Pulling Needles out of Your Data Haystack

3 steps to act on data you’re already collecting. 

The Impossible is Now Possible

Industry 4.0 is moving fast and I’d like to let you in on a few very valuable developments about the data you’ve been collecting. It can now help you make better decisions. You can talk to your industrial data and it’s talking back to you, letting you know what’s working inside your operation and what’s not.

It’s exciting for me to see GrayMatter and our partners innovating by taking the data you’ve been collecting through sensors on industrial equipment and applying artificial intelligence and machine learning in the cloud so you can find insights on performance. Then you know exactly where to make improvements.

You need a system to sort through the haystack of data and pull needles out to focus your subject matter experts. That’s what we can do now.

It all starts by framing up the action strategy in three parts.

Step One: Set Your Goals

Start at the end and work backwards.

What return on investment do you want to see? You don’t need all the data you think you need. What information will help you solve the problems you want to solve? What’s the path to getting there? Having this roadmap first is critical, because otherwise a lot of time and money can be wasted.

Step Two: Start Creating Digital Twins

You hear the term digital twin, but what does it really mean?

Simply put, creating a digital twin is the process of merging physical and digital worlds.

The process takes a physical machine and uses technology to get all the information about past states, present states and predictions. That information creates a digital model that’s alive – taking in a stream of data – using that to adjust so the model is personalized to be a precise representation of the asset.

The software version is used for what used to be a physical inspection – requiring people to be right next to the machine. The virtual version can be done from anywhere and at any time, expanding the value of those inspections and allowing them to have more of a real-time impact. It creates a constant inspection that allows the operators to predict failures sooner.

Digital Twin Value

The digital model of a machine, built and run in a virtual environment used to be available only to the biggest companies with the largest budgets. But the Industrial Internet and an explosion in sensor technology have lowered the cost and broadened the access beyond the elite.

pulling needles out of data haystack

People are not only connected to people, they’re connected to every kind of device at home and now work. Manufacturers stand to win big from this. Factory floors are outfitted with tremendous amounts of sensors to collect data, but because that data has been locked up it hasn’t provided value.

The digital twin allows us to unlock that data and not just for one asset at a time. We can now model machines in groups – for example, a machine builder with thousands of machines installed across hundreds of customers – will now be able to operate best in class using digital twins.

There’s potential to unleash productivity and efficiencies like we’ve never seen before.

Step Three: Get Behavioral Information from Digital Twins

In order to move to more advanced use cases, such as adaptive diagnostics, condition-based maintenance or predictive failure, Industrial IoT systems need to know more than simply the current device state.

They need to know why. Knowing current device state only helps from a monitoring standpoint.  While important, it’s really just the beginning of what we can expect out of IIoT systems. If we know why an asset exhibits a certain state, we can determine what conditions lead to that state and take proactive steps to prevent future occurrences. 

This new layer of getting insight through behavioral information allows you to ask for more. You can search your data and get answers back right away. It’s like an instant messenger for operational technology.

Step Four – Get Digital Twins to Interact

Achieving this may mean digital twins built using multiple discrete machine learning algorithms potentially spread across multiple IoT platforms, not simply relying on one. Eventually, we should expect that digital twins will interact with one another in virtual space.

Leap Ahead

If you’re short on time, staffing or budget – GrayMatter can get you up and running to achieve value quickly. You know you need an Iot strategy in the near future, but may not know how to go about it. Rather than trying to design, source and build it yourself we can put the strategy in place in days or weeks.

You also don’t have to do everything at once, you can start with a limited selection of assets and scale up or down as you learn performance and asset behaviors.

Our strategy is a Salesforce version of a remote monitoring and diagnostics center that you can buy and implement incrementally.

GrayMatter’s Digital Twin Strategy

We use data, predictive capabilities and machine learning to identify your best and worst performers in each asset group. Your operators are automatically alerted to the worst performers, then they use an intuitive web interface, to turn the worst into the best.

