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Page: 1 | 2013-04-23| © ProcessIT Innovations
ProcessIT Innovations
Anders OE JohanssonProcessIT Innovations
www.processitinnovations.sewww.ProcessIT.EUwww.processindustriellautomation.seanders.oe.johansson@ltu.se
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Bothnia Bay Areaplants &facilities
Tornio
Kemi
Oulu
Raahe
Kokkola
Örnsköldsvik
Umeå
Skellefteå
Kalix
Gällivare
Kiruna
Rovaniemi
Mining andsteel production
Mechanichalindustry
Pulp andpaper
Metals andstainless
Energy
• Boliden Skellefteå Fields• Boliden Rönnskär• Skellefteå Kraft
• Alimak• Brokk
• Hydrauto• KMT
• Boliden Kokkola
• Rautaruukki
Piteå
Luleå
• Stora Enso• Kemira
• Outokumpu Mine• Stora Enso
• Metsä-Bothnia
• Stora Enso
• Outokumpu stainless
• Billerud
• LKAB• Nybergs Mekaniska
• LKAB• Mecon
• Boliden Aitik
• Ferrufom• Gestamp Hardtech
• SSAB• LKAB/EBF
• swerea-MEFOS
• SCA• Smurfit Kappa• BL Gasification
• SCA• Bio Fuel• Komatsu
• Volvo• Ålö
UmU
LTU
UoO
Ore to steel
Precious metals• Domsjö• Mondi• M-real• SEKAB
• BAE-Systems• Hägglunds Drives• MacGregor Cranes
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ICT Trends for device growth Towards Trillion Node Net (cum grano salis)
● "[In 10 years' time], everything hasconnectivity. We're talking about 50 billionconnections, all devices will haveconnectivity...” Håkan Djuphammar, VP ofsystems architecture, Ericsson (2009)
● “...at least 20 billion connected devices by2020 and a 300-fold increase in traffic...” JohnWoodget, global director, telecoms sector,Intel (2009)
● ... the smart grid network will be “100 or 1,000times larger than the Internet” Marie Hattar,vice president of marketing, Cisco NetworkSystems Solutions
● “The next billion SAP users will be smartmeters” Vishal Sikka, CTO of SAP (2009)
Källa: SAP
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The BIG picture World population
increase x 4
World population
increase x 4Globalaeconomy
x 20
Globalaeconomy
x 20
Källa: McKinseyGlobal Institute
Blue Institute | Örjan Larsson | mars 2013
Demand on resources increased
600 to 2 000 %
Demand on resources increased
600 to 2 000 %
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The BIG picture World population
increase x 4
World population
increase x 4Globalaeconomy
x 20
Globalaeconomy
x 20
Källa: McKinseyGlobal Institute
Blue Institute | Örjan Larsson | mars 2013
Demand on resources increased
600 to 2 000 %
Demand on resources increased
600 to 2 000 %
The BIG Picture
Källa: McKinseyGlobal Institute
Blue Institute | Örjan Larsson | mars 2013
Commodity prices have increased sharply since 2000, erasing all the declines of the 20th century
The BIG Picture
DEMANDDEMAND
+ 2 Bpeople
+ 3 Bmiddle class
+ 40 %energy
+ 80 %steel
Blue Institute | Örjan Larsson | mars 2013
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The BIG Picture
GlobalAssets
Resources
GlobalAssets
Resources
DemandNeeds
DemandNeeds
INDUSTRIALINNOVATIONSINDUSTRIAL
INNOVATIONSBlue Institute | Örjan Larsson | mars 2013
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The Third Wave: Industr ia l IT and AutomationM A N A G I N G , A N A LY s I N G , O P T I M I Z I N G
Blue Institute | Örjan Larsson | mars 2013
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Transparancy3. We will opimize use of resources and
energy more and better
1. We will measure more
2. We will be better to integrate
Blue Institute | Örjan Larsson | mars 2013
15 000 B USD = BNP in USAT h e v a l u e o f ” I N D U S T R I A L I N T E R N E T ” y e a r 2 0 3 0
Source: General Electric | inkluderar viss flyg- och medicinsk teknikBlue Institute | Örjan Larsson | mars 2013
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STRONG MARKET GROWTHS T R A T E G I C , I M P O R T A N T A N D U N D E R I N V E S T E D M A K E S T H E M A R K E T I N T E R E S T I N G
We expect the global industrial automation market to grow at
about 1.5 times global industrial production (IP) over the next
cycle…
C r e d i t S u i s s e , a u g u s t i 2 0 1 2
Blue Institute | Örjan Larsson | mars 2013
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ERP
MES
DCS
Källor: Manufacturing Execution Systems Market 2011-2016, MarketsandMarkets, 2011; Global EnterpriseResource Planning Software Industry 2012-2017, Lucintel, 2012; Bearbetad av Blue Institute, 2012
Blue Institute | Örjan Larsson | mars 2013
STRONG MARKET GROWTHS T R A T E G I C , I M P O R T A N T A N D U N D E R I N V E S T E D M A K E S T H E M A R K E T I N T E R E S T I N G
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Blue Institute | Örjan Larsson | mars 2013
