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Industrial Control Systems and Edge Computing

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APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

ENABLING AN OPERATIONAL
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APPLICATIONS
AND ANALYTICS

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Industrial Control Systems and Edge Computing
ENABLING AN OPERATIONAL ARCHITECTURE
FOR APPLICATIONS AND ANALYTICS

CONTENTS

SECTION 1:
Introduction and Research Demographics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 2:
Production Metrics and IIoT Architecture Impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 3:
Dynamics of Edge Adoption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SECTION 4:
Edge in Operational Architectures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

SECTION 5:
Use Cases Should Drive Data Architecture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SECTION 6:
Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

ACRONYM
QUICK REFERENCE
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lnsresearch.com
SECTION 1

Introduction and
Research Demographics
 Introduction
Computing infrastructure is an ever-changing landscape of technol- Establishing an Operational Architecture with the flexibility in
PAGE
ogy advancements. Current changes impact the way companies strategy to utilize distributed computing and virtualized servers
4
deploy Smart Manufacturing systems to leverage advancements. creates a production environment to leverage people, process and
This LNS Research report reflects that shift, and builds on our previous technology in a scalable manner, without the need to lock into a
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

research and developments with MESA International. specific vendor or solution construct. However, as many operations
The rise of Edge and Fog computing capabilities coupled with tradi- will rely on legacy systems to fit into an overall architecture, virtual-
ARCHITECTURE FOR

tional industrial control system (ICS) architectures provides increasing ized hosts, data management, and open API tools will be necessary
levels of flexibility. Furthermore, time synchronized applications and to guarantee a future-proof production environment.
analytics augment or in some cases minimize the need for larger Big
Data operations in the Cloud, regardless of cloud premise.
LNS Research believes that current Industrial Internet of Things
(IIoT) technologies support highly distributed intelligence. This
includes distribution of hosting and computing such that companies
TABLE OF can implement a truly distributed control and information system. The
CONTENTS
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production data and analytics to their appropriate constituencies.
4 5 6

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 Research Demographics
This research ebook is based on the 2018 edition of the Ana-
PAGE
lytics That Matter survey, ebook, and research project. The
5 19%
focus of that survey was across manufacturing executives 4%
26% 28%
responsible for operational technology (OT), but it was
5%
APPLICATIONS AND ANALYTICS

44%
ENABLING AN OPERATIONAL

open to all. To the extent possible, the analysts eliminated

vendor responses which resulted in a good cross-section
ARCHITECTURE FOR

6%
of reliable respondents. At the time of publication (June 20%
2018) the total number of responses for the analysis was 20% 28%
approximately 350.
The essential starting points for Industrial Transforma-
tion are somewhat dependent on the specific industry. That
DISCIPLINE / ROLE INDUSTRY
holds true for the application of Edge computing; the defini-
tion, location, and indeed use cases for Edge depend entire- Operations Maintenance Discrete Manufacturing
TABLE OF ly on the unique nature of each organization. Engineering Research and Process Manufacturing
CONTENTS Development
Information Technology Batch Manufacturing
Quality All Others
SECTION
1 2 3
4 5 6
13% 12%
27%
11% 34% 37%
23%
50%

26% 16%
29% 22%

GEOGRAPHY REVENUE JOB TITLE

COLOR BY HQ LOCATION COLOR BY COMPANY REVENUE
Senior Executive
North America Small: <$250M Director
Europe Medium: $250M-$1B Manager
Asia / Pacific >$1B Consultant
Rest of World All Others
 Defining the Industrial Edge
Consolidation and the centralized nature of cloud computing has There is no distinct hardware definition of industrial edge comput-
PAGE
proven cost-effective and flexible over recent years, but the rise of ing today; it’s in the eye of the beholder as to how much compute pow-
6
IIoT and mobile computing has put a strain on networking band- er or data response may be required in a given application or across
width. Ultimately, not all smart devices need to utilize cloud comput- a specific production process. Dedicated servers with virtualization
APPLICATIONS AND ANALYTICS
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ing to operate. In some cases, architects can — and should — avoid can host apps with significant footprints, store related production
the back and forth. Edge computing could prove more efficient in data, communicate to the Cloud, and perform onboard analytics in
ARCHITECTURE FOR

