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The Future of Predictive Maintenance in Metalworking - Technician handling metal roll. Parker Hannifin With metalworking companies across all industries facing increased demands, engineers need to rethink plant and maintenance tasks and operations. Customers are expecting greater manufacturing flexibility, more reliable, fast-turnaround product shipments and higher quality standards — all at lower costs.

To stay competitive, metalworking companies need to identify more efficient approaches to a variety of production tasks. This need for ongoing efficiency is leading metalworking companies to what some have described as the 4th industrial revolution. At the heart of this latest revolution is a greater reliance on smart, data-driven technologies.

Nowhere has data-driven technology taken a more prominent role as it has in predictive maintenance.


The Future of Predictive Maintenance in Metalworking - download the white paper - Parker HannifinDownload our white paper and explore how trends in industrial manufacturing equipment are driving innovation in metalworking





What is predictive maintenance?

Predictive maintenance (sometimes referred to as condition-based maintenance) is a failure inspection strategy that uses real-time data and models to predict when equipment components will wear down or malfunction so proactive corrective actions can be planned. It covers a wide array of topics, including failure prediction, failure diagnosis, recommended mitigation and suggested maintenance actions to be taken after failure.

In comparison to its predecessor strategies of reactive maintenance and preventative maintenance, predictive maintenance represents a more forward-thinking, cost-effective approach. With a reactive maintenance strategy, assets keep running until they fail. The problem is that such untimely failures result in unexpected and extended downtime and maintenance. With preventative maintenance, in contrast, problems are prevented before they occur. While this approach reduces or eliminates unplanned equipment failures and maintenance downtime can be planned, it does not allow for full utilization of an asset’s service life.


What are the benefits of predictive maintenance?

Predictive maintenance allows for planned downtime while avoiding premature maintenance so plants can get the full value from components. Predictive maintenance analyzes data gathered from numerous equipment sensors to provide a holistic view of asset health.

The concept behind predictive maintenance is not new. It has existed in some form for decades and is already a dominant strategy in many other industries. It has only been recently, however, that the technology, including the sensors, computers and software, has caught up and become affordable for more widespread use in a wide array of industries, including metalworking. 

The data captured from the various connected systems and sensors provides unprecedented insights into the health and total service life of critical components, making smarter maintenance strategies possible. Artificial intelligence (AI) uses algorithms to find patterns and predict mechanical failures before they occur. Instead of simply scheduling maintenance procedures based on preset intervals, a machine learning system can analyze thousands of data points to prioritize maintenance and reduce failure risks.

Predictive maintenance remains one of the most effective approaches, to date, for equipment-maintenance scheduling. It has proven to offer significant bottom-line benefits by increasing equipment availability (productivity), reducing total maintenance costs and avoiding more costly repairs. By preventing major malfunctions, a predictive maintenance program also can help to reduce accidents in the plant to create a safer working environment.


What is monitored as part of a predictive maintenance program?

Machinery connected through an Internet of Things (IoT) platform sends continuous updates on a wide array of factors that affect long-term equipment performance. Some of the more commonly used condition monitoring techniques include:

  • Thermography, which analyzes equipment while in operation to examine areas that are generating excess heat. Thermographic images help prevent failures due to overheated motors, loose or overly tight bearings or connection points, lack of lubrication, misaligned belts, electrical surges, damaged electronic components and much more.
  • Vibration analysis, which can pinpoint issues with extreme accuracy and even specify the source of abnormal vibration. Problem-causing vibration can result from an imbalance in weight on a rotating component, lubrication issues, too tight to too loose bearings, misalignment of belts, shafts and other components, broken or bent components, and many other anomalies.
  • Oil analysis, which examines viscosity and possible contaminants. The quality of the oil can significantly impact how well moving parts operate.
  • Moisture analysis, which utilizes humidity sensors to monitor the water content in hydraulic and lubrication oils. Excess moisture can result in corrosion and interfere with the proper operation of moving parts.
  • Electronic pressure sensors, which monitor the amount of pressure in equipment, such as the fluid moving through a hydraulic system.  A drop in pressure could indicate a partial blockage or other internal issues. In contrast, a spike in pressure could signify that a break, eruption or possible explosion is imminent.
  • Ultrasonic air leak detection, which checks for leaks. Many critical components in a metalworking operation require a well-sealed chamber that contains gas, a specific pressure level, a vacuum or air flow. If the seal is compromised at any point, serious leaks can occur. Ultrasonic air leaks emit sounds at frequencies outside the range of human hearing. Sophisticated detection equipment can monitor sealed systems like pumps, vacuum containers, ducts, ventilation systems and the like.
  • Acoustic monitoring, which analyzes and translates the acoustics and noises generated by electrical and mechanical equipment with moving parts to check for unusual noise.