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Technology Trends in Industrial Systems● Increasing usage of Internet Technologies e.g. TCP/IP, web
services etc.● Information Driven Interaction vs. Communication focus● Distributed Business Processes● Virtualization and Cloud Computing● Multi-core Networked Embedded systems and GPU computing● SOA-ready devices and systems● Commercial DBs and tools for vizualisation & management● Integration with business systems e.g. ERP, GIS etc.● High performance analytics, asset management, reporting, etc.
Källa: SAP
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The Future Internet and its services will depend on CPS
Källa: SAP
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Some facts
Swedish process industry43% of exports 13% of Sweden's GDP 25% of business investment
Important customers for Swedish automation suppliers
Swedish automation industry
10% of the global automation industry
Turnover of around 50 billion SEK
> 1500 new jobs needed over the next five years in Mälardalen
The Global Automation Market €188 billion 2007.
(€ 500 bn estimated to 2020)
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SUMMARY CHALLANGES
Productivity create growth. Industrial IT & Automation are both practical and strategic conditions for productivity and for sustainable industrial processes.
R O L E
The industry needs to create new business models that releaseinvestment and that valuate improvements. The industry needs to increase RDI investments.
T E M P O
The industry must develop robust solutions for data analysisand for process optimization that are simple to manage and implement.
TECHNOLOGY
The industry needs to attract new skills and talents in the area of methodology and analysis but also increase its knowledge about production processes.
COMPETENCE
Blue Institute | Örjan Larsson | mars 2013
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Good and accessible IT systems and developed process automationGood and accessible IT systems and developed process automation
More efficient maintenanceMore efficient maintenance
Improved production processes
Improved production processes
Higher capacity for change
Higher capacity for change
Good market flexibility
Good market flexibility
increased competitivenessincreased competitiveness
Results in
Industrial process automation projects
Higher plant capacityHigher plant capacity Better utilization of resources
Better utilization of resources
Niche productsproducts from
secondary flows
Niche productsproducts from
secondary flows
Leads to
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Accelerating IT development continues ... examples
• Artificial Intelligence: High-frequency trading, Software agents, Natural language interpretation, Machine translation, Procedural storytelling, VR-only lifeforms, Machine-augmented cognition
• Internet: Cloud computing, Cyber-warfare, 4G, Mesh networking, Internet of things,Virtualcurrencies, 5G, Reputation economy, Interplanetary internet, Remote presence, Exocortex
• Interfaces: Multitouch, Gesture recognition, Speech recognition, Augmented reality, 4K, Haptics, Holography, Telepresence, Immersive virtual reality
• Sensors: Depth imaging, Near-field communication, Pervasive video capture, Biometric sensors, Smart power meters, Biomarkers, Machine vision, Computational photography, Optogenetics, Neuroinformatics
• Ubicomp: Tablets, Volumetric (3D) screens, Flexible screens, Boards, Picoprojectors, Eyewear-embedded screens, Context-aware computing, Fabric-embedded screens, Reprogrammable chips, Skin-embedded screens, Retinal screens
• Robotics: Appliance robots, Smart toys, Robotic surgery, Self-driving vehicles, Powered exoskeleton, Commercial Unmanned aerial vehicles, Domestic robots, Swarm robotics, Embodied avatars, Utility fog
http://envisioningtech.com/envisioning2012/?ncid=edlinkusaolp00000008
Source: Envisioning Technology
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More short-term automation solutions
More short-term automation solutions
Unstable system environment,
increased system maintenance
Unstable system environment,
increased system maintenance
Reduced internal control system
support
Reduced internal control system
support
Reduced adaptability to new customer and market requirements
Reduced adaptability to new customer and market requirements
Reduced competitiveness and lower profitabilityReduced competitiveness and lower profitability
Increased supplier dependency.Worse internal automation expertise.Lower internal purchasing expertise.