some areas where cloud computing operates. the footprint of an appliance, a server, or a PC in a PLC rack. For the
Edge computing enables processing of data closer to where it's purpose of this discussion, we will define the functionality just de-
created (i.e., motors, pumps, generators, or other sensors), reducing scribed versus defining the specific hardware footprint it may occupy.
the need to transfer that data back and forth between the Cloud. Above all else, organizations must agree internally on standards
Think of Edge computing in manufacturing as a network of mi- of functionality required for various processes and then on the ap-
cro data centers capable of hosting, storage, computing and analysis propriate hardware and vendor(s) to fulfill the need. When refer-
on a localized basis while pushing aggregate data to a centralized ring to Edge, it will almost always be on-premise or at-asset to avoid
TABLE OF plant or enterprise data center, or even the Cloud (private or public, over-generalizing the IT infrastructure at the plant level.
CONTENTS
on-premise or off) for further analysis, deeper learning, or to feed an
SECTION
artificial intelligence (AI) engine hosted elsewhere.
1 2 3
4 5 6
SECTION 2

Production Metrics
and IIoT Architecture Impact
 Industry 4.0 and Smart Manufacturing: Impact of Operational Architecture
Apps and analytics provide visibility and potential prescriptive re-
PAGE
sponses for immediate impact on key performance metrics (KPIs). The
8
Operational Architecture a company deploys will affect the degree of
impact on those metrics.
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL
ARCHITECTURE FOR

METRICS WILL REMAIN

On time delivery Successful NPI WIP inventory turnover

60% 37% 27%

Net profit margin OEE First pass yield

TABLE OF
CONTENTS
60% 37% 26%
SECTION
1 2 3
Average manufacturing cycle time Downtime vs. operating time Number products produced per plant
4 5 6
43% 36% 24%

Workplace injuries Number SKUs produced Average supplier incoming quality

39% 32% 23%

Capacity utilization Average changeover time None of the above

37% 30% 6%

∆ in output/throughput Mean cost per unit excluding materials

37% 29%
 Industry 4.0 and Smart Manufacturing: Impact of Operational Architecture (Cont.)
Manufacturing organizations benefit as they leverage the IIoT for
PAGE
the Operational Architecture of the future. Technology and tools
9
that are continuously evolving will bring about the widely discussed
Smart Manufacturing models. There are dozens of associated
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

technologies and uses, but this discussion focuses primarily on

manufacturing and process operations and the link to the Digital
ARCHITECTURE FOR

Twin, operational improvements and the technology shifts affecting

the metrics that matter.

INDUSTRIAL INTERNET
INDUSTRIAL INTERNETOFOF
THINGS PLATFORM
THINGS PLATFORM

APPLICATION ENABLEMENT
TABLE OF
CONTENTS • Integrated Development • Workflow and Business • Search • Engineering Content Integration / Digital Twin
Environment: JAVA, HTML5 Logic Modeler • Location Services
• SaaS - Traditional Enterprise Applica-
SECTION • IIoT Data Model and • Collaboration, Social tions, Next-Gen IoT Enabled Applications • Industrial Cyber-Security - Authentication,
Execution Engine • Mobile • 3rd Party App Store Access Control, Configuration Management,
1 2 3 Cryptography, Logging, Compliance
4 5 6

EDGE AND CLOUD ADVANCED INDUSTRIAL ANALYTICS

• Private/Public/Hybrid
• IaaS - Compute, Storage,
Network
• PaaS - Run Time, Queue,
Traditional SQL DB/DW,
Advanced NoSQL DB,
Data Historian, In-Memory
Database, Hadoop/Data Lake
• Industrial Compute / • Statistical Programming: • Statistics Based Models
Industrial Data Centers R, SAS, SPSS
• 1st Principles Based
• IIoT Gateways
• Search, Text Mining, Models
• Industrial Cyber-Security - Data Exploration, Native
Authentication, Access Control, • AI/ML Based Models
Language Processing
Configuration Management,
Antivirus/Spyware, Cryptography, • Collaboration /
Logging, Data Tagging, Compliance Visualization / Reporting

