Smart Factory IoT solutions for production automation, analytics and reporting

The Industrial Internet of Things (IIoT) promises advancements in smart manufacturing, with which comes a smart factory revolution. Factory IoT software platforms such as zenon create interconnected and intelligent manufacturing processes that optimize industrial automation. Discover smart factory technology and zenon's role in Industry 4.0-based manufacturing.

 

Smart factory technology

Smart factory technology is built upon the transformation from traditional automation to a more open, connected and flexible system. By incorporating system-wide physical, operational and human assets, it enables factories to better manage the entire production landscape through interconnected equipment, operations and facilities, as well as to predict and make real-time adjustments to changes. The result is increased production efficiency and less downtime.

 

To create a smart factory, IoT solutions are essential. Connected IoT devices such as cameras for machine vision and sensors are needed throughout a manufacturing facility to check the status, gather data, analyze it and use insights to optimize operations. In addition to data-collecting devices, however, software compiles IoT data and allows users to monitor and control all aspects of automated production. The zenon Software Platform from COPA-DATA delivers IoT smart factory solutions to pave the way for increased productivity and enhanced supervision in the age of Industry 4.0.

 

zenon assists manufacturers with the following aspects of smart factory management:

 

  • Data collection: zenon securely collects and stores hardware-independent data from your equipment, processes and people. With its more than 300 native communication protocols, you can connect all existing devices from PLCs to business management systems or cloud applications.
  • Visualization and control: zenon displays real-time operational data in a customizable interface, allowing for increased awareness and efficient control over processes locally and remotely.
  • Data management: zenon allows you to contextualize data across equipment and facilities in one simple platform, so you can make more informed and reliable business decisions.
  • Analytics and reporting: zenon uses advanced algorithms, connects your real-time data with machine learning applications, as well as distributed intelligence and networking to make calculations and provide predictions and estimates. The software bases analysis on both historical and real-time data for the most accurate conclusions.
  • Engineering and maintenance: zenon comes with a set of powerful wizards and easy-to-use tools, so you can create and maintain your projects without needing programming skills. Through the open application programming interfaces (API) and the possibility to engineer mixed version environments due to its backward compatibility, zenon ensures high productivity for your engineering team.

 

The impact of IoT on smart factory components

Smart factory technology and IoT devices have far-reaching implications for efficiency, product quality and safety. IoT technology can empower elements of smart manufacturing such as:

 

  • Manufacturing operations: By collecting real-time data at every stage of manufacturing, IoT components reveal process redundancies and inefficiencies to be eliminated.
  • Quality assurance: The IoT components of a smart factory can collect data on product defects. Combined with simultaneously collected data on other parts of production, this data can reveal the source of quality issues.
  • Equipment maintenance: Smart factory technology can streamline equipment maintenance to minimize downtime and maximize productivity.
  • Sustainability and safety: By providing data insights into energy use, environmental performance and events like workplace injuries, IoT devices can help factories create a more sustainable process and a more positive work environment.
  • Warehouse operations: IoT can help you see how products should move in and out of your warehouse to optimize efficiency and minimize labor costs.
  • Inventory management: Use resources more effectively and automate inventory management by tracking what materials are used and restocking at the right time.

 

With smart factory technology based on zenon, you can improve these elements in food and beverage, pharmaceutical, automotive and other manufacturing industries.

 

Smart factory solutions with zenon

With zenon, you can jump start your digital transformation and make the transition to a smart factory with your existing equipment. Combined with IoT devices, the zenon Software Platform can analyze data, automate processes and improve overall operations to make your factory more productive and competitive in the future marketplace. zenon helps you implement IoT technology in your existing factory operations in the following areas:

 

Horizontal and vertical integration

A smart factory featuring zenon enables horizontal integration among machines and vertical integration across your enterprise. zenon allows you to connect machines, systems and resources, as well as share data from the sensor to enterprise resource planning (ERP). The result is a smart factory that eliminates knowledge silos in the company and streamlines communication across machines and facilities.

 

Energy data management

The factories of the future prioritize sustainability and energy efficiency. Minimizing energy consumption means cost savings for the business and reducing consumption of valuable resources for the environment. As an energy data management system (EDMS), zenon provides a company-wide profile of consumption data from your machines and processes, which empowers you to manage your usage effectively on a long-term basis. The software platform meets TÜV Süd requirements for certified energy data management and is compliant with the ISO 50001 standard on monitoring, measurement and analysis.