Leads to
gives
Risks with increased complexityin IT and automation systems
More downtime, lower availability, reduced customer flexibility, etc.More downtime, lower availability, reduced customer flexibility, etc.
More difficult to see the potential in new solutions.
Harder assess skill needs.More functionality can not be utilized
Increased high competence and skills competition.
Worse holistic approach to systems support.
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Bothnia Bay Areaplants &facilities
Tornio
Kemi
Oulu
Raahe
Kokkola
Örnsköldsvik
Umeå
Skellefteå
Kalix
Gällivare
Kiruna
Rovaniemi
Mining andsteel production
Mechanichalindustry
Pulp andpaper
Metals andstainless
Energy
• Boliden Skellefteå Fields• Boliden Rönnskär• Skellefteå Kraft
• Alimak• Brokk
• Hydrauto• KMT
• Boliden Kokkola
• Rautaruukki
Piteå
Luleå
• Stora Enso• Kemira
• Outokumpu Mine• Stora Enso
• Metsä-Bothnia
• Stora Enso
• Outokumpu stainless
• Billerud
• LKAB• Nybergs Mekaniska
• LKAB• Mecon
• Boliden Aitik
• Ferrufom• Gestamp Hardtech
• SSAB• LKAB/EBF
• swerea-MEFOS
• SCA• Smurfit Kappa• BL Gasification
• SCA• Bio Fuel• Komatsu
• Volvo• Ålö
UmU
LTU
UoO
Ore to steel
Precious metals• Domsjö• Mondi• M-real• SEKAB
• BAE-Systems• Hägglunds Drives• MacGregor Cranes
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The Mining Industry in Sweden.The Mining Industry in Sweden. LKAB. Number one industry investor in Sweden 2010. Invest 5 – 6.000 MSEK / year
Boliden Investments in Garpenberg 3.900 MSEK (2012-2013) 17% of all cost is energy Recycling of electronics. From 45 KTon to 120 Kton
SMIFU - Sustainable Mine and Innovation for the Future LKAB, Boliden, KGHM + a number of global suppliers Strive for zero accidents, 30% reduction energy consumption, CO2, emissions ore losses
Energy /electricity LKAB approx 4.0 TWh/year energy 2012.
With 1.5 %of the nation’s total consumption Boliden 3,7 TWh 2010.