• Network Infrastructure -
Wired, Wi-Fi, Cellular, Device
Management, Device/Asset
Inventory and Visibility
CONNECTIVITY
• Communications Stan- • Complex • Industrial Cyber-Security - Authentication, Access Control, Intrusion
dards / Protocols / Data Event Detection/Prevention, Firewalls, Application Whitelisting, Antivirus/
Acquisition - OPC-UA, Processing / Spyware, Cryptography, Logging, Data Tagging, Compliance, Anomaly
MQTT, AMQP, DDS, APIs Edge Analytics Detection, Asset Inventory, Secure Media, Risk Management, etc.

© LNS Research. All Rights Reserved.

SECTION 3

Dynamics of Edge Adoption

 Digitization of Manufacturing: The Shift from Traditional Tech to Modern Equivalents
Edge can sit at the control level or above it, providing real-time
PAGE
responses and structured cost benefits.
11
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL
ARCHITECTURE FOR

EVOLUTION OF TRADITIONAL ARCHITECTURES

TRADITIONAL EMERGING OPERATIONAL

ISA-95 APPROACH ARCHITECTURE APPROACH

TABLE OF
CONTENTS MAINFRAME • Less IT infrastructure
CLOUD, ERP
Finance and analytics apps, • Deeper learning Finance and analytics apps,
SECTION
supply chain supply chain, AI and ML
1 2 3
4 5 6
DATACENTER ON PREMISE CLOUD
Production scheduling,
• Less IT infrastructure
Production scheduling, EDGE COMPUTE
• Flexible hosting
records, inventory records, inventory AND ANALYTICS:
As close to the source
as required by
L2/MES SERVERS EDGE COMPUTE response timing
• Real-time compute,
SCADA, runtime history, MES, SCADA, runtime history,
host, store
operator workflows operator workflows, app hosting

CONTROL CONTROL
• Network / control
Control, sensing, Control, sensing,
bandwidth
peer communications peer communications
 Reference Model for Analytics and Apps Requires Multiple Compute Layers
The new LNS Research take on Operational Architecture based on
PAGE
the IIoT platform views analytics in the same context as all other
12
applications. It also supports the concept of Cloud to Edge without
GUIDE TO OPERATIONAL ARCHITECTURE
implying any difference between them. The definition of Edge leans
Common Data, Apps, and Analytics
APPLICATIONS AND ANALYTICS
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towards a hardware-centric view of the enterprise – any system that

is below a plant data center (or corporate one if no plant data center
ARCHITECTURE FOR

exists) is considered part of the Edge. That’s not a hard and fast rule,
but excellent guidance to further the discussion about Operational
Architecture with distributed applications.
FIRST
PRINCIPLES
STATISTICS -
INDUSTRIAL ANALYTICS + APPS BASED
ARTIF ICIAL
INTEL LIGEN CE ( AI )
DE
VE / MACHINE T
LO
PM LEAR NING ( ML ) O NM
EN
EN
TABLE OF TE N VIR
CONTENTS NV TE
IRO
NM M EN
EN L OP
T VE
DE
SECTION
TIME
1 2 3 SERIES
ED
4 5 6 BIG DATA MODEL T UR
R UC
STRU CTURED ST
UN

DIGITAL TRANSFORMATION
FRAMEWORK by LNS Research describes
COMPUTE + STORAGE ON CLOUD
a systematic approach to simultaneous and - PR
EM GE
interconnected digital initiatives, in order to CO ISE ED
NN IV IT Y
EC CT
manage transformation across all levels and TIV
IT Y NN
E
CO
functions of the organization.
PRODUCTIO N
ASSE T
Click to learn more about the INDUSTRIAL OPERATIONS
Digital Transformation Framework
BUSINESS
 Edge is in the Eye of the Beholder
Depending on organizational viewpoint, Edge infrastructure
PAGE
can be complementary to or inclusive of level 1 or 2 control and
13
information layers of the production process. An organization can
define industrial Edge as an extension of Cloud activities or as an
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

extension of Control activities based on requirements of speed,

data structure, volume, and velocity.
ARCHITECTURE FOR

Organizational agreement on location (e.g., an unmanned

pumping station), capabilities, use cases and desired outcomes is
critical before conducting any pilots or scalable implementations.