 

Predictive maintenance

Maintenance plays a vital role in production — if a system breaks down, it can lead to expensive downtime and delays in order fulfillment. By collecting data in real time about connected machinery, zenon predicts when you should service a machine or switch a component to avoid downtime.

 

Smart factory benefits with zenon

With zenon technology, you can improve your factory operations through these advantages:

 

  • Production throughput: zenon provides detailed data on asset performance to help you optimize their usage. Reduce asset downtime, limit change over time and maximize your capacity. Through these improvements, you can minimize waste, achieve lean production and make your operations more efficient.
  • Product quality: Let zenon enhance the quality of your product through data trends and insights. zenon provides an overview of your operations data so you can quickly locate the source of a product defect.
  • Cost efficiency: By optimizing your processes through zenon's automation and data management, you can enhance their cost-efficiency. Improve the consistency of your operations and processes and increase your overall equipment effectiveness (OEE).
  • Project scalability: Easy to integrate, zenon provides a flexible architecture scaling from single machines to unified multi-line factory solutions. Together with its extensive life cycle and backward compatibility, zenon ensures low start-up cost and cost-effective extensions of your existing production assets.
  • Optimal security: COPA-DATA is certified for the IEC 62443-4-1 security standard for industrial automation and control systems. This ensures a secure development life-cycle (SDL) of zenon that aligns with the latest industrial IT security guidelines. In addition, zenon’s unparalleled security features such as server redundancy, user authorization, and network encryption fully protect your projects from data loss and unauthorized access.
  • Improved work environment: Foster a more environmentally friendly workplace by optimizing your use of assets and operations. Improve safety for your personnel by automating laborious and repetitive activities and improving the HMI visualization for a better overview.

 

Manufacturers and system integrators can use zenon in different ways to maximize these benefits. Our experts will assist you through various training and support options so you can get the most out of zenon.

 

Plan your IoT factory automation with the zenon Software Platform

At COPA-DATA, we provide next-generation automation solutions through our zenon Software Platform. Discover how to transform your plant into a digital smart factory with zenon's IoT solutions. For more information about our software and services, contact us today.

How to efficiently automate individualization

The ongoing trend for customized products as well as the bold vision of Industry 4.0 requires maximum flexibility from OEMs, while also turning the screw on cost cutting. This balancing act cannot be accomplished manually thus preparing the stage for more automation in engineering.



Spotlight Automated Engineering

IU Magazine Article

Spotlight Automated Engineering

720 KB

Modular applications and decentralized intelligence

Flexible process concepts can break up and replace the often rigid structures of conventional automation. They shorten product time to market while optimizing efficiency.

 

Get ready to enter the exciting world of automated engineering and download our full article.

Automated engineering with zenon

Lot size 1, decreasing manufacturing costs and ever shorter product cycles. How can the ambitious goals of Industry 4.0 be achieved? COPA-DATA is working on it, with automated engineering. Start video now!

 

Automated engineering with zenon

Developing HMI/SCADA engineering

Automated engineering is nothing new at COPA-DATA, as zenon has supported the technology for more than ten years. During this time, the promising concept has been continually on the rise.

More efficiency, less errors

The demand for individualized production facilities is continually increasing, which results in higher complexity of the software controlling the machines and plants. Integrating upstream engineering systems enables efficient and flexible engineering while at the same time lowering the risk of errors.



CEO Interview - Benefits of Automated...

IU Magazine Article

CEO Interview - Benefits of Automated Engineering

319 KB

System integrators will also find automated engineering interesting, as they are normally at the receiving end of their customers’ mounting time and cost pressures.

 

In his interview Thomas Punzenberger, COPA-DATA’s CEO, explains the many positive aspects of automated engineering.

The long path to modern automated engineering

The history of automated engineering dates back to the 1940s where it was used for military and space projects. System theories and models were developed as early as the 1950s in order to map out and automate complex industrial processes and infrastructures such as metropolitan areas. It took until the 1990s to come up with a name for this development: systems engineering was born.