Continuous improvement becomes expected, simplified, and routine. As your team builds new improvements or optimized settings, they can be scaled out, automatically, to every instance of a specific machine or piece of equipment.

You Don’t Need a Data Scientist

The complex algorithms that can leverage your data are pre-built so anyone can start creating the models and analytics to generate insights. One person no longer holds the keys to data, with this unique platform everyone gets a better understanding of your businesses processes, so you’re not focusing on the math to bring the insight, you’re focusing on creating better outcomes for your customers.

Think Big, Start Fast

You need to think big to truly transform your organization, but you also have to start acting on your data today.

We’re anxious to spread the word about how easy this is and to un-complicate it for you. Let me know if you’d like to discuss further.

– Jim Gillespie, GrayMatter CEO.

Click to download the case study to start acting on your data:

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TechHub: Digital Transformation in Steel, the Industrial Technology Future & Pittsburgh Tech 50

Gerdau Saves Millions Annually, Accelerates Their Digital Transformation

$4.5 million in annual savings with a complete ROI in only 8 months.

Gerdau has enjoyed a long reputation as a process innovator in the steel industry for more than a century.

For a company with more than 35,000 people across 13 countries, the goal of a 20% reduction in maintenance cost was significant. It would not be easy to accomplish, but accomplishing the reduction was critical to the company’s profitability.

When an asset fails, the company loses an average of $12 thousand per hour in downtime.

The transformation Gerdau needed would take them into uncharted territory for many in the steel industry: the digital realm of the Industrial Internet of Things (IIoT).

Dreaming big pays off

Download the case study to view the roadmap for digital transformation in the steel industry:

Download the Case Study

The Industrial Technology Future

Open software platforms are an increasingly popular trend within the industrial technology sector that is highlighting the important relationship between operational technology (OT) and information technology (IT).

For GE Digital, Predix is the nexus where app engines, digital twins, machine learning and asset performance management meet, said AutomationWorld after a meeting at GE Digital headquarters in San Ramon, Calif.

“Platforms are where tech is going,” said Gytis Barzdukas, head of product management for Predix at GE Digital. “Like Apple, Amazon, Microsoft and Alphabet have their platforms in the consumer space, we want to do the same thing in industrial space. That’s why Predix is an open platform with regulated participation. Predix has been developed as a common data layer into which third-party supplier products can plug into.”

Although the focus in the past on Predix has focused on its cloud-based operations, but Barzdukas was quick to point that Predix can run operate at the edge, in the cloud or in hybrid applications.

cloud platform

A diagram of the GE intelligent platform Predix. Image: AutomationWorld

Addressing cybersecurity concerns around the transmission and storage of such data in the cloud, Barzdukas said Predix currently uses public key encryption and is moving toward inclusion of private key capabilities for users who want it. Predix’s public key encryption security operates in addition to the security provided by Amazon Web Services on which Predix’s cloud functions run. Barzdukas added that Predix will also soon be running on Microsoft Azure.

Pittsburgh Tech 50

The Pittsburgh Technology Council’s Tech 50 finalists were announced, recognizing the most successful and innovative companies in the Pittsburgh area.

Companies range from health IT, life sciences, manufacturing, consumer products, consulting services and more, and are broken up into the following categories:

  • CEO of the Year
  • Solution Provider of the Year, Consulting and IT Services
  • Culture Leader of the Year
  • Innovator of the Year, Consumer Products
  • Solution Provider of the Year, Innovative Technology

GrayMatter is a finalist for Solution Provider of the Year, Innovative Technology, with CEO Jim Gillespie a finalist for CEO of the Year.

The award ceremony will be Thursday, October 12 at the Wyndham Grand Hotel.

TechHub: Industrial Market Growth, Advancement in Smart Cities & Homeland Security Urges Cyber

The Industrial Market Opportunity

Manufacturing and industrial companies are the backbone of the U.S. economy. With the advancement of the digital age, more factories and utilities are looking to cut costs, decrease downtime and streamline operations.