TABLE OF
ROLE AFFECTS PERCEPTION OF EDGE
CONTENTS

SECTION
1 2 3 SMART CONNECTED ENTERPRISE
IT EXECUTIVE OPERATIONS EXECUTIVE
4 5 6 VIEW OF THE WORLD VIEW OF THE WORLD

Cloud Cloud

On-Premise

On-Premise
Edge

Edge
 Edge Adoption Lags Cloud; Edge Services Not Well Defined
Edge is still in early stage adoption, but one thing is clear: Edge devices use case. While Cloud level interfaces and apps will migrate to the
PAGE
are subject to large-scale investments from cloud suppliers to offload Edge, and industrial application hosting and analytics will become
14
bandwidth and latency issues caused by an explosion of Internet of common at the Edge, using virtual servers and simplified operational
Things (IoT) data in both industrial and commercial applications. technology (OT) friendly hardware and software.
APPLICATIONS AND ANALYTICS
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In the near future, Edge will likely increase in adoption where Benefits in network simplification, security and bandwidth
there are questions to the applicability of cloud for the specific accompany the IT simplification.
ARCHITECTURE FOR

Corporate Analytics: Location

PRODUCTION SUPPLY CHAIN FINANCE ENGINEERING CORPORATE QUALITY CUSTOMER RELATIONS

Public cloud 23% 12% 8% 9% 12% 13%

Private cloud 23% 32% 21% 22% 20% 24%

TABLE OF
CONTENTS Corporate data center 40% 42% 56% 42% 45% 41%

SECTION Plant data center 14% 13% 11% 18% 15% 13%
1 2 3 Edge device / asset 5% 6% 5% 5% 12% 8%
4 5 6
None 6% 6% 6% 9% 7% 12%

Industrial Analytics: Location

PRODUCTION INVENTORY / LOGISTICS MAINTENANCE QUALITY

Public cloud 24% 15% 10% 13%

Private cloud 22% 30% 25% 22%

Corporate data center 38% 44% 48% 37%

Plant data center 28% 31% 32% 38%

Edge device / asset 8% 10% 8% 7%

None 4% 3% 4% 5%
SECTION 4

Edge in Operational Architecture

 Traditional Models Challenged by Highly Distributed Intelligence and IIoT
Across operations segments, utilization of distributed data processing PLC) and highly distributed compute power in edge devices hosting
PAGE
will be provided in three primary areas: Cloud, Edge, and controller. applications and analytics tied closely to the PLC/DCS/device and
16
As processing power and reliability of in-plant devices improve, its attributed data. Where common data types can be structured or
more cloud operations will move closer to the asset to eliminate semi-structured, edge devices can act as virtual hosts for apps and
APPLICATIONS AND ANALYTICS
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complexity and latency. analytics that span machines or lines providing visibility, historians,
This compression of compute power will ultimately result in tracking and analytic functions.
ARCHITECTURE FOR

more control-based data processing (PLC-based analysis or PC in the

Big Data Analytics, Collaboration, and Mash-Up Apps

TABLE OF
CONTENTS

ANALYTICS & APPS ANALYTICS & APPS ANALYTICS & APPS

SECTION
1 2 3
4 5 6

Connectivity and Data Model

EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS

AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS

EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS
AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS

SUPPLIERS OPERATIONS CUSTOMERS & PRODUCTS

 Adding Compute Capabilities to Common Reference Architecture
Operational views of the architecture have focused on network archi- While cloud platforms have become popular in their adoption
PAGE
tecture and security while users continue to deal with legacy control for advanced industrial analytics, the latency and costs of pushing
17
and network diversity issues. Connectivity between OT and IT and data through cloud services may not be the best answer for real-
the inherent security measures are necessary however these architec- time impact on production issues. Adding Edge computing to the
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

tures fail to address the distribution of compute and hosting activities Operational Architecture allows us to simplify data flows, security
necessary for effective production management and analytics. and network traffic while maintaining the integrity of the converged
ARCHITECTURE FOR

plantwide ethernet (CPwE) standards.

