Advanced technologies in equipment maintenance – Internet of ThingsProf Igor Kuzle, PhDUniversity of ZagrebFaculty of electrical engineering and computing

CROATIA Osijek

Split

Dubrovnik

Zagreb

Rijeka

Zadar

Pula

CROATIA Marco Polo

Nikola TeslaJosip Broz 

Tito

BIGGEST AND OLDEST CROATIAN PUBLIC UNIVERSITY

FOUNDED IN 1669 BY EMPEROR AND KING LEOPOLD I HABSBURG

Grantied status and privileges of university to Jesuit Academy of Royal Free City of Zagreb

OLDEST UNIVERSITYIN SOUTH-EASTERN EUROPE

Today 30 faculties, 3 art academies and 1

university center 70.000 students (48.5 % of all

students in Croatia) 7.500 academic and administrative

staff

50 % of annual research output

Today 30 faculties, 3 art academies and 1

university center 70.000 students (48.5 % of all

students in Croatia) 7.500 academic and administrative

staff

50 % of annual research output

University of Zagreb

Internet of Things

Source: Dr. Kayarvizhy N. – Introduction to IoT

Internet of Things

Internet of Things (IoT) is a computer concept based on the idea that all common physical objects are connected to the Internet and have the ability to identify themselves with other devices. 

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Internet of Things is aroundCyber‐physical systems

• things that  have unique identities, we can find it(object + identity become more important that object alone)

• things that are traditionally not associated with the Internet(pumps, motors, utility meters, car engine etc.)

• things communicate and exchange dana (data base), they can becontrolled from anywhere. In spite of limited computing resources of single object connection to global Internet network enable new possibilities of monitoring, control and advanced services.

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Things connected to Internet

Izvor: Cisco IBSG

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50% of connected devicesdeployed between 2015 and 2025 will be industrial

Kevin Ashton 1999.

Smart devices&Ambiental inteligence• Two‐way or multi‐way communication between objects• Object can generate data continuously• “Smart” devices should contain an OS that runs Apps.

• Requirements for the „smart environment” ‐ object can communicate with and receive orders from network and act based on these orders.

• Coordinate actions of objects is known as ambiental intelligence.

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10

Internet appears everywhere in the worldIt is primarily connection between people

Idea: Move from Internet of People    Internet of Things

Internet of Things is a plan to connect things also using the same medium

Source: Dr. Kayarvizhy N. – Introduction to IoT

Connectivity From any time, any place, connectivity foranyone, we will now have connectivity foranything!

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Internet of Things ‐ Evolution

Source: Dr. Kayarvizhy N. – Introduction to IoT

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Difference between M2M and IoT

Source: Dr. Kayarvizhy N. – Introduction to IoT

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Why IoT is happening now? 

•Advancements in: (1) sensor technology ‐ tiny, cheap, variety, (2) cheapminiature computers, (3) low‐power wireless communication, (4) capablemobile devices, and (5) power of the cloud. 

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Accelerometer Pulse Sensor

Force Sensor VGA Camera

Bluetooth LE (up to 2 years lifetime on  a single coin‐cell 

battery)

(1)

(2)

(3)

Lily TinyFlash: 8 KbytesPin Count: 8 Max. Operating Freq: 20 MHzCPU: 8‐bit AVR Max I/O Pins: 6 Ext Interrupts: 6 SPI: 1, I2C: 1

IoT Challenges

Big dataData in SILOS ‐ Cloud

Security (related to data storage & residency)Loss of reputation/credibilityLoss of revenue and time

Rapid EvolutionMultiple user types with different requirements

Connectivity

Data is increasing exponentially• 90% of all the data that has ever existed

was created in the last 2 years

Cloud‐based IoT Big Data applications 

Massive monitoring 

Real‐time actionable insight 

Observation

Performance and optimization

Proactive and predictive

Prescriptive and descriptive

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Convergence of IoT, big data and cloud• Number of billions of connected devices is an indicator of IoT. The connectivity is just an enabler but the real value of IoT is on data (data‐driven economy).

• For Big data, data collection is one of the main concern, and IoT can play an important roles for data collection and data sharing.

• Cloud offers Everything as a Service business model for IOT and big data. 

is a King, Big data is a Queen and Cloud is a Palace.

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What sectors use the IoT? 