Systems Engineering Klaus Mainzer

IU Magazine Article

Systems Engineering Klaus Mainzer

257 KB

An important part of Industry 4.0

Buzzwords such as the internet of things, industrial internet and cyber-physical systems are more than hype and will determine the industry’s future. Today, modern automation faces more complex challenges than ever before, and bringing in automated engineering is one of the main ways to solve this.

 

In his article, Prof. Klaus Mainzer of the Technische Universität München (TUM) takes us on a fascinating journey from the beginnings of automated engineering into its future.

Hitting the market faster with DIMA

International automation technology player WAGO has been working on a concept to efficiently individualize production facilities since 2014. It should enable manufacturers to combine stand-alone production modules to create a flexible overall infrastructure which significantly decreases a product’s time-to-market. DIMA utilizes the paradigm of service-oriented architecture (SOA) and builds on the standardized approach of the NAMUR 1.12 committee.



Project DIMA

IU Magazine Article

Project DIMA

270 KB

New paths in process automation

COPA-DATA’s zenon software platform contributes to the project. zenon uses standardized descriptions of modular production facilities, called module type packages (MTP), to automatically create each individual process control system.

 

Read our comprehensive report on the DIMA project.

Automate your engineering with zenon

The software lets you experience the advantages of automated engineering in HMI and SCADA projects, providing powerful automation tools such as the zenon Excel macro, the zenon automotive generator (zag) or the project wizard.



Automated Engineering - Efficient...

IU Magazine Article

Automated Engineering - Efficient Engineering

1.1 MB

More efficient XML projects

Various applications are available for your day-to-day work. The zenon Editor allows you to work with variables in an easy and clearly laid out way using techniques such as importing/exporting with XML. The integrated PLC system zenon Logic offers even more interesting options to help you handle your projects more efficiently.

 

Efficient engineering with zenon: Read our article and learn how you can automate your engineering.

Automate engineering processes with zenon

Implementing projects in a time and cost-efficient way while minimizing the risk of error is essential in automotive manufacturing. The industry tackles these seemingly contradictory challenges by outsourcing automated engineering processes.



zenon Automotive Generator AUDI

IU Magazine Article

zenon Automotive Generator AUDI

281 KB

Data analysis, visualization and more time

AUDI AG has been using the zag for three years. The zenon automotive generator thereby takes over numerous standard processes in automotive manufacturing projects.

 

The wizard shows its strengths especially when controlling the transport of components. PLC data is analyzed and translated into easy-to-understand and clearly laid out visualizations in order to automatically assign the function blocks. This means project engineers can gain time for more challenging tasks.

 

Read our in-depth report on how zag is applied by AUDI AG.

Achieving EAS

Achieving EAS

with zenon EDMS

The Energy Auditing Scheme (EAS) is a compulsory energy assessment and energy saving identification scheme which applies to large businesses in Ireland. The Energy Auditing Scheme was established by the Sustainable Energy Authority of Ireland (SEAI) on behalf of the DCENR in response to the requirement for all Member States of the European Union to implement Article 8 of the Energy Efficiency Directive – the directive has been transposed into Irish Law as Statutory Instrument (SI) 426 of 2014, part 3 of which covers energy audits.



Roadmap to Energy Efficiency (British...

White Paper

Roadmap to Energy Efficiency (British industry)

403 KB

The good news is that…

if you use zenon as an Energy Data Management System (EDMS) to achieve ISO 50001 certified status, this should be sufficient to constitute an EAS Assessment. This is providing the EDMS:

  • has been certified during the compliance period
  • is valid at the compliance date
  • covers all of your company’s energy usage
  • is certified by a SEAI Registered Auditor

You’ll still need to notify the SEAI of your compliance.

How can achieving EAS help my business?

By implementing a framework for continuous energy efficiency improvement

If you have a transparent EDMS you can save money by consuming less energy; typically making savings of ten to 20 per cent on energy within the first five years of implementation.

By being transparent and positive about energy efficiency

The criteria of the EAS scheme, which is only applicable in Ireland, fits within the ISO 50001 certification - recognised internationally - and is relevant regardless of the size and industry of the company.

 

At COPA-DATA, we’ve been helping organisations all over the world meet ISO 50001 certification with zenon EDMS, so we can help you find a solution which suits your business’ individual needs.