This industry’s operations are extremely different from IT enterprises and rely on partner companies that specialize in operational technology in order to connect and protect their assts.

GrayMatter was highlighted in CRN, a news analysis online publication for technology companies.

“We help customers in these markets connect their factories, connect their big expensive assets,” said James Gillespie, CEO of GrayMatter, in CRN. “Those are things we’ve been working on, to digitize the information, and to help customers get better results.”

Jim Gillespie, CEO of GrayMatter

The article explores various aspects from the operational issues companies face, to a continuously growing partnership with GE and the possibilities the Industrial Internet has for companies.

Part of that partnership is collaborative engineering on cutting-edge ideas like Brilliant Manufacturing by GE Digital, a suite of software enabling predictive analytics on a scalable intelligent system powered by the cloud-based operating system Predix.

“It’s enabling digital transformations at a scale that would have been harder to do in the past,” said Gillespie. “Predix is like the iOS of the operating systems and now there’s people coming together to write apps — there’s a whole group of people emerging in a community of developers and solution providers.”

Cloud technology is now in an advanced place where it’s becoming universally affordable, dependable and reachable. The community around the operating system is pushing the industry forward, and everybody needs to jump on board.

View all of the technology services GrayMatter has to offer:

View Services

Homeland Security Urges Industrial Cybersecurity

The U.S. Department of Homeland Security Industrial Control Systems Cyber Emergency Response Team (ICS-CERT) issued an alert about a malicious BrickerBot permanent Denial-of-Service (DoS) attack.

BrickerBot exploits hard-coded passwords in Internet of Things (IoT) devices to cause a permanent denial of service, locking operators out of their systems.

The team encourages asset owners to know that their control systems are deployed securely and not exposed to threats through open internet connections by thoroughly auditing their networks.

Control systems often have devices accessible to the internet without operators knowing, leaving them at a greater risk for an attack. Completing a vulnerability assessment allows operators to know what devices are connected, how strong authentication methods are, vulnerable firewalls and use of unauthorized remote access.

To learn more about cyber security for the OT, download the GrayMatter cyber security guide for operational technology:

Download the Guide

The Advancement of Smart Cities

San Diego announced a new partnership with GE to deploy the world’s largest Internet of Things platform using smart streetlights. This will reduce energy costs by 60-percent and transform them into a single, connected digital network that can optimize parking and traffic, enhance public safety and track air quality.

Over 3,000 smart sensors will be deployed, with a potential to expand an additional 3,000 in the future, to upgrade over 14,000 city lights.

By reducing energy needs, greenhouse gas admissions will be reduced. Light pollution will also decrease with the implemented new technology enabling dimming and brightening features either automatically or remotely, depending on natural light conditions.

GE’s intelligent lighting in San Diego. Image: GE Lighting

The GE Current CityIQ sensor nodes will support a range of applications varying from gunshot detection, to smart parking and air quality control.

“This technology is powerful. Downtown visitors will be able to find parking easily and in real time using a smart phone, and the environmental and transportation data will help Downtown meet the goals of the Climate Action Plan. This is a huge win for San Diego,” said Kris Michell, the President & CEO of the Downtown San Diego Partnership.

Deployment of the platform will begin in July and is expected to be completed by the end of 2018.

It’s expected to save the city over $2.4 million annually in energy costs.

TechHub: Digital Disruption, IoT Expanding Digital Footprints and More

Digital Disruption Transcending Industry Borders

With the first quarter of 2017 coming to a close, it’s clear that the exponential growth within the technology industry is not slowing down.

25,000 new information-related jobs were created in February this year alone, according to Forbes.

As this tech push continues, we’re seeing more and more of the Digital Twin emerge as physical and digital worlds blend together.

The Digital Twin is the computerized companion of physical assets, using data sensors to show real-time data analytics.

The adoption of this trend is becoming increasingly popular as companies realize the countless benefits that the Industrial Internet of Things provides, and Augmented Reality and Artificial Intelligence become mainstream.