• IoT allows objects to be sensed and controlled remotely across existing network infrastructure Improved efficiency, accuracy and economic benefit Operations efficiencies  

Asset management and maintenance  

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Market size

10 107

5 5 4 3 25

2

8

40 40 40

25

15 1512 12 12

5

30

0

5

10

15

20

25

30

35

40

45

Discretemanufacturing

Transportationand logistics

Utilities B2C Healthcare Process Energy andnatural

resources

Retail Government Insurance Other

Spen

ding

in b

illion

U.S

. dol

lars

2015 2020*

Source(s): BCG; ID 666864

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Spending on Internet of Things worldwide by vertical in 2015 and 2020 (in billion U.S. dollars)Internet of Things spending worldwide by vertical 2015 and 2020

1.590

350

1.160

150

3.700

930

740

1.660

850

170

200

410

70

1.210

160

210

930

560

0 500 1000 1500 2000 2500 3000 3500 4000

Human

Home

Retail environments

Offices

Factories

Worksites

Vehicles

Cities

Outside

Impact in billion U.S. dollars

High estimate Low estimate

Source(s): McKinsey; ID 580778

Forecast economic impact of the Internet of Things (IoT) in 2025 (in billion U.S. dollars)IoT economic impact forecast 2025, by sector

Industrial IoT – Maintenance 4.0

Industrial Internet of Things4th industrial revolution

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AutomationData 

exchange2000+

Compute1970+

Mass production1900+

Engines1800+

The era of industry digitization ...

IoT: communicationbetween man, products, systems and machines

Mechanical assistance Electronics andcontrol systems

Maintenance 4.0

Industry 4.0 Includes

‐ The internet of things,‐ Big data,‐ Improved diagnostics, ‐ Shared protocol,‐ Augmented reality, ‐ Cyber‐physical systems, ‐ Cloud computing, ‐ Cognitive computing‐ Robotics. 

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Wout Theuws, Bosal (Belgium)

Source: Deloitte,

SmartBuildings

SmartHomes

SmartGrid

SmartMobility

SmartLogistics

Smartproducts

andmachines

SmartServices

Internet ofdata

Internet ofpeople

Internet ofservices

Internet ofthings

SmartFactory

Industry 4.0

Industry 4.0 environment

Features:• monitoring the process in the real world• creating a virtual copy of the factory• making decentralized decisions• interface for the communication between smart objects and humans

CPS is a system that integrates virtual and physical processes, using embedded computers and the Internet.

(Lee, 2008)

“

Cyber-physical system (CPS)

©N. Štefanić

1

Smart andconnectedproducts

2

Digitization of manufacturing,

services, public

administration and public services

3

Optimal use of resources

4

Standardizationand legal

regulations

5 6 7

Digital knowledgeand skills

Robotisation Cybersecurity

IoT / IoS / IoE/ Big Data /

“From product to integrated

system” model

Innovations / New business models / Lower

costs

Productivity/ Competitiveness/

Renewable sources of

energy/ PROJECT:

Give a chanceto Nature

Integrated development of

education system / New types of jobs

Communication of robots,

machines and people /

Application of robots in

production and services /

Augmented reality

Technical standards/ Data

ownership/ Monitoring and

control of people/

Communication protocols

Model of cyber security and

safety in Industry 4.0

Digital transformation in 7 steps

Source:Capgemini Consulting, 2015

Properties of smart machines

Industry 4.0 ‐ Maintenance 4.0

• Industry 4.0 creates what has been called a "smart factory". Within the modular structured smart factories, cyber‐physical systems monitor physical processes, create a virtual copy of the physical world and make decentralized decisions

• Over the Internet of Things, cyber‐physical systems communicate and cooperate with each other and with humans in real time, and via the Internet of Services, both internal and cross‐organizational services are offered and used by participants of the value chain.

• Maintenance is directly concerned by these new technologies where diagnosis, prognosis and all maintenance processes based on data collection and analysis will be strongly improved.