By saving time and avoiding future fines

Fortunately for Ireland, there are no planned penalties for non-compliance in 2015. However, compliance assessment is scheduled to begin in 2016 and penalties (as outlined in the legislation) will be introduced at this time. By having zenon as an EDMS, you can avoid any delays in energy savings and begin saving money and resources in no time.

More on EAS, ISO 50001, EDMS and EnMS:

Video: Roadmap to Energy efficiency

Read: EU Energy Efficiency Directive (EED)

Read: 'Energy Auditing Scheme: Non-SME Audit Guidance Note 2015' published by the Sustainable Energy Authority of Ireland

Achieving ESOS

Achieving ESOS

with zenon EDMS

The Energy Savings Opportunity Scheme (ESOS) is a compulsory energy assessment and energy saving identification scheme which applies to large businesses throughout the UK. ESOS was established by the Department of Energy and Climate Change (DECC) in response to the requirement for all member states of the European Union to implement Article 8 of the Energy Efficiency Directive.



Roadmap to Energy Efficiency (British...

White Paper

Roadmap to Energy Efficiency (British industry)

403 KB

The good news is that…

if you use zenon as an Energy Data Management System (EDMS) to achieve ISO 50001 certified status, this should be sufficient to constitute an ESOS Assessment. This is providing the EDMS:

You’ll still need to notify the Environment Agency of your compliance.

Infographic: Achieving ESOS compliance: 7 simple steps

click picture to enlarge

How can achieving ESOS help my business?

By implementing a framework for continuous energy efficiency improvement

If you have a transparent EDMS you can save money by consuming less energy; typically making savings of ten to 20 per cent on energy within the first five years of implementation.

By being transparent and positive about energy efficiency

The criteria of the ESOS scheme, which is only applicable in the UK, fits within the ISO 50001 certification - recognised internationally - and is relevant regardless of the size and industry of the company.

 

At COPA-DATA, we’ve been helping organisations all over the world meet ISO 50001 certification with zenon EDMS, so we can help you find a solution which suits your business’ individual needs.

By avoiding penalties

All qualifying organisations must carry out their ESOS assessment and notify the Environment Agency by 5 December 2015. Companies who fail to comply with ESOS will be faced with fines ranging from £5,000 to £50,000. An additional £500 fine will be applied for each working day starting on the day after service of the compliance notice, until the breach is remedied, subject to a maximum of 80 days.

Read more on ESOS, ISO 50001, EDMS and EnMS:

Read: EU Energy Efficiency Directive (EED)

Read: Complying with the Energy Savings Opportunity Scheme (Version 3.0) by the Environment Agency

Read: The Energy Savings Opportunity Scheme Regulations 2014

Mit zenon fit für das 
Energie-Gesetz
“EDL-G”

Mit zenon fit für das
Energie-Gesetz
“EDL-G”

Mit dem Inkrafttreten des Gesetzes für Energiedienstleistungen und weitere Energieeffienzmaßnahmen (EDL-G) müssen sich Unternehmen im Energiemanagement neu aufstellen. Ziel des Gesetzes ist es, den Primärenenergieverbrauch in der Europäischen Union und damit auch in Deutschland bis zum Jahr 2020 um 20 Prozent zu senken. Von dem Gesetz „EDL-G“ sind alle Unternehmen betroffen, die mehr als 250 Mitarbeiter beschäftigen, einen Jahresumsatz von mehr als 50 Millionen Euro erzielen oder eine Bilanzsumme vorweisen, die höher als 43 Millionen Euro ist.



Gesetzeskonformes Energiedatenmanagement...

White Paper

Gesetzeskonformes Energiedatenmanagement (EDL-G)

868 KB

Das EDL-G sieht vor, dass alle Unternehmen, die in diese Kategorien fallen, bis zum 05. Dezember 2015 ein Energieaudit nach DIN EN 16247-1 durchführen – und in Folge alle vier Jahre. In diesem Audit müssen Unternehmen belegbare Daten zum Energieverbrauch und den Lastprofilen vorweisen können. Dies schließt ein Energieverbrauchsprofil von Gebäuden oder Gebäudegruppen sowie von Betriebsabläufen in der Industrie und industriellen Anlagen ein.

Neben der Einhaltung der gesetzlichen Vorgaben bietet Ihnen ein Energiemanagementsystem noch zahlreiche weitere Vorteile: Nachhaltige Erfolge im Ressourcen- und Energiemanagement!

