Digitisation of production

"Following the pandemic, we are facing disrupted global supply chains and bottlenecks in machine spare parts," explains Matthias Morath, PLM Innovation Consultant at Liebherr IT Services. "In addition, there has been a lack of planning certainty when purchasing new machines, new requirements in relation to the processing of machine data and IT security guidelines. This showed us that we cannot solve the networking problem by outgrowing and gradually replacing the machinery". 

The catalogue of requirements also included comprehensive monitoring of all IT components, their dependencies and services. Using automated diagnostics, related error patterns can be quickly recognised and assigned to the appropriate first and second level support. The implementation of various standardised interfaces is planned for secure remote access. Maintenance as well as problem monitoring and rectification and the realisation of optimisation options should thus be guaranteed on-site and remotely at any time.

Alliance for development work 

"Innovations need freedom and cannot be trialled in active production. This requires a playground where experts can meet and collaborate in an informal and open approach," comments Matthias Morath from his knowledge of his day-to-day work. This approach has been confirmed during testing of the IIoT Box. With the Aachner Werkzeugbau Akademie (WBA) and the European 4.0 Transformation Centre (E4TC), the range of functions has been expanded and put through its paces in close collaboration with Cisco. The WBA and the E4TC are both centres on the RWTH Aachen Campus. Cisco contributed its expertise and experience in the integration of traditional IT with OT environments. WBA contributed its technical expertise in micro service, visualisation and evaluation of the production-relevant data to the project. Pioneering solutions have been trialled in the demo factory at three production facilities at RWTH. "We welcome the open approach and close collaboration between Liebherr and Cisco. As a consultant for medium-sized companies in the planning and introduction of modern industrial landscapes, we all benefit from this," emphasises Jan-Hendrik Wiese, Head of Innovation and Digital Solutions at WBA.

Successful integration of different services

Today, Liebherr can use the new solution to connect its OT-based devices on a uniform communication platform. This has created the basis for current and future requirements for networking in the smart factory. A common example is the activation of a remote service. Network profiles in the switch can be activated on site through a key switch if required. Positive activation is indicated by a signal lamp. The alarm output of the Cisco Catalyst IE3400 Rugged Series Switch can also be used to switch individual components or areas on or off for fault diagnosis. This enables rapid automated diagnostics to be performed in the event of faults in the production process. The Catalyst IE3400 Rugged Series Switch is designed for operation in critical environments. It can be installed in a control cabinet and remains readily available even in environments with high temperatures.

Application diversity in IIoT increases productivity

By offering an IIoT Box, the basis has been created for any production facility to be networked and upgraded to a defined current standard. Using the BOX's in-house production, conversion kits can be easily created and rolled out on a large scale. Standardisation enables a joint training concept and promotes the exchange of knowledge across locations. Secure connectivity to familiar systems such as the Manufacturing Execution System (MES) and Production Data Acquisition (PDA) is also facilitated. The predictive maintenance option reduces production downtimes. Active monitoring enables an up-to-date status description across all components of the machinery. By controlling and monitoring the technical infrastructure, such as technical gases including compressed air, cooling and heating, existing resources can be utilised more efficiently. The modernised production environment should enable comprehensive transparency and optimisation of cost control. Real-time and historical data reveals waste and promotes agility. Existing systems that have been completely written off can also be retrofitted with a network. This extends the amortisation periods for the machinery. Expensive investments in new systems can be omitted. "The harmonisation and standardisation of our production with our IT environment is an ongoing process. With the IIoT Box, we have achieved the basis for greater transparency. This enables us to react with speed and agility to bottlenecks or changes," Matthias Morath sums up.