New innovations in predictive maintenance are allowing for the monitoring of multiple factors simultaneously. For example, Parker’s SensoNODE Bluetooth-powered sensors catch performance fluctuations across a wide array of components and transmit the data through the Voice of the Machine Mobile App, which records data in real-time while also tracking historical performance.


In addition, the Parker Tracking System supports any predictive or diagnostic maintenance program.

Some metalworking plants are taking their predictive maintenance programs to new levels by adding machine-learning software. Although machine learning has been researched for years, its use in applying AI in industrial plants is now advancing more quickly.


What other technologies are making a difference in metalworking?

Automation technologies are also integral components of the 4th industrial revolution, even though metalworking has traditionally been slower than other sectors in its adoption of automated processes.

Robots and their smaller cobot counterparts have, more recently, been making their way into the metalworking industry. Now with lower costs, robots and cobots are seen as attractive solutions to counter skilled labor shortages.

Also gaining popularity are 3D printers, which have proven valuable due to their ability to manufacture more complex and lightweight parts and offer the design flexibility that’s necessary to compete in today’s highly competitive markets. Today’s 3D printers can create intricate parts directly from a CAD drawing, effectively eliminating the need for multiple lathe and mill setups. Until recently, 3D printing was almost exclusively used in the plastics industry, but it is now being adapted for metalworking.


How is technology shaping the future of the metalworking industry?

A new generation of technology is allowing metalworking plants to become more efficient and competitive.

Predictive maintenance innovations that can help reduce production downtime and contribute heartily to corporate bottom lines are key. Although many people in the industry may not think of the maintenance shop as being a prime location for investing in cutting-edge technology, the reality is that new maintenance metalworking technologies offer tremendous potential.


The Future  of Predictive Maintenance in Metalworking - Download the Industrial Manufacturing Trends white paper - Parker HannifinTo learn more about trends in metalworking, read our Industrial Manufacturing Equipment Trends White Paper.



Article contributed by the IoT and the Fluid and Gas Handling Teams. 


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Follow Parker's Industrial Manufacturing Equipment Technology Page on LInkedInFor the latest industry trends, product innovations and expert engineering advice, follow our industrial manufacturing equipment technology page on LinkedIn.


The Future of Predictive Maintenance in Metalworking

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 As the management of manufacturing plants and other assets grows more complex, integrating automated monitoring of key performance indicators (KPIs) at the discrete level provides a built-in safeguard against unplanned downtime or consequential damages. 

And it addresses one of the roadblocks many have discovered with a top-down enterprise-level path to IoT: the requirement for significant investments in infrastructure around equipment and business processes, with little ROI to show for it in the near term. 

A detailed analysis by Accenture and GE revealed that in the Connect-Monitor-Analyze-Predict-Optimize continuum, companies reported a higher percentage of Analyze activity than Connect and Monitor over the course of IoT’s time in their industrial space. In an increasingly connected world, these findings point to an out-of-sequence disconnect.

They suggest that efforts to understand the voluminous amount of data have come before establishing the connected infrastructure needed for data-driven decision making – and well before making a coherent business case for the data collection. In other words, the raw data available often has not been connected to the specific insights required.


The discrete IoT approach to ROI

Discrete IoT views a large machine asset as a collection of systems and subsystems with data onboard that can be given a voice with sensors, and deliver ROI in short order. Every subsystem contributes to the overall performance of an asset, and knowledge in that subsystem can be harnessed to assess its health or predict its failure. Consider which products in a motion control subsystem could provide safety, reliability and productivity insights. Pumps, actuators, valves, and filters all contain current-state performance and diagnostic data.