Mit zenon gesetzeskonform agieren

Unsere HMI/SCADA-Lösung zenon erfüllt nicht nur die Norm ISO 50001, sondern liefert auch die Grundlage für ein Energieaudit nach DIN EN 16247-1. Aktuell bieten wir ein kostengünstiges, kompaktes Lösungspaket für Energiemanagement-Anwendungen, das Unternehmen optimal dabei unterstützt, ein EDL-G-konformes Energiemanagement umzusetzen: das zenon Energy Data Management System. Das Angebot inkludiert einen für Energiemanagement maßgeschneiderten zenon Operator sowie den zenon Analyzer inklusive ausgewählter Reports, die für das Energie-Monitoring im Unternehmen relevant sind. Ergänzend unterstützen wir Sie dabei auch gerne bei der Konzeption – für alle Interessenten kostenfrei. Unsere kompetenten Kollegen erarbeiten mit Ihnen anhand der Ist-Situation und der vorhandenen Datenquellen ein Grobkonzept für Ihr Energiemanagement, stellen Ihnen Best-Practice-Beispiele vor und führen eine Kosten-Nutzen-Analyse durch.

 

Falls Sie Fragen oder Interesse an unserem Angebot haben, steht Ihnen Stefan Reuther, unser Spezialist für Energiemanagement, jederzeit gerne zur Verfügung. Wir freuen uns auf den Dialog mit Ihnen!

Energy Management for Smart Factories

energymanagement smart factory

Energy and resource management is playing an increasingly fundamental role for manufacturers. On one hand, increasing energy expenses are becoming noticeable in production costs, and on the other hand, profitable margins can only take effect if costs are reduced.

 

Manufacturers need approximately 37% of total global energy use in 2017. Although manufacturers are starting to look for green energy solutions, they still face many challenges related to energy management:

 

  • Budget: Poor energy management can lead to high expenses when overloading machines can cause breakdowns or underloading decreases productivity. Manufacturers need to ensure they are minimizing energy usage while maximizing its utility. 
  • Data collection: Manufacturers cannot make informed decisions if they don't know how much energy each piece of machinery uses and what level of power will lead to optimal functioning. Without IoT technology, data collection requires time-consuming sampling procedures and results in data that cannot be interpreted in real time.  
  • Government assistance: To receive some kinds of government aid, such as tax incentives, manufacturing organizations in many countries must comply with certain standards for energy efficiency. Without the right tools, meeting government requirements for energy management may be difficult, if not impossible. 

 

Manufacturing companies can resolve these challenges and make more informed decisions if they know how much energy each piece of machinery uses and what level of power will lead to optimal functioning. Energy data management systems (EDMS) based on real-time data from sensors and IoT devices are therefore essential to successful digitalization and the development of Smart Factories.

 

Energy Data Management with zenon

 

What does an EDMS do?

An EDMS can support your organization by:

 

  • Collecting energy data from various sources across your infrastructure: A quality EDMS like zenon will gather data on energy usage from all areas of your organization — including production and facility management. An EDMS will automatically collect energy data from equipment regardless of its manufacturer, allowing you to see how efficiently each component is running in one convenient location. zenon can collect data effectively even in factories with decentralized and complex infrastructure.
  • Providing an overview of energy consumption: An EDMS will collect all your energy usage data in one location, allowing you to see large-scale trends in energy consumption. zenon displays energy data in real time using an easy-to-understand interface. With a clear overview of energy consumption throughout your facility, you can quickly evaluate progress toward your goals.
  • Monitoring data of new and existing equipment: Using an EDMS, you can easily monitor and compare the energy consumption of both new and old equipment. Understanding what equipment uses the most energy is key to profitability and making evidence-based purchasing decisions.
  • Identifying opportunities to increase equipment efficiency and reduce consumption: An EDMS like zenon makes it easier to analyze energy data and improve equipment efficiency. View trend curves and graphical reports, and consider data in conjunction with productivity and cost. If you notice a piece of equipment is lagging behind in productivity while using more energy than necessary, you can look for ways to replace it or improve its performance, reducing costs.
  • Evaluating deviations to ensure error-free energy provision: Every piece of equipment should receive the exact amount of energy necessary to maximize productivity. An EDMS can help you avoid costly errors in energy provision by alerting you to abnormal activity. Depending on the problem, your EDMS may even be able to resolve it automatically, allowing you to focus on other tasks. If the event requires intervention, chronological event list will ensure that you have the information you need to evaluate the deviation’s cause and prevent the error from recurring.

