The performance data of our own production at a glance. © Forcam

The next step is to transform big data from the machines into usable smart data in real time. This requires high-performance and rule-based data processing machines. Ultimately, the aim is to generate digital mirror images on all the computers required on the store floor, which production managers and workers can use to virtually analyze operating states and production progress and optimize them in real terms.

Such real-time data processing is achieved, for example, by rule engines that work on the basis of main memory-based IN-MEMORY and CEP technology (Complex Event Processing). They act as a bridge between the store floor and the top floor, on which precisely measured production data flows into the corporate management system (ERP), such as SAP. Tanja Knechtskern from Controlling at Grammer AG recently reported at an Industry 4.0 congress: "This actual feedback to SAP is a real enrichment for us in Controlling."

2. get started right away: With pre-installed applications that are important

There are a handful of applications that are essential for managers of digital transformation projects. Seamless traceability of all processes is a must in all industries today. "Customers demand this from us," says Alexander Stappert from BorgWarner Europe. "We need seamless traceability of all processes. The main aim is to minimize liability risks. Because as a supplier, the burden of proof lies with us in the event of damage."

In a BorgWarner Europe factory project in Poland, for which Alexander Stappert was responsible, the traceability of all parts and processes was the primary objective of the digital control system. The result: the data records from seven months - several million in total - are now displayed and evaluated in two seconds. A pleasant "side effect" of seamless traceability: BorgWarner was able to increase productivity in various factories by between five and 15 percent.

Companies can therefore expect a modern IIoT platform to have the most important applications for production pre-installed and pre-configured. These include Performance analyses for overall equipment effectiveness (OEE), visualizations and alarms, detailed planning & control of orders and capacities, energy data management, traceability (track & trace), production data management (documents).

3. remain fit for the future: Integrate third-party solutions with open interfaces

The BDE terminal. © Forcam

Being smart means being open: The latest criterion for a modern IIoT platform comes from a "freedom movement" in the USA - the OPEN API Initiative(http://www.openapis.org). It has set itself the goal of promoting the free exchange of data between applications and applications from different manufacturers through open user programming interfaces (API - Application Programming Interface).

Another movement, the Force Bridge Community, is pursuing the goal of developing an open industry standard for smart manufacturing (http://edu.forcebridge.io/). Leading industrial companies, software pioneers and universities have come together in this specialist community. The result is the first open interface for smart manufacturing - the Force Bridge API, now in its second version (https://docs.forcebridge.io/api/).

This interface gives companies great freedom: programmers can seamlessly integrate existing IT systems as well as third-party systems such as applications for tool data management, quality assurance or predictive maintenance.

One example of the advantage of vendor independence: the family-owned company Kostal, one of the top 100 automotive suppliers in the world, combines SAP applications with the Forcam platform, for example. "This allows us to specifically overcome weaknesses in the standard systems and supplement them in a targeted manner," says Kostal IT Manager Patrick Saslona. MES systems for production data acquisition (Manufacturing Execution System) do not offer this great freedom because they represent closed IT silos, even if they are often marketed as an open platform.

"Get digital or die"

Digitization is not an end in itself. It should bring concrete results: Making work processes and tasks easier, increasing productivity in terms of safeguarding sites and jobs. Raynald Richard from the Swiss company MPS Micro Precision Systems AG in Biel, a leading manufacturer of precision parts for medical technology, watches, automation, aviation and optics, describes the benefits for workers and managers alike. Raynald Richard speaks of "flying blind" before the introduction of digital manufacturing. Today, after switching to digital control, the production status of 700 products is displayed visually at MPS. Top and store floor are seamlessly interlinked, there is maximum cost transparency thanks to real-time data, and efficiency is continuously improved.

Conclusion: The successful digitalization of production that increases productivity is not witchcraft, but depends on high-tech solutions for the machines as well as modern change processes for the employees. Technological and cultural change must go hand in hand. The following applies to the technological part of the transformation: production managers should choose the most powerful and manufacturer-independent IT platform.

If you want to secure your future, you can no longer avoid digitalization. The former CEO of General Electric, Jeff Immelt, put it in a nutshell: "If you went to bed last night as an industrial company, you will wake up today as a software and analytics company." Or simply: get digital or die.

Franz Gruber, founding managing director of Forcam / ag