Root Causes of Downtime, Quality Issues, and Production Slow Downs required by Operations Teams to support Lean Factory Management practices, allowing them to drill down on historical data until sources of waste are identified and permanently fixed, continuously improving Factory Efficiency • Root cause issues creating Downtime, Scrap, and Slow Production • Create consensus within your Operations Team on Top Issues to solve • Allow Decision-Makers to manage Factory Operations in real-time Metal Working Consumer Packaged Goods MAJiK Visual Factory – Product Overview 10
- 11. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Co nnect 35-45 % Reduction in Downtime 7-10 % Reduction in Waste The Process Connect integration provides the data and framework to apply Statistical Process Control in your plant and across your organization so Process Engineers can monitor the telemetry of any automated process or production method to drive the improvement of critical workflows • Explore Industrial Processes using queries & charts • Create & share intuitive Dashboards with your team • Set up Alerts & Notifications based on trends in your data 5 Day Standardized Implementation Packages Process Connect – Product Overview 11
- 12. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. MAJiK AI 12 MAJiK’s AI-Driven Platform delivers actionable insights on performance-to-plan, suggests predictive maintenance actions, and identifies best practises for your organization by automatically contextualizing data from people as well as Industrial IoT sources and continuously building models about the normal performance of your operations to supercharge your instance of MAJiK’s award-winning Enterprise Manufacturing software suite, helping your entire team find new ways to improve your operations. q Smart Shift-Target Adjustments q Real Available Labor- Force Goals for Shift V i s u a l W o r k C e l l A I q Smart Identification of Best Practices q FinanceImpact Intelligent Reports q Unlock Industry 4.0 Technology V i s u a l E n t e r p r i s e A I q Smart Detection of Assets & Tags q OT Network Health Monitoring q Dynamic Network Health Optimization I I o T C o n n e c t A I C o n n e c t o r s Schedule Connect – Dynamic Schedule Optimization Maintenance Connect – Asset Health Profile Process Connect – Waste Reduction & Energy Optimization A I V i s u a l f a c t o r y q OEE A-P-Q Highlight Service q “AI”TBF – AI-Based Time Between Failures q Smart Quality Escalations A I
- 13. © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. MAJiK – InfluxDB Architecture 13 • Follows MS’ Azure IoT Reference Architecture • Provides “Warm” path for IoT Time-Series Data • Orchestrated through Terraform deploy scripts for Enterprise-level roll outs • MAJiK Tenant or Customer Tenant
- 14. Extrusion Press – Real-time Issue Notification © 2020 All rights reserved. Private and Confidential. Not for Distribution. • Automated Alert for Downtime exceeding 30 min threshold is triggered in MAJiK Visual Factory • In-App Notification prompts user to investigate Downtime more thoroughly
- 15. Press - Issue Analysis © 2020 All rights reserved. Private and Confidential. Not for Distribution. • Drill Down in MAJiK Visual Factory shows issues occurring much more often Jan 31 compared to Jan 30 on the Press • Many smaller stoppages that would not trigger the current configured alerts • Difficult to determine more from Downtime Analysis because Downtime Reasons are not currently assigned (customer had just begun using system)
- 16. Press - Equipment Telemetry Exploration © 2020 All rights reserved. Private and Confidential. Not for Distribution. • Used MAJiK Process Connect with Influx+Chronograf to review Press Telemetry Data • Multiple points where Butt Length is between 5” and 7” when it should usually not be exceeding 2” • Timing correlates with Downtimes found in Downtime Analysis
- 17. Press - Directed On-The-Floor Investigation © 2020 All rights reserved. Private and Confidential. Not for Distribution. • 7” Butts were being used to suck metal out of hollow dies • Butt Shear mechanism required repair to reduce 1.250” discard sizes • Issue has been occurring for certain dies for some time – captured and root caused using real-time data • Action: Additional Alert will be set up to notify Operations team whenever a Butt Length of over 1.5” is hit • They are now able to respond immediately and avoid Engineered Scrap + Potential Downtime
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- 21. Demo 22
- 22. Demo 23
- 23. Real-Time Manufacturing Analytics © 2022 MAJiK Systems Inc. All rights reserved. Private and Confidential. Not for Distribution. Jared Evans – MAJiK Systems jevans@majik.io 1 833 MAJIK-IO www.majik.io