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5G investment key to untethering IoT intelligence for manufacturers

5G’s lighting-fast speeds will reshape consumer expectations for entertainment, shopping and social connectivity.

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Manufacturers are starting to understand just how much business intelligence is possible with the Internet of Things: Connected devices streaming reams of valuable data to algorithms that, in turn, learn how to spot trouble before it happens. Every step of the process — from manufacturing to product service — can benefit from smart devices communicating in real-time.

But even businesses using the fastest 4G networks are starting to question that oft-used term: “real-time.” 

Case Study: Advancing Smart Manufacturing Operations Value with Industry 4.0 Platform

4G can support approximately 2,000 devices per square kilometer, and as mobile devices proliferate those boundaries are under stress.

But there are promising solutions on the horizon. The cutting edge, often-hyped 5G network tech currently being rolled out and tested by global telcos is poised to become essential to leveraging business intelligence. 

Its technical details are complex, but 5G is, simply put, faster and better. It’s projected to support one million devices per square kilometer. Downlink speeds are spec’d at 20Gbps, and latency (how long it takes data to travel from A to B through a network) is expected to max out at four milliseconds versus 4G’s 20 milliseconds. 

[Download]: Real Estate Manager Goes Digital

Even though widespread 5G connectivity is still a few years away, Sharath Prasad says many manufacturers are trying to gauge their investment in the space. As Cognizant’s connected products portfolio lead, Prasad says “the pervasiveness of 5G, the cost of 5G and its adoption rates can all drive operational intelligence.”

Vivek Diwanji, senior director of technology at Cognizant, says this shortened latency is the real potential benefit to IoT-enabled businesses. “5G and edge devices are where the overall story is going to change in terms of the way data will be consumed, analyzed and leveraged,” he said.

So what does this mean for manufacturers? A number of things:

If a connected manufacturing device senses a problem on the line, for example, getting shut-down instructions in four milliseconds instead of 20 could save thousands of dollars in faulty product coming through the pipeline. 

The value of IoT doesn’t always end inside the factory walls. Once some connected products leave the factory — an automobile for example — and deploy into the field, 5G connectivity can feed product engineering teams with more data and insight on how a product functions on the — traditionally — dark side of the moon.

The list of benefits of 5G is long.

“I think that’s going to be the bigger impact of 5G overall,” says Diwanji, “not only as a backbone for infrastructure, but from the overall customer experience standpoint.”

[Download]: A New Approach to PLM

Relying on telcos to deploy 5G at scale may be a waiting game, but manufacturers can also outfit their own facilities with 5G networks to reap benefits today.

Prasad says groups such as CBRS (Citizens Broadband Radio Service) are working to expand 5G capabilities into existing mobile network technology thanks to recently released radio spectrum

With some hardware investment, he says manufacturers can set up their own 5G-based network using the CBRS’s framework and “actually do away with dependence on a carrier … Even if factories are located in remote areas without reliable wireless connectivity, they can actually set-up a CBRS-based 5G network just to cover their factory and provide good quality connectivity there without having to shell out a huge cost to carriers.”

5G’s lighting-fast speeds will reshape consumer expectations for entertainment, shopping and social connectivity. So too will it reshape the business sector. In a world where one company’s “big data” intelligence is pit against another’s, speed will define market leadership. 

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Manufacturing

IoT + big data analytics = operations intelligence: An equation that draws a better picture

In the equation IoT + X = Operations Intelligence, what role does big data analytics play as the X factor?

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Global pressures to decrease energy consumption and the speed of business are accelerating the call for new ways of delivering efficiencies. 

What if a fridge could tell us that the food it stores was going to spoil in a day? What if buildings could cut down heating costs by selectively turning down the heat depending on occupancy? For a fridge to “talk” in this way, it would need a way of measuring the parameters that indicate data spoilage. The Internet of Things (IoT) delivers just that.

