Discrete Sensors and PLCs

The Industry 4.0 revolution has grown in importance as well as in the minds of many organisations. Many organisations are exploring new ways to leverage IoT, its potential and benefits with an expectation of increasing the overall throughput of their existing process automation systems such as SCADA by overcoming existing challenges and also integrating the organization's entire value chain. SCADA systems, which consist of PLCs, RTUs, Sensors, and so on, are prevalent in heavy asset industries and can be reconfigured to adopt IOT in order to realign manufacturing processes and integrate them seamlessly.
  • Solution

    IoT adds value to SCADA and extends its value chain, making business more predictable, reducing costs and waste, and increasing profitability. One of the data sources for IoT is information generated by SCADA systems. Data is captured using Edge Gateway from various sources such as sensors, PLCs, and SCADA, as well as additional data captured from existing legacy systems and manual data entered by operators. All of this collected data is routed to an AI/ML & prediction engine for analytics and forecasting, after which it is stored in a cloud-based centralised database and displayed on business intelligence dashboards for data visualisation. The solution can be used for monitoring energy consumption, OEE, assets and equipment, operator health , etc. In real - time and generate alerts on anomaly detection to enable predictive maintenance.

  • Places

    The solution can be implemented in industrial setups which rely on their existing SCADA and automation systems for daily operations such as manufacturing plants, food production facilities ,mass transit systems, water and wastewater systems, electric generation, transmission and distribution systems, and oil and gas systems.

  • Need

    Since IoT has revolutionized the sheer amount of data that can be generated and collected, which when analysed creates a whole new value paradigm, existing SCADA and Legacy systems must be even more relevant in enabling upstream and downstream value creation rather than simply running processes efficiently. Most businesses are moving in the direction of developing intelligent systems that can learn, adapt, and potentially act autonomously rather than simply carrying out predefined instructions. By leveraging the internet, interconnected and discrete systems, and allowing a strong interface between applications and hardware, IOT paves a new path and opens new doors to a true digital enterprise.

  • Impact

    IoT can transform SCADA and other existing automation systems in an industrial setup by increasing standardisation and openness. It provides scalability, interoperability, and enhanced security while also assisting in improving manpower utilisation and increasing overall productivity by integrating smart maintenance, waste reduction, increased efficiency, decreased downtime, and equipment life extension. These advantages allow the solution to enhance OEE by 1-5% and also reduce maintenance and operational costs 25%-35%.