LEVEL 2 Connectivity: Industrial Networking

OPERATIONAL
ARCHITECTURE ENTERPRISE

Plant Data
Center /
TABLE OF Firewall Application
CONTENTS External DMZ/Firewall External DMZ/Firewall Server
Big Data Analytics, Collaboration, and Mash-Up Apps

Plant Data Center /

SECTION Application Server
ANALYTICS & APPS ANALYTICS & APPS ANALYTICS & APPS Core Switches
1 2 3 Firewall
Controller

4 5 6 CELL 3
Edge
CELL 4
Device

Connectivity and Data Model

Edge Device Firewall
EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS
AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS

EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS EDGE ANALYTICS
AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS AND APPLICATIONS

SMART CONNECTED
Drive
Distribution DEVICES AND MACHINES
Switch
SUPPLIERS OPERATIONS CUSTOMERS & PRODUCTS
ON
TI SECURIT Y

A
UR
FIG
Gateway to

D AT
ON
SE TUP AND C
Edge Plant or

A
Controller
Device IoT Network

HARDWARE SETUP
Controller with

Y
& INSTALLATION
Edge Device

VIT
I/O

TI
EC
FUNCTIONS NN
CO

Mobile Device
CELL 1 HMI Instrumentation CELL 2

PLANT

PLANT DEMILITARIZED ZONE

ENTERPRISE

INTERNET
 Edge Is Powering Up
Manufacturing is only one of many IoT universes where Cloud and Edge a company could decide to provide sufficient processing power in a
PAGE
coexist. However, the growing number of IoT devices and applications PLC to run local analytics. That might be cost-effective and fit with
18
requiring immediacy of response dictates that more cloud-like the analytics goals, but it doesn’t preclude the company from running
functions will move back to the Edge where on-sight management and analytics elsewhere, as long as there is a logical connection to the
APPLICATIONS AND ANALYTICS
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response can be managed similarly to a hosted public environment. architecture without being tied to hardware.
Eventually, the Cloud will be overwhelmed by smart transportation, Ultimately, decisions about PLC versus Edge versus Cloud-based
ARCHITECTURE FOR

cities, infrastructure, agriculture, and healthcare providers and the
dilemma of too much cloud data will sacrifice time-critical applications.
Further, the sophistication of algorithms and the data thirst of machine
learning will require ever more compute power in the Cloud.
Every major cloud provider recognizes that the growth of IoT
devices will require more localized cloud services with less latency
and deterministic closed-loop response. Therefore they are investing
TABLE OF billions of dollars into Edge compute infrastructure. Similarly, PLC
CONTENTS
vendors are providing more robust in-rack solutions for compute and
SECTION
minor app hosting to provide high response without the dependencies
1 2 3
on outside providers. The ultimate answer will be a compute power
4 5 6
shift to smaller, at-the-asset devices that OT staff can manage with
minimal support post-startup.
Response, reasoning, and reaction in real time will be in the fluid
edge domain, shared by PLC-based compute and stand-alone edge
hosts. This, in turn, will save cloud services for non-time critical data
aggregation and analytic functions.
We don’t differentiate between applications and analytics
running at the Edge from those running in the Cloud. An Operational
Architecture is primarily software-based, and applications and
hosting and analytics depend on data volume, structures, and velocity
accompanied by the response latency and the degree of difficulty in
data normalization between disparate data producers.
For example, a PC in a PLC may host a historian or light analytic
apps but may not be suitable to aggregate other sensor or machine
data outside its specific vendor's legacy network without extensive
programming across PLC platforms. An on-premise, supplemental,
edge device may be:
• Simple to configure as a virtual host;
• Capable of hosting multiple (and larger) apps and analytics
across more machines;
• Easier to execute necessary data normalizing and protocol
conversion techniques;
• Better at unburdening in-rack processing for more reliable
speeds and memory utilization;
• Easier to configure for high-reliability situations;
• Easier to upgrade and update for evergreen operations; and