The biggest mistake companies are making right now is assuming these technologies won’t influence their business or impact their industry.

Industry 4.0 is real, and it’s here.

Smart technology is becoming integrated into every facet of life, resulting in customers having the ability to buy anything, anytime, anywhere.

“The convergence of cloud, mobile, social and data have ushered in a new wave of business models that will present unique challenges for various industries,” said Bob Weiler in Forbes.

With this new technology comes new challenges and questions emerging for industry leaders.

To stay ahead of the competition— and win— organizations will need partners who can provide a new level of knowledge and experience within the industry, according to Forbes.

Rethinking business models within critical industry operations is necessary to maximize performance.

The pace of change is accelerating fast. Organizations need to jump on board and embrace emerging digital technologies.

To learn the first three questions to ask in your digital transformation, join our webinar on Thursday, April 6, at 2:30 PM EST: Transform Your Operation: Vision Before Action.

Gray Matter Director of Professional Services John Benitz will demystify the beginning of the digital journey for you using his expertise on various transformations like the GE Brilliant Manufacturing process.

Reserve My Spot

Digital Transformation: Solving Big Manufacturing Problems

The top problems manufacturers are struggling with are visibility into operations, sharing information across one or multiple plants and allowing the right people to access the necessary data.

The solution? Digital transformation of plant operations.

“Digitizing production processes is more about running an efficient business than it is about jumping onto the next technology bandwagon,” said Industry Week.

Automating processes and storing big data on the cloud allows for a single connected platform with production visibility. It allows for a single-set of accurate data and increases the control plant operators need, according to Industry Week.

Instead of having information documented on manual paper processes like Excel spreadsheets, it can be accessed in real-time across one or multiple plants.

Access to product information, inventory, quality data and more increases the productivity and decreases downtime throughout the plant.

Automating the plant is also automating the communication, in turn freeing up people and resources. Instead of having to track down the necessary information and data, workers have instant access to it at a moment’s notice.

Going paperless and automating processes is a critical step within the industry, and lays the groundwork for future innovations.

Gray Matter has a new solution to help transform manual data entry processes into digital insights for manufacturers, utilities and energy companies.

Mobility@Work digitizes information that would have been buried in stacks of paper and puts data in a format that can be used for big picture analysis.

Hauling manifests, inspections, scheduling, incidents, inventory and time sheets are all transformed from piles on someone’s desk to an easy to read digital presentation.

“There are a lot of correlations you can make if you have the data working for you instead of in a stack of paper.” – Kemell Kassim, Gray Matter VP

Download the free white paper to learn how Gray Matter solved the manual data entry problem and helped save a leading energy company nearly $1 million in just the first year.

Download Here

IoT Devices Expanding Digital Footprints & Vulnerabilities

Security Week defines IoT devices as convenient.

They allow us to have access to data remotely and process it faster than ever.

However, with the convenience comes risk, and most people aren’t locking down their systems like they should be.

There are more avenues now than ever for cybercriminals to breach systems as more devices are connected and the digital footprint of plants are expanded.

The reality of IoT hacks is eminent. Recent research highlights how PLC controllers can be hacked and potentially taint water supply, according to Security Week. Not enough devices are accounted for, and too much personal and business data is intermingled.

The top recommendations to fix this are to get a clear policy in place, designate accountability and segment your network.

By having clear rules, placing risk and responsibility on people or teams and designating sections of your network help block the threat of cybercriminals. It makes finding an easy path into the network nonexistent.

IoT devices have a lot to offer in the world of operational technology and plant management, the risk just needs to be mitigated and vulnerabilities need to be tracked.

Gray Matter offers a vulnerability assessment for OT networks that creates a security baseline for each asset with an IP address.

In a recent interview with ARC Advisory Group, Gray Matter VP Kemell Kassim detailed recent cyber initiatives and ROI case studies.

Download the Q&A Here

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