Having a current-state view of machine health is better than nothing, but simply publishing it on a dashboard screen stops short of being able to optimize a system or a process. The greatest power of IoT stems from the ability to perform historical analysis with time-series data, whether it be KPI-driven alerts and alarms to maintenance personnel; profiles and trend curves that pinpoint root causes of failures; or notifications to ordering systems. One primary goal is to be able to examine the conditions preceding work orders, unplanned downtime or other failures as data is correlated and presented on user-friendly interfaces that make the decision options very clear.


What is the sensor?

 In motion control subsystems, pumps, actuators, valves, and filters all contain current-state data about a machine’s health that can be inspected, unlocked and sent from the equipment to a decision-maker via networked, wireless sensors. A sensor converts a physical condition such as air pressure, in-line and ambient temperature, flow or vibration into an electrical signal capable of being analyzed via the cloud or local applications for a manufacturing system.

Sensors are plugged into a machine’s existing ports or through a custom integration, and trigger alerts or alarms when tied into a control system or gateway programmed to observe when thresholds for defined performance parameters are exceeded. In this way, plant professionals can safeguard the peak performance of their operations.

With today’s wireless sensors and powerful software, it is possible to:

  • Notify responsible parties of an event requiring preventative or corrective action through text alerts

  • View real-time actionable data in graphical form from a dashboard

  • Export data for further analysis of historic trends to any internet-connected device 


 Download our Ebook, Voice of the Machine: Manufacturing's Digital Transformation for an in-depth look into how a discrete approach to the Internet of Things can lay the foundation for your company's growth. 



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Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - Panorama of Parker Booth - Parker China

The ever-changing industrial Internet of Things has revolutionized the traditional landscape and business model of the construction machinery industry. Domestic and foreign parts and service providers have increased their investment and continuously launched innovative products and technical solutions based on the industrial Internet of Things.

From November 27th - 30th, 2018 Parker brought its Voice of the Machine™ industrial IoT platform to the Shanghai Bauma Exhibition. The technology covers the "last mile" of discrete IoT with a focus on interoperability, security and scalability.

In addition, Parker’s booth featured four models to fully demonstrate the powerful and comprehensive traditional hydraulic technology, covering the cab control system, chassis drive system, vehicle implement system and engine power system.


Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - Engine model - Parker China

"Aligned with the new industrial landscape brought by the industrial Internet of Things, Parker created a breakthrough platform, Voice of Machine, to deliver connected products and systems. Our system integration capabilities will help address the increasingly demanding application needs of customers worldwide."   

 Hou Yifei, president of Parker’s Transmission and Control Group, Asia Pacific



Covering the "last mile" of the Industrial Internet of Things

Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - VOM display - Parker China

At present, Internet of Things technology focuses on enterprise-level solutions, but the key component data identified and collected by the enterprise-level Internet of Things is only 10%, which greatly limits the potential of mechanical equipment to predict failures and optimize performance. Discrete IoT can deliver the remaining 90% of the core component data, which is the "last mile" that the Industrial IoT does not reach.

To this end, Parker initiated a centralized strategy to ensure that all IoT-based products and systems use the same communication standards and best practices to deliver interoperability, security, scalability and visibility.


An ecosystem of connected products and services

Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - HMI Display _ Parker China

Through the Voice of the Machine online platform, users can interface with products, systems and professional engineers to ensure global monitoring and asset management for critical system operations.

Both IQAN® and PTS are software products based on the Voice of the Machine platform, which was also unveiled at the Shanghai Bauma Show. IQAN® Interconnect Software integrates intelligent hydraulic components and electronically controlled hardware and software to optimize device performance and simplify remote monitoring.

No matter where you are, users can use the IQAN® Interconnect Software to remotely diagnose vehicle faults and learn about current performance status through the Parker Vehicle System Gateway. IQAN® Interconnect Software provides a large number of standard function modules and a custom configuration interface. It features an adaptive web interface, which is convenient for users to view from multiple channels such as a PC, tablet or mobile phone and can easily publish data to the cloud.

Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - Mobile Scan for PTS - Parker China

The PTS Parker Tracking System is an asset management solution for critical wear components. The PTS software records detailed information about parts and assets, and users can connect to the Internet for secure access from multiple sources. The PTS generates a unique identification code printed on the barcode or RFID tag for each hose assembly.

Record and extract hose information through barcode and RFID traceability system to quickly, regularly and accurately perform equipment maintenance and repair, reducing downtime of engineering equipment. PTS can also establish an asset location database, customize inspection templates, store retrieval history inspection results, and set up scheduled maintenance reminders.


Improve system integration capabilities of traditional hydraulic technology

Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - Ecoreach forklift assembly - Parker China

The EcoReach forklift assembly system is the highlight of Parker’s traditional hydraulic technology. The electric forklift is usually handled by an electro-hydraulic system. The powertrain consists of a series of separate components: an inverter that converts battery energy into alternating current; an induction motor that outputs torque and speed; and a hydraulic pump that provides flow and pressure; and a hydraulic system controls the valve block to control the flow and pressure of the required hydraulic function.

Parker Showcases Industrial IoT Solutions with Voice of the Machine at Bauma China 2018 - Implement display - Parker China

The EcoReach Forklift Assembly System integrates and optimizes these components to improve performance and efficiency, extend battery life and increase loading and unloading speed. The Parker Hannifin EcoReach Forklift Assembly system uses a fully integrated electro-hydraulic system assembly that plugs and uses to minimize the complexity of upgrading the forklift through the EcoReach system.

A large number of test results show that the system brings great potential benefits: the time to stabilize the oscillating load is reduced by 60%, the handling efficiency of the operator is improved, the time required for the entire lifting cycle is shortened, the production efficiency is increased by 13%, and the energy consumption of the entire lifting cycle is reduced by 48%. If you use the same battery to charge, the electric forklift works longer.


Learn more at Parker Voice of the Machine - Industrial IoT


Additional articles on Voice of the Machine:

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Industrial IoT Solutions With Voice of the Machine at Bauma China

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 It seems like every industrial company is at some stage of planning for or deploying industrial Internet of Things (IoT) technology. According to a survey of IoT decision makers and influencers in the manufacturing, oil, and gas, and transportation industries by Bsquare for their 2017 Annual IoT Maturity Survey, 86 percent of participants had adopted IoT solutions. Almost all believed that the technology will provide a significant or tremendous impact on their industry.

Yet, while there is certainly good news on the IoT front, you can also find plenty of articles suggesting that IoT adoption is proceeding slower than many expected. A 2017 Cisco study found that 60 percent of IoT initiatives stall at the Proof of Concept stage and only 26 percent of companies considered their IoT initiatives a complete success.

The difference in those two surveys may result from who was surveyed. For their report, Bsquare surveyed “experienced, senior-level IoT decision makers” in select industries with a well-defined IoT value proposition, while the Cisco report was based on a broader survey of IT and business decision makers.

Still, there is no denying the complexity of deploying IoT broadly. It requires installing sensors or replacing legacy equipment with IoT-enabled equipment, as well as an implementation of software to support sensor management, data collection and visualization and, in some cases, machine learning. Plus, many organizations will need to address the skill gap that currently exists in the areas of IoT implementation and management.

All of that makes the move from small pilot programs, where conditions and unexpected consequences can be carefully managed, to broad deployments one of the most significant challenges we face as an industry.


Planning for scale

If you are coming off a successful pilot, you have proven the technology based on your use case and have the opportunity to build on that momentum to make a significant, positive impact on your business. Capitalizing on that opportunity starts with conducting a thorough capability and needs assessment across functional departments. Based on this assessment, you’ll need to assemble a dedicated cross-functional team to plan for and manage the deployment.

There are two factors I want to emphasize in regard to that team. First, collaboration across the business, particularly IT and OT personnel, along with engaged executive sponsorship, is crucial to a successful deployment. Second, don’t hesitate to bring in consultants and partners as needed. As the Cisco survey found, “organizations with the most successful IoT initiatives leverage ecosystem partnerships most widely. They use partners at every phase, from strategic planning to data analytics after rollout.”

One of the first questions this team must address is, what exactly does scale look like for our organization? Be clear and set expectations with executive sponsors and division leaders on what success looks like and what is required to achieve it.