(72% of all energy is Electricity) Energy usage 2011 (est.) 384 TWh
Industry 36%, Transport 25% Service&building 38%
Energy in Industry (2008)50% Pulp & paper, 15% iron&steel, 8% Chemical, 3% mining
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The Forrest industryThe Forrest industry
A QUANTUM LEAP IN Innovation Efficiency!www.processitinnovations.se
● 10 -12 % of Swedish Industry employment, value added, export
● Export value 2009. 123 BSEK
● Small import of goods – large contribution to trade balance
● Directly employs 70 000 people and about 200,000 indirect
● Invest, on average ,10 billion per year
● High-tech processes
● Leading Swedish exporter
● Lowest CO2 emissions per ton ( pulp & paper) in the world
Source: Skogsindustrierna och TVA-underlaget
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Innovation System model
NEW BUSINESS
PROCESS INDUSTRIES -Plant owner
ACADEMIA -University & institute
PUBLIC AUTHORITIESand CLUSTERS
TECHNOLOGY and SERVICE SUPPLIERS
IDEA● Needs● Big potential● Risk
RESULT● Regional growth● Stronger SMEs● Regional partners
Meetings – PROJECTS● Studies● R&D Projects● Commercialization
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Martin Ärlestig
Steering BoardLars Atterhem Chairman BiosteamN N Govenor VästerbottenThomas Brännström InternetBayKent Tano LKABMargareta Rönnqvist SSABJerker Delsing LTULena Gustafsson Umeå UniversityAnders Kyösti SCA Packaging MunksundUlf Marklund BolidenTomas Lagerberg ABB Corporate ResearchSeved Lycksell Skellefteå KraftMarin Ärlestig Komatsu Forest
Industry Advisory BoardKnowledge in industry processes and needs
ProcessIT Management
Executive ManagementAnders OE Johansson ProcessIT, LTUPer Levén ProcessIT, UMUThomas Gustafsson LTUKatrin Jonsson UMUJan Björkman LKABKajsa Andersson Expandum
Project officers (full or part time)Pär-Erik Martinsson LuleåAnders Jonsson UmeåRobin Norrman UmeåUlf Andersson LuleåKjell Olsson Luleå
Staffan Sandström Seved LycksellLena Gustafsson
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ProcessIT Innovations● Recognized by OECD as a strong national
R & I Milieu● High and growing number of innovations
and commercialization● Constantly increasing revenue and growing
industry relations● Increasing primary industry and supplier
involvementOver 80's companies involved in our project activities
● Building projects from continuous need inventory studies
● Strong impact on universities and research groups
● More and growing number of strategic partnerships
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The ISA Pyramid
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ProcessIT AreaINDUSTRIAL SYSTEMS
ICT-BASED
measure-ment
moni-toring
control inter-action
communi-cation
INTEGRATION
TECHNOLOGIESEMBEDDED SYSTEMS TECHNOLOGIES
Production
Maintenance(e-maintenance)
Training
Engineering
Logistics
COLLABO-RATION
INFORMATIONEXCHANGE
IND
US
TRIA
L P
RO
CES
SES
Defined by today’s and tomorrowsindustrial processes and ICT systems
Page: 31 | 2013-04-23 | © ProcessIT Innovations
PS
Large scale Process industry M&C scenarioP
roce
ss
Equ
ipm
ent
Fiel
d de
vice
s, s
enso
rs, I
/OP
roce
ss C
ontro
lE
nter
pris
e m
anag
emen
tM
anag
emen
t exe
cutio
n
PowerSubstation
Othersubsyst.
Control Network
Enterprise Network
PS
Fiel
d bu
ses
PS
Remote access
Inte
rfac
eG
atew
ay/A
PI
Firewall
Fiel
d bu
ses
Fiel
d bu
ses
History
Training
GWY
GWY
Black-box
LegacyDCS
BBdevices
Handhelddevices
Operator consoles
Control and eng. room/rooms Control and eng. room/rooms
Operator Engineering
Black-box
controlsystem
prop
rieta
rybu
sses
/con
nect
ions
Engineering
Process section Process section Process section
BackupUPS
PLCs
ERP MES QMS MIS
Managers, planners etc desktops
crushing, screening, conveying, feeding, grinding, separation, pumping, concentration, processing, pelletizing, materials, transformers, switchgearProcess equipment Process equipment Process equipment Process equipment
GWY
Asset mgmtMaintenance
Process section
LocalHMI
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• Regional• RDI-projects (in different stages - Pre-studies,
pre-projects, projects and need finding activities)
• Project portfolios (SCOPE, GRAM, ….. )
• Technology clusters (Optical, Interaction, simulation)
• National (Swe - Finland)• National strategic agenda
”Industrial Process Automation”• Project portfolios. Competence provision.• Collaboration. Automation region, PPI, PIC, FindIT etc.