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Aspects of Maintenance 4.0

• Safe, healthy, (cyber)security, environmental • Maximize asset availability― Big data analatics

data moving back to the edge reliability

― Communications systems; Wireless― Physical‐to‐digital‐to‐physical (P‐D‐P) loop informations

• Predictive maintenance― The Internet of Things (IoT) sensors video― Smart factory; analytical and cognitive technologies so that decisions 

are made correctly and on time,― Spare‐parts management

• Spare‐parts management― 3D printing

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Wout Theuws, Bosal (Belgium)

IoT Predictive maintenancePredictive maintenance: Reduce costs by 10 ‐ 40%, Reduce downtime up to 50% Reduce capital investment 3 ‐ 5%

• Based on sensors. Sensors can send out data on the status of parts and components, allowing manufacturers to analyze this data to predict part failure and, thus, avoid breakdowns: When a failure is likely to occur. The potential extent of the failure. Which components will be associated with the failure.

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Remote monitoring

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IoT Predictive maintenance• The average cost of IoT sensors dropped from nearly 60% in the past decade

30% and 40% of preventative maintenance expenses are spent servicing assets with low failure impacts. IoT allows manufacturers to focus on machines that actually need attention. IoT enable manufacturers to put advanced machine learning technology to work. By accurately mapping user behavior, identifying failure patterns and quickly recognizing recurring issues, original equipment manufacturers (OEMs) will be able to design out failures, improve their product and guarantee uptime. 

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IoT Predictive maintenance

• Predictive maintenance. With more and more systems shipping with Internet connectivity, the concept of predictive maintenance is likely to expand exponentially in the Internet of Things.

• Real‐Time Data Analysis. The Internet of things takes M2M to the next level by including a third element: data. The availability of all machine data in one virtual network gives original equipment manufacturers (OEMs) the ability to aggregate and analyze the data to generate better predictive analytic models.

• Accurate Performance Metrics. Availability, reliability and other key performance metrics such as mean time between failures (MTBF) and mean time to repair (MTTR) can be calculated automatically by the system and fed to reporting dashboards.

• Automatic Software Upgrades. Internet‐connected machines make the software upgrade process easier and more efficient. When software fixes or patches are needed, the OEM vendor can push the upgrades to all systems in the fleet at the same time without customer assistance.

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IoT Predictive maintenance

• Recommended Repair Actions. Repair options can be taken automatically by the system, and actions can be recommended to the technician if necessary. All possible failure data will be used to direct the repair, including system operating conditions at the time of failure, previous repair data from the computerized maintenance management system (CMMS), wear patterns and operating data from the equipment fleet.

• Tighter Parts and Inventory Control. Effective inventory control can have a significant impact on limiting equipment downtime and controlling maintenance budgets. Connected stockrooms that proactively monitor inventory movements and stock on hand to ensure the site is only holding what is needed will become commonplace in facilities everywhere.

• Accurate Performance Metrics. When it comes to unplanned breakdown maintenance, imagine connected assets such as wind farms, substations and pumps generating their own work orders in the CMMS with a proposed list of action items and recommended list of spares to complete the job.

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IoT Predictive maintenance• Reduce unplanned downtime to 3.5% – Amount  of unscheduled downtime against total availability

• Improve Overall Equipment Effectiveness to 89% –Availability x Performance x Quality = OEE

• Reduce maintenance costs by 13% YoY – Total maintenance costs including time and personnel

• Increase return on assets (RoA) by 24% – Profit earned from equipment resources through improved uptime.

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Example: Smart Loos 

Found in Heathrow’s Terminal 2, these smart loos have embedded sensors that track people’s movement and bathroom flow, and can alert maintenance crews if there’s a problem

London’s Heathrow Airport 

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IoT Analytics (Examples)

•Categories of applications include: (1) push notifications, (2) predictive maintenance, and (3) real‐time stream analysis. 

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US Air Force saved $1.5M through real‐time vehicle 

tracking.https://www.rtinsights.com/u-s-air-force-sees-benefits-from-condition-based-maintenance/https://www.thyssenkrupp-elevator.com/en/

ThyssenKrupp predicts when to repair elevators

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TAP diagnostics example

IoT Analytics (Examples)

•Categories of applications include: (1) push notifications, (2) predictive maintenance, and (3) real‐time stream analysis. 

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http://www.fool.com/investing/general/2016/04/29/what-the-internet-of-things-means-for-car-companie.aspx

Corporate aspect• IoT is a transformational force that can help companies improve performance through IoT analytics and IoT Security to deliver better results.

• IoT platforms can help organizations reduce cost through improved process efficiency, asset utilization and productivity.

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The Future of IoT

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Sense of connection!

“Nothing ever exists entirely alone; everything is in relation to everything else”‐ Buddha

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