Case Study: Advancing Smart Manufacturing Operations Value with Industry 4.0 Platform

With IoT, everyday “things” such as refrigerators, machines, warehouses, televisions, washing machines, broadcast data about their health through outfitted chips and sensors. So large is this data deluge, that the IoT market is expected to grow at an astonishing 24.7% and reach $1111.3 billion by 2026.

Big data analytics

We need big data analytics to harvest this torrent of IoT information in useful ways. Simply spitting out data is not enough, big data analytics help companies make sense of the data and thereby deliver intelligence.

The classic definition of big data is that it presents in three “Vs”: large volumes, variety and high velocity. So the concept of big data is not new, even if this set of parameters has evolved since the early 2000s when it first took root. The introduction of IoT, however, has increased the number of sources which contribute to the data dialog. Whether or not these data points contribute to a symphony or merely create a cacophony depends on data analytics.

Case Study: Advancing Smart Manufacturing Operations Value with Industry 4.0 Platform

“Big data provides context to a world in which IoT is working,” says James Jeude, Vice-President and Practice Leader of Cognizant’s Digital AI & Analytics Strategic Initiatives Group. “As an industry we have solved the volume problem [of big data], where today’s big data really matters is that it delivers on variety. It is variety that really matters [for intelligence] at this point.” 

Take the example of a refrigerator in a grocery store. To know when the compressor is about to break, the store can measure both the refrigerator temperature and the current input. The higher the electric current flowing to a refrigerator to maintain the same temperature, the more likely it is to fail. These two indicators might be the canary in the coal mine but IoT and Big Data allow a variety of additional efficiencies. Measuring the gases emitted by the food can be a window into when the food might spoil; measuring outside temperature and humidity might tell us acceleration patterns of food spoilage. The number of times a grocery store refrigerator is opened and closed is also a useful parameter to measure.

Case Study: Advancing Smart Manufacturing Operations Value with Industry 4.0 Platform

The promise of big data analytics is that it allows a whole new range of IoT variables to participate in the conversation. 

IoT facilitates information gathering from more sources so everyone who contributes to a situation gets a hand at the table. Data analytics leverages this IoT data to deliver a more comprehensive picture of the situation. The net analysis is more nuanced and more valuable. Indeed IoT + Big Data Analytics = Valuable Intelligence. 

With IoT and big data analytics, you no longer  have to picture an elephant by merely touching its ears and tail. You can now access more touchpoints to visualize the whole animal.

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What you need to know if you’re attending AVEVA World Summit

AVEVA World Summit is where the most innovative industrial executives from around the world gather for an exclusive opportunity to network with 400 global digital leaders across diverse sectors. 

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AVEVA World Summit is where the most innovative industrial executives from around the world gather for an exclusive opportunity to network with 400 global digital leaders across diverse sectors. 

The summit is an opportunity to discover how these leaders and Cognizant — a Platinum Sponsor — are transforming the entire asset and operational lifecycle.

To help you prepare, here is a selection of articles, case studies, ebooks, and clips from Cognizant, discussing digital transformation:

  • Learn Cognizant’s 4 key success factors to Industry 4.0 transformation. For starters, lead with strategy, not the technology. Watch the video here.
  • AI, Machine Learning, and IoT are ensuring the efficacy and efficiency of one of the most demanding engineering projects in the world. Learn how Cognizant helped Norwegian offshore engineering firm Kvaerner adopt these digital technologies.
  • The promise of Industry 4.0 is compelling, but for many traditional manufacturers, the reality is less than ideal. In this new Cognizant report, find examples of manufacturers that are navigating the shift.
  • It’s all about speed: Insight from Cognizant on how 5G will transform the business sector and create a leadership race for data intelligence.
  • Not all smart factories are created equal: Cognizant takes stock of the state of IoT intelligence, and what industrial organizations need to ensure both digital maturity and success. Read more here.
  • The many touchpoints of IoT connectivity allows AI to really shine, and prove its value to manufacturers in the form of proactive preventive maintenance, says James Jeude, VP in Cognizant’s Digital AI & Analytics Strategic Consulting Group, in this piece.
  • The human factor in IoT intelligence is key: Connected employees can “dynamically manage situations as they change,” explains Cognizant’s AVP of engineering and IOT solutions Phanibhushan Sistu.
  • The leap to IoT is a necessary one for your organization. This Cognizant ebook looks at 14 such businesses that jumped confidently into the digital future.
  • It took less than 12 weeks for Cognizant to implement an IIoT platform for a leading global industrial manufacturer. Get the case study here.
  • Without the duo of IoT and the Digital Twin, your organization is living in a black-and-white outlined world, in terms of operational intelligence. Color it in, get more accurate predictions, and fully realize potential.