analytics can run anywhere in the enterprise architecture that • Better to eliminate cloud latency issues while still utilizing
makes sense. This approach means you can build the Operational cloud for more extensive data operations.
Architecture without concern for hardware limitations. For example,
 The Evolving Role of Edge Computing
Distributed control and compute will merge as cloud applications This movement to the Edge, regardless of platform, solves many
PAGE
become more portable and edge devices become more powerful, issues relating to IT infrastructure and cloud-based hosting or
19
including additional power at the controller. aggregation: network availability, latency, bandwidth, and security
Real-time analytics, artificial intelligence (AI) and app hosting specifically.
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

at the Edge will form virtualized intelligent agents, supplementing

traditional PLC or DCS control. In some cases, companies will
ARCHITECTURE FOR

equip devices themselves with chips that contain AI or with

analytic chips embedded.

EDGE SOLVES INFRASTRUCTURE ISSUES FOR OPERATIONAL ARCHITECTURE

TABLE OF
CONTENTS
PLC/PAC/PC
SECTION Control /
1 2 3 Network EDGE AGILE
4 5 6
COMPUTE
Process
DCS Control / APP
HOSTING CLOUD
Network AGGREGATION
EDGE AGILE BIG DATA
=
Robotic HOSTING
ANALYTICS
LATENCY
Control /
Network
EDGE
Network ANALYTICS
LATENCY
Appliance

COMPUTE CAPABILITIES
 Edge Gains Traction
Edge computing will become more necessary as analytics become want to be able to store fast and voluminous data locally for a short
PAGE
more mainstream and Cloud becomes more crowded. As we move time while we conduct local analytics. Longer term decision making
20
into more advanced fields such as Edge analytics and Big Data ana- will take place at a higher level in the data stack (perhaps in MOM
lytics in the Cloud, data abstraction and cleansing will become ever or in the Cloud) and require reduced velocity and volume through
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

more important. Managing local analytics at the deep Edge (e.g., on consolidation. Similarly, the longer-term feedback loops will not re-
a motor controller) and directly feeding the control system changes quire much speed or volume, but they must deliver the necessary
ARCHITECTURE FOR

the dynamics of data. We often talk about the “four V's” of data – feedback to the system as designed.
velocity, volume, variety, and veracity. In the deep Edge example, we

EXTENDED PERSPECTIVE OF CONTROL

TABLE OF
CONTENTS
Live Data In

SECTION
1 2 3 Aggregate Data
4 5 6
ANALYTICS APP

MACHINE
PLC
EDGE CLOUD
STORAGE

Prescriptive Advice

Control Command
SECTION 5

Use Cases Should Drive

Data Architecture
 Data Architecture Considerations
When building the data and analytics architecture, companies
PAGE
should consider:
22
• DATA LOCATION: Edge (device/asset), on premise (plant
APPLICATIONS AND ANALYTICS

data center, enterprise data center), Cloud

ENABLING AN OPERATIONAL
ARCHITECTURE FOR

• DATA SPEED: decision time and bandwidth constraints;

streaming/protocols; historical; pointers or replicated

• DATA TYPE: structured, semi-structured, unstructured

What are the top IIoT use cases your company
• ANALYTICS MODEL: statistical, first principles, artificial
is pursuing today?
intelligence (AI)/machine learning (ML)
(N=252, all respondents)

TABLE OF
CONTENTS
Remote monitoring 29%
Energy efficiency 25%
SECTION
1 2 3 Asset reliability 24%
4 5 6 Quality improvement 23%
Production visibility 23%
Internet enabled products 22%
Business model transformation,
e.g. selling capacity
19%
Asset and material tracking 19%
Traceability and serialization 17%
Customer access to information 15%
Improving safety 12%
Supplier visibility 6%
Improving environmental
performance 5%
0% 5% 10% 15% 20% 25% 30% 35%
 Use Case Scenarios: Edge Application Hosting and Analytics
Thin client hosting of operator intelligence, historians, light analytics.
PAGE
23
Sub-second decision making, large volumes of streaming data with
bandwidth constraints, including:
APPLICATIONS AND ANALYTICS
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• Advanced process control