• European / International• ProcessIT.EU• Projects. Arrowhead.• Roadmap
Regional – National – European /International
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eMaint satsning i Malmfälten GramCOBS. Transportbandssystem MätteknikOnlinemätning av COD i bioreningsanläggning - fas II ScopeMätning i mobil miljö Styr & MätMätning flotationstank Styr & MätSimulering av bandtransportör SimuleringVSB ProITBeslutstöd via Interaktiv Display för Lean II InteraktionFibermätning MätningStendetektering MätteknikBrötdetektering BildanalysMassaindex MätningEnergieffektivisering vid malning MätningAESOP FP7 IP projekt KommunikationDeltagande i JILIN projektet ProITBranschanalys för VINNOVA (Gruv + IKT) ProITPlattformsstrategi för svensk processindustri (del B) ProITNationell agenda fas 2 processindustriell automation ProITSDR-radiomätning i Aitik GramGasflödesmätning fas 3 GrameMaintenance for Smart Asset Management ProITNOSEG ProITBeröringsfri mätning stock ProITSimulering av sekundärvärmesystem och energibalanser ScopeEnergy and Quality oriented modeling and control of REFiners ScopeNIR-kluster ScopeMobile Warp ScopeGlobal LinksLjud i kontrollrumsmiljöUtveckling av sensor för mätning av tvättföluster Scope
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Entrance A
Entrance B
Entrance C
OperationsMonitoring
Engineering
Project
Management
SalesProcurement
Maintenace
HR
Logistik
Overall idea
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Phase 2 – A SIO proposalAutomation RegionProcessindustriella Centran Li-LuProcessIT Innovations
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More effective and broader corporate partnerships:
1. Establish an Industrial national leadership and a national collaboration platform for the area.
Stronger integration with the university and college world:
2. Coordinate projects and networking activities with university and college based RDI environments that are identified as particularly strong and relevant to the area.
3. Coordinate and implement combined skills development initiatives with both business community, university and college partners.
Strengthen the area’s role and position in national and international innovation systems:
4. Substantial investments in National RDI programs in this area.
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Processindustriell automation
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Our ambition is to highlight industrial process automation as a key enabler for the future
European process industry.
In the area ● Accelerate growth and technology development in Europe● Innovations in ICT and automation technology.● Incubation and implementation of strong R&D projects.● European automation world class research thru access to
highly challenging industry contexts.
PURPOSE
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Ideal concepts.Identified “white areas” that require further development
ROADMAP IDEAL CONCEPTS ARE:
1. Instant access to virtual dynamic factory
2. Increased information transparency between field devices and ERP
3. Real-time Sensing & Networking in Challenging Environments
4. Process industry as an agile part of the energy system
5. Management of Critical Knowledge to support Maintenance
Decision Making
6. Automation service and function engineering
7. Open simulator platform
8. Automation system for flexible distributed production
9. System wide balancing of safety, security and production flexibility
Page: 41 | 2013-04-23| © ProcessIT Innovations
● 5 application pilot domains:● 4 years● 80 partners● LTU / ProcessIT.EU coordinator● 69 Beuro● Sweden, Austria, Belgium,
Czech, Denmark. Finland, France, Italy, Latvia, Norway, Portugal, Spain, Netherlands, UK
1. Luleå tekniska universitet2. Eistec AB,3. Fotonic,4. Abelko Innovation5. SKF6. Boliden7. LKAB8. Noda 9. BNearIT10. Midroc Electro AB
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Short time goal Target and goals in new projects 1. Instant access to virtual dynamic factory
Automatic model life cycle management, computational resources, business service development. Data to information. Training of staff and model based reasoning.
2. Increased info. transparency between field devices and ERPIP everywhere, middleware nowhere, seamless integration, industry requirements.
