Cisco fog applications provide factory maintenance
Machine tool provider Mazak teamed with Cisco to increase its manufacturing line availability and improve machine utilization through the use of fog applications. Mazak required a common, standards-based method to securely connect and receive value from the raw data in its machine’s tools.
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“The Mazak iSMART Factory concept centers around open connectivity and the internet,” said Bran Papke, president of Mazak. “We must also provide those manufacturers the highest level of security possible, and we do so through our Mazak SmartBox technology developed in collaboration with Cisco Systems.”
According to Cisco, fog applications offers customers and ecosystem partners the ability to transform IoT sensor data and perform control functions within the distributed network infrastructure. The app ran on the network infrastructure to achieve real-time detection of anomalies and operator alerts. By processing the data locally rather than in a data center or cloud, Mazak provides manufacturers with secure, real-time processing right next to their critical data sources.
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Through adaptive learning of expected thresholds, the combined fog application and real-time analytics monitor sensors data for any aberration or deviation from expected norms. This means Mazak’s customers can now prevent downtime, predict necessary maintenance and improve equipment effectiveness from continuous monitoring and detection of sudden temperature spikes, erratic vibration patterns and changes in pressure or coolant levels.
According to the networking equipment giant, the Japanese machine tool company needed a security system that was suitable for IT and operations technology (OT) to protect it from internal and external attackers. The application needed to run on the network infrastructure on the factory floor, immediately transforming process, overall equipment effectiveness (OEE) and sensor data. The fog application needed to support the MTConnect specification for integration with existing systems and sensors. Real-time analytics were gathered thanks to Cisco’s solution, which were able to process high frequency vibration, temperature, coolant, and sound inputs to inform operator action and drive business support systems.
Outcomes and solutions
Cisco detailed some of the business outcomes that came from this partnership:
- Expanded market opportunity with Mazak SmartBox Connected Machine service.
- Cost consolidation through running fog application and real-time analytics on IoT network infrastructure.
- Rapid time to value with measurable customer impact: improved OEE, continuous customer service, and increased machine utilization.
The entire solution consisted of four key elements:
- Internet of things (IoT) connectivity from an the Industrial Ethernet 4000 (IE 4000) Switch.
- Application framework via Cisco’s IOx.
- Fog application: MTConnect.
- Real-time analytics with the Connected Streaming Analytics tool.