ARCHITECTURE FOR

• Model predictive control

• Quality inspections

• Device failure

TABLE OF
EDGE APPLICATION HOSTING AND ANALYTICS SMART CONNECTED
CONTENTS
DEVICES AND MACHINES
SECTION
Connectivity: Industrial Networking
1 2 3
4 5 6 ON
ENTERPRISE TI SECURIT Y

A
UR
FIG
Plant Data
Center /
Firewall Application

D AT
ON
External DMZ/Firewall External DMZ/Firewall Server

SE TUP AND C

A
Plant Data Center /
Application Server
Core Switches
Firewall
Controller

CELL 3 CELL 4
Edge
Device

Edge Device Firewall

HARDWARE SETUP
SMART CONNECTED
Controller with

Y
& INSTALLATION
Drive
Distribution DEVICES AND MACHINES

Edge Device
Switch

VIT
ON
TI SECURIT Y
A
UR
FIG

Gateway to

TI
D AT
ON
SE TUP AND C

Edge Plant or
A

Controller
Device IoT Network

EC
NN
HARDWARE SETUP
Controller with
Y

& INSTALLATION

FUNCTIONS
Edge Device
VIT

I/O

CO
TI
EC

FUNCTIONS NN
CO

Mobile Device
CELL 1 HMI Instrumentation CELL 2

PLANT

Mobile Device
CELL 2
PLANT DEMILITARIZED ZONE

ENTERPRISE

INTERNET
 Use Case Scenarios: Edge On-Premise Analytics
Seconds or longer decision making, sufficient bandwidth, supporting
PAGE
existing on-premise applications, data type limitations, or data sharing
24
limitations, including:

• Production performance dashboards

APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

• Reliability-centered maintenance
ARCHITECTURE FOR

EDGE ON-PREMISE ANALYTICS

Manufacturing
TABLE OF
CONTENTS Enterprise Manufacturing Intelligence (EMI)
ENTERPRISE MANUFACTURING INTELLIGENCE (EMI)
SECTION
1 2 3 Role-Based Drill-Down
KPIs & Alerts Analytics
4 5 6
Continuous Business Units, Sites,
Improvement Projects Products, Assets, Teams
Edge Device Role-based
enables hosting KPIs and
and analytics analytics
Corporate Offices Utilities Manufacturing Distribution
& Warehousing
PRODUCTION DATA:
Schedules • Orders
Materials • Output
BUSINESS DATA: ENERGY DATA: PRODUCTION DATA: LOGISTICS DATA:
Yield • Quality
Customers Price Schedules • Orders Schedules • Orders
Partners Usage Materials • Output Inventory Efficiency
Plans • Orders
Costs • Assets
Renewables
Yield • Quality Shipments Assets • Personnel
Efficiency Facilities • Assets
Materials Efficiency Projects Assets • Personnel Personnel Safety
Compliance Demand Response Safety Safety
 Use Case Scenarios: Edge to Cloud Analytics
Seconds or longer decision making, sufficient bandwidth, supporting
PAGE
cloud applications, Big Data requirements, and data sharing
25
requirements, including:

• Asset performance benchmarking

APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

PERFORMANCE DASHBOARD DIGITAL TWIN SAFETY DATA

• Fleet/plant network visibility and benchmarking
ARCHITECTURE FOR

Cycles Efficiency E-Stop Activations

22.36%
• OEM monitoring and services Machine Guarding Opened
0.994%
Light Curtain Tripped
17.13%
Energy Money

EDGE TO CLOUD ANALYTICS

$
0100010111011000100101
010010001
PERFORMANCE DASHBOARD
0100010111011000100101
0100010111011000100101 0100010111011000100101
010010001
010001011101
10110111010010010001 010010001
PERFORMANCE DASHBOARD
TABLE OF
Cycles Efficiency
Cycles Efficiency 0100010111011000100101 0100010111011000100101
10110111010010010001 010010001
CONTENTS
0100010111011000100101 0100010111011000100101
0100010111011000100101
10110111010010010001