 

As an EDMS, the zenon Software Platform from COPA-DATA provides critical features that you will need for your Smart Factory energy management, such as Energy Performance Indicators, energy analysis, trend curves, Alarm Message Lists, Chronological Event Lists and many more.

 

Benefits of successful energy management

zenon will help you collect plant energy data from sensors and other IoT devices to monitor and manage energy consumption across the shop floor in real-time, resulting in more successful energy management efforts. TÜV Süd requirements for certified energy data management are met by the software platform, which is fully compliant with the ISO 50001 standard on monitoring, measurement and analysis. The benefits you can expect from zenon include:

 

 zenon helps you to collect plant energy data from sensors and other IoT devices to monitor and manage energy consumption across the shop floor in real-time. The software platform meets TÜV Süd requirements for certified energy data management and is compliant with the ISO 50001 standard on monitoring, measurement and analysis. The benefits you can expect from zenon include:

 

  • High efficiency: Using the data collected and analyzed by your EDMS based on zenon, you can make decisions that improve energy efficiency and boost productivity. You can even keep machinery running at the optimal voltage for productivity.
  • Cost savings: By identifying leakages and other sources of inefficiency to be addressed, as well as avoiding costly power peaks, a successful energy management solution can provide significant cost savings for a manufacturing facility.
  • Improved safety: Better energy management can help you increase worker safety by preventing machine overheating and ensuring necessary repairs occur before a malfunctioning system or inadequate power backup leads to an accident.
  • Energy reliability: Continuous monitoring of energy usage creates high operational reliability. With real-time measurements and historical data, you can see potential problems and correct them early to prevent unexpected downtime.

 

Contact COPA-DATA about Smart Factory energy management

From automating data collection and analysis to informing decisions, zenon will support every aspect of your energy management with one unified system. This hardware-independent software platform can be easily integrated into your existing production assets. In addition, zenon meets ISO 50001 standard requirements and comes with a user-friendly graphical interface and robust security features.

 

We can assist with your energy management project from start to finish and provide solutions tailored to your requirements. To learn more about Smart Factory energy management, contact us today.


Energy Data Management with zenon

Energy Data Management with zenon

1.1 MB

Road to Energy Management System

Poster

Road to Energy Management System

5.4 MB

Energy Management - IU 25 Spotlight

IU Magazine Article

Energy Management - IU 25 Spotlight

2.2 MB

Success Stories

Horizontal and vertical integration in a Smart Factory

horizontal vertical integration

Industry 4.0: Networking, communication and efficiency

Industry 4.0 allows manufacturers to produce with greater flexibility, react more quickly and, in doing so, become even more efficient – with minimal consumption of resources.

 

The Internet was invented in order to use the capacities of mainframe computers more effectively. Even now, when we have the Internet of Things (IoT), networking and the integration it makes possible are still important factors for increased efficiency. For example, in the case of correlating production data from different sources within a manufacturing operation.

 

Two of the most important factors for production in a Smart Factory are horizontal and vertical integration. Horizontal integration means networking between individual machines, items of equipment or production units. Vertical integration networks beyond traditional production hierarchy levels — from the sensor to the business level of the company.

 

Essentially, horizontal integration ensures that machinery, IoT devices and engineering processes work together seamlessly. Vertical integration, on the other hand, allows production data to be used for making business, staffing and other decisions by allowing communication between the horizontally integrated shop floor network and other systems, such as Enterprise Resource Planning (ERP).

 

Horizontal and vertical integration challenges manufacturers face

In the interconnected Smart Factory, horizontal integration ensures machinery, IoT devices and engineering processes work together seamlessly. Vertical integration ensures production data is used at higher organizational levels when making marketing, staffing and other decisions.