Aveva World Summit takes place September 16-18, at Marina Bay Sands, Singapore.  

One session to highlight? “Digital Transformation in Hybrid Industries,” featuring Cognizant’s VP of IoT and Engineering services, Frank Antonysamy. This session will examine the benefits of digital transformation, and addressing challenges through a sustainable platform that can adopt best practices, continuous improvements, and grow with the business.

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IoT + Digital Twin = Operations Intelligence: An Equation that Delivers Useful What-If Scenarios

In the equation IoT + X = Operations Intelligence, what role does a digital twin play as the X factor?

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Measure twice, cut once. This basic premise, that it would be advantageous to visualize outcomes before you act, forms the backbone of an entity known as the digital twin. This approach is particularly useful in today’s high-stakes industries such as manufacturing, construction, mining and more. Measuring twice and cutting once allows enterprises to tweak every aspect of the production process to maximize revenue.

The digital twin enables companies to envision what-if scenarios for various operating conditions in the virtual world before it affects processes in the real world. The more fully the digital twin avatar is fleshed out, the more accurate its predictions. This means enterprises need IoT (the Internet of Things) to color in the picture completely. IoT helps the digital twin realize its full potential to deliver operational intelligence. 

The promise of the digital twin

A digital twin is a replica, described by data, of physical assets, processes and systems that helps organizations understand, dissect, predict and optimize their performance. It can combine design and engineering details with operating data and analytics about anything from a single part to multiple interconnected systems to an entire manufacturing plant.

Case Study: Advancing Smart Manufacturing Operations Value with Industry 4.0 Platform

If you need to describe a physical asset (say a motor running on a shop floor) through data, you need that motor to both generate data and make that data easily accessible. This is where IoT falls into the picture: it “sensorizes” a variety of physical machines and brings them into the digital twin conversations, says Vivek Diwanji, senior director of technology at Cognizant. IoT-enabled embedded devices can then transmit data about their health under a variety of operating conditions and channelize that information through an Internet connection from shop floor to enterprise resource planning (ERP) software. 

Layered possibilities

A digital twin is about different perspectives – essentially comprised of many layers that are progressively overlaid with more detailed data input. The level of detail depends on the insights you’re looking to derive. If you need to know when a vehicle tire is going to wear-out, all you need to measure is temperature and air pressure. Long-term durability intelligence on the other hand, also needs to measure ambient conditions, daily operation numbers, road type and more.

[Download]: A New Approach to PLM

A lack of common IoT standards across industries makes the data difficult to gather, but that conversation might change with the advent of 5G, Diwanji predicts. For now, digital twin is a powerful tool that enables companies to deliver field services, conduct smart operations and evaluate product development outcomes before investing millions into the pipeline.

By 2020, 30% of Global 2000 companies will be using data from digital twins to improve product innovation success rates and organizational productivity, according to IDC. They can realize gains of close to 25%. And IoT is a key player in that equation to deliver such operational intelligence.

“Digital twin is an application that leverages IoT. The very definition of a digital twin necessitates that a digital model is running in conjunction with a physical model. That connection, between the physical and the digital, happens through IoT,” Diwanji says. “IoT is really the backbone of the digital twin.”

[Download]: Real Estate Manager Goes Digital

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1 download. 14 Case Studies.

Download this report to learn how 14 companies across industries are demonstrating the reality of IoT-at-scale and generating actionable intelligence.

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