0100010111011000100
010010001 10110111010010010001 10110111010010010001
010010001 0100010111011000100101
SECTION 10110111010010010001
10110111010010010001
10110111010010010001 010010001
Energy Money
0100010111011000100101 010010001
1 2 3 Energy Money 10110111010010010001

4 5 6 $ 0100010111011000100101 10110111010010010001
0100010111011000100101
$ 010010001
0100010111011000100101
010010001
0100010111011000100101
010010001
0100010111011000100101
0100010111011000100101
10110111010010010001 010010001
0100010111011000100101
0100010111011000100101
10110111010010010001
0100010111011000100101
010010001 10110111010010010001
010010001
10110111010010010001
10110111010010010001
0100010111011000100101
0100010111011000100101
010010001
SECTION 6

Recommendations
 Aligning People, Processes and Technology
When mapping out an Edge strategy, manufacturers should avoid PROCESS
PAGE
making it just a discussion about technology; indeed it’s about Don’t underestimate the potential for Edge to offload cloud-based
27
properly aligning people, processes and technology to create the algorithms and AI to on-premise edge appliances. This scenario
right environment to drive outcomes. may signal the need for changes in process control and operator
APPLICATIONS AND ANALYTICS
ENABLING AN OPERATIONAL

workflows to accommodate immediacy of response.

TECHNOLOGY:
ARCHITECTURE FOR

• Companies will benefit with easier hosting of more PEOPLE

complex apps provided by emerging software-as-a- Skills required to manage Edge/Cloud and analytics transitions are

service and rising dependence on virtualization. in high demand. Simplicity at the OT level is key to enabling the
workforce. Industrial companies will need to up their production
• The potential for machine-as-a-service and evergreen
optimization game without becoming dependent on service
upgrades will grow dramatically using edge computing
providers or IT resources to manage hosting.
on-machine.
TABLE OF
CONTENTS • Production problem resolution will accelerate with
the rise of scalable analytics and IA on small footprint
SECTION
1 2 3
edge computing devices. It will require less network PEOPLE PROCESS
4 5 6 bandwidth and sidestep many Cloud security risks
when they use Edge on-premise.

• Edge in the PLC rack is a viable option today as are

Edge compute and IIoT gateway systems; PC-based
solutions are limited but that may change.

• Don’t discount the potential for network devices to

manage the industrial control system (ICS) software
suite, or potentially real-time control kernels.

TECHNOLOGY
 Recommendations
Regardless of where the company is in its Industrial Transformation,
PAGE
it should think and act strategically to ensure greatest success, and
28
maximum benefit:
Author:
APPLICATIONS AND ANALYTICS

1. DO WHATEVER IS REQUIRED TO ENSURE THE OPERATIONAL ARCHITECTURE Matthew Littlefield

ENABLING AN OPERATIONAL

strictly supports the organization’s Strategic Objectives. Principal Analyst

ARCHITECTURE FOR

matthew.littlefield@lns-global.com
2. ESTABLISH CONSENSUS ABOUT DATA MANAGEMENT, the analytics
strategy, and the artificial intelligence implications of Industrial
Transformation initiatives:

• Examine functional, vertical and horizontal pro-

cesses for improvement Connect:
• Drive organizational alignment on decision factors
TABLE OF
CONTENTS
ACRONYM
that will dictate on-premise or off; Edge or Cloud; QUICK REFERENCE
VIEW ON BLOG
SECTION device, appliance or server-based compute and host
1 2 3
• Don’t forget about data location, decision time,
4 5 6
bandwidth constraints, data type, and analytics type

3. INDUSTRIAL USE CASES SHOULD DRIVE THE DATA ARCHITECTURE. Archi-

tecture should be Edge and Cloud, not, Edge versus Cloud (con-
Presented by:
sider analytics and virtual hosting).
License to distribute this research
4. START WITH SMALL PROJECTS (as pilots) to drive initiatives, with report has been granted to:
the right platform to scale quickly.

© LNS Research, 2018. All Rights Reserved.