 

Although horizontal and vertical integration can streamline production and enable smarter business decisions, the transition can pose some unique challenges related to:

 

  • Lack of communication: Horizontal integration assumes that a factory has devices and software capable of collecting production data and sharing that data with other systems. To begin integration, you’ll need to either purchase new IoT-enabled equipment or change existing equipment to allow interconnectivity. Strategies for IoT enabling legacy systems include retrofitting them with sensors and connecting programmable logic controllers (PLCs) to the Internet using converters. 
  • Knowledge silos: Knowledge silos occur when a factory's different information systems are incapable of sharing data with one another, trapping information in one part of the machinery, production process or organization. If your architecture is already compatible and relatively new, you may be able to eliminate knowledge silos by simply integrating existing systems, setting them up to share data freely. In other cases, you may have to address incompatible architecture before you can share production data with the rest of the business.
  • Asset management: Once you've integrated machines, data systems and devices in your Smart Factory, you must continue to manage these assets to assure security and productivity. Implementing continuous network monitoring and choosing industrial software with robust security features can help with asset management.
  • Supply chain management: For horizontal and vertical integration to impact resource efficiency, supply chain management must be included in the network. Whether networking with external suppliers or integrating the internal supply chain, manufacturers need to leverage data-driven technology to ensure smooth collaboration and sound decision-making.
  • Economies of scale: Different shop floors must be horizontally and vertically integrated individually. Surveys have shown that small and medium-sized businesses spend an average of $250,000 implementing Smart Factory technology, and large businesses are likely to spend even more. The lack of economy of scale means manufacturers must make a serious investment in technology, including new software for planning, controlling, visualizing and analyzing the operational performance. The investment usually pays off, though, as the integration results in more cost-effective production, consolidated management and reduced overhead costs.

Horizontal integration with zenon

In the typical manufacturing environment, horizontal integration must connect many types of equipment. As a hardware-independent system, zenon Software Platform from COPA-DATA makes connecting disparate machines in an existing system simple, supported by a variety of key features:

  • Over 300 native communication protocols
  • Multi-project administration
  • Client/Server – Server/Client topology
  • straton binding
  • Application programming interface (API)

In one example, Sidel, a global packaging manufacturer, used zenon to integrate different PLC systems into a single platform independent of hardware and operating systems, significantly increasing management efficiency.

 

Vertical integration with zenon

Vertical integration creates connections between production and other parts of a manufacturing organization. Essentially, it networks beyond traditional production hierarchy levels — from the sensor to the business level of the company.

 

With user-friendly graphical interfaces and flexible reporting tools, COPA-DATA's zenon is ideal for vertical integration, with essential features such as:

  • Over 300 native communication protocols
  • ERP interface (SAP ERP, Microsoft Dynamics, etc.)
  • SQL Server Interface
  • Web Server or HTML5 Web Engine
  • zenon Service Grid
  • Everywhere Server (Smartphone App)
  • Cloud integration

One pharmaceutical equipment manufacturer, SKAN AG, chose zenon as a uniform interface to connect the sensors with the MES and ERP level, leading to improved business decisions.

 

Contact COPA-DATA to assist in horizontal and vertical integration

Horizontal and vertical integration may seem like a challenge in a Smart Factory, but zenon can help you overcome integration difficulties and eliminate any doubts you may have about your ability to benefit from Industry 4.0 developments. This hardware-independent software platform can be easily integrated into your existing production assets, along with a user-friendly graphical interface and robust security features.

 

At COPA-DATA, we assist with your horizontal or vertical integration projects and provide solutions tailored to your unique requirements. To learn more, contact us today.


Horizontal and Vertical Integration

IU Magazine Article

Horizontal and Vertical Integration

114 KB

Vertical integration from sensor to ERP system

Fact Sheet

Vertical integration from sensor to ERP system

792 KB

Multi Project Administration

Fact Sheet

Multi Project Administration

445 KB

Smart Factory Insights

Transformacja w inteligentną fabrykę stawia przed producentami nowe wyzwania. Poznaj siedem kroków do pomyślnego wdrożenia technologii Smart Factory.

zenon makes data collection, management and analysis much easier. Learn how manufacturing efficiency can be improved through data.

Process control automation enables manufacturers to master complex operations. Learn how to yield the many benefits of automating process control.

Konwergencja systemów IT i OT otworzyła drzwi dla bardziej inteligentnej produkcji. Jak zenon może pomóc fabryce w przejściu do Industry 4.0?

How secure is your SCADA? Prepare your SCADA system for potential cyber threats and external vulnerabilities.

Vertical and horizontal networking as a success factor in smart automobile production.