3. Real-time Sensing & Networking in Challenging EnvironmentsRobustness, calibration, energy harvesting, IoT, in situ sensors, cyber physical systems,M2M
4. Process industry as an agile part of the energy systemAgile Integration, production flexibility. Automation for short and long term variations. Collaborative automation. Technologies for “look up, loosely coupling and late binding”,.
5. Management of Critical Knowledge to support Maintenance DecisionsQuality assurance, context awareness, targeting and timing of information, business models
6. Automation service and function engineeringFunctionality for systems of systems, configuration and requirement management, model based development,
7. Automation system for flexible distributed productionFaster product changes, faster ramp-up/down. Scheduling. Material tracking.
8. Open simulator platformInteroperability, numeric's, reusability, development tools.
9. System wide balancing of safety, security and production flexibilityRisk management. Cryptography and intrusion detection & prevention. System architecture
Page: 43 | 2013-04-23| © ProcessIT Innovations
And what is this?
Something to worry about?
Page: 44 | 2013-04-23| © ProcessIT Innovations
“known” physical world camouflage in an office near you ! (?)
• The industry's first enterprise-class penetration testing drop box. Through its innovative, patent-pending design, the PwnPlug covers the entire spectrum of a full-scale pentestingengagement, from physical-layer to application-layer.
• Includes all release 1.1 features• Includes 4G/GSM cellular, Wireless (802.11b/g/n), high-gain
Bluetooth, & USB-Ethernet adapters• Fully-automated NAC/802.1x/RADIUS bypass!• Out-of-band SSH access over 4G/GSM cell networks!• Text-to-Bash: text in bash commands via SMS!• Simple web-based administration with "Plug UI"• One-click Evil AP, stealth mode, & passive recon• Maintains persistent, covert, encrypted SSH access to your
target network [Details]• Tunnels through application-aware firewalls & IPS• Supports HTTP proxies, SSH-VPN, & OpenVPN• Sends email/SMS alerts when SSH tunnels are activated• Preloaded with Debian 6, Metasploit, SET, Fast-Track, w3af,
Kismet, Aircrack, SSLstrip, nmap, Hydra, dsniff, Scapy, Ettercap, Bluetooth/VoIP/IPv6 tools, & more!
• Unpingable and no listening ports in stealth mode• Includes 16GB SDHC card for extra storage• Includes stealthy decal stickers• Compatible with SIM cards from AT&T, T-mobile, Vodafone,
Orange, and GSM carriers in over 160 countries• HSDPA/UMTS (850/1700/1900/2100MHz)• GSM/GPRS/EDGE (850/900/1800/1900MHz)
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Stuxnet: Lessons Learned• Security awareness low and risk assessment is faulty.• Many live on the “don’t touch a running system” / “I am not on
the Internet” motto• Security problems of 2+ years old were not addressed• Lifecycle management of assets and processes has to include
security and be adjusted/revised on-demand for critical systems• Do NOT trust single sources of data / verify independently
(multiple information paths / checks). TRUST at device and system-wide level needs to be assessed!
• Security 101: ask/verify/check security/safety/quality requirements on supplier
• Prepare for the known threats, and plan for the unknown (e.g. via heuristics)
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ProcessIT – the next steps• More and deeper industry engagement
• Higher share of corporate automation R & D located ProcessIT cooperation • More and stronger ICT companies
• Both regional and within the ProcessIT Network • Stronger university collaborations • More frequent interaction with students. • Regional, national and European • Initiate and drive the national strategic agenda "Automation for
process industries“• Powerful presence on the European arena thru ProcessIT.EU • Increased interaction with various regional growth actors. Eg municipalities, regional, clusters, industry associations, etc. • An organizational supporting a long-term responsibility for regional development • Build on established structures and practices
• To further accelerate the creation of innovation projects • Establish “ProcessIT Academy” for regional knowledge transfer !?
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TACKFor more info please visit:www.processindustriellautomation.sewww.processitinnovations.sewww.processit.eu
Or contact: [email protected]