This is where an IoT planning framework becomes a powerful tool. There is the experience to be gained from other adopters, but there is no off-the-shelf plan you can plug into your organization. The framework I’ve found most effective is one built around the five core components of an IoT solution. These include:

  1. The “things” that will generate data.

  2. How those things will be connected to the internet.

  3. How data from those things will be collected.

  4. Where that data will go.

  5. Who is responsible for managing the data.

It sounds simple, but this framework can impose the necessary discipline to minimize unexpected consequences, ensure consistent collaboration and support the successful transition from limited to broad deployment.



Planning and managing the deployment

Once you have your team and framework, it’s time to begin planning the deployment. In terms of the things that will be generating data, you need to gain an understanding of their shape, operating specifications, and environmental limits. Where do sensors currently exist and where do they need to be added? For sensors that need to be added, is the most economical choice to retrofit legacy equipment or replace that equipment if it is already approaching the end of its functional life? Carefully analyzing the specific requirements of your things during the planning stage can save huge amounts of time and hassle later in the process.

The same is also true for connecting things and collecting data. This is one of the areas where collaboration between IT and OT personnel is essential. Identify exactly who from each group will be required to support the installation and commissioning and the time commitment required. Also, develop contingency plans for addressing equipment failure so you can react to those situations, if they occur, in a controlled manner that minimizes consequences.

Another important consideration is opening communication channels with on-site personnel. If they aren’t on board with the plan, the chances for success are diminished. As with any new technology, you may face resistance and skepticism, and this should be addressed early in the process.

When you’re ready to begin the deployment, the same framework used for planning can be employed. In terms of things, the challenge shifts from defining requirements to managing logistics. Who is responsible for ensuring the sensors, equipment and other technology required to support the deployment get where they are supposed to be when they are supposed to be there? The complexity of this task should not be underestimated, particularly for multi-site deployments.

This same challenge extends to the human resources required to support the “connect” and “collect” functions of the framework. Do you have the installation resources lined up, contracts in place and wiring diagrams harmonized?

Deployment is also an additional opportunity to connect with on-site resources to reinforce the why behind the new technology. Again, human factors play a key role in the success of IoT and should be addressed at every stage. Finally, take the time to practice the contingency plans you developed during the pre-deployment phase.

As you move into the post-deployment, this framework allows you to address key questions associated with system health monitoring, the integrity of data collection and internet connectivity systems and who is responsible for each, how results are reported to various stakeholders and who makes decisions about changes to the system.


Crossing the bridge

The challenge of moving from a successful pilot program to a broad deployment can be daunting and shouldn’t be undertaken lightly. But, if you have identified high-value use cases it is one that must be addressed. Developing a deployment framework that considers things, connectivity, collection, learnings and action at each stage can help impose discipline across the process and increase the likelihood of success. 


Jeff Smith, business development manager, Internet of Things, Parker HannifinThis post was written by Jeff Smith, business development manager, Internet of Things.






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Defining the Value of IoT in a Connected World

The Internet of Things: How Your Company Can Get Ready

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The Industrial IoT Journey: A Framework for Moving from Pilot to Broad Deploymen...

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 As a company that has produced motion and control components and subsystems in core industrial sectors for 100 years, Parker has recently taken a significant step forward by embarking on a digital transformation. Between our own journey and working with customers seeking to leverage the Industrial Internet of Things, we’ve arrived at certain truths about the process of building digital ecosystems of connected products. One of those truths is that an effective enterprise of connected “things” must have oversight and buy-in from a broad spectrum of stakeholders.    


A culture of silos has no place in a digital transformation

Going digital affects too many aspects of an organization, often in ways that only become apparent later on. That’s why it makes sense to marshal perspective and talent from every corner of the enterprise when determining how best to participate in what has essentially become another Industrial Revolution.

At its most simplistic, deploying IoT effectively can achieve two things for your organization: improve your ability to save money, or improve your ability to make money. That’s the power of understanding the health of your machine assets before they break down, and carving out a market advantage based on the intelligence provided by connected devices. The decision to move into this realm requires a clear-eyed assessment of where your business is now, and where you want it to go, with input from everyone whose functional experience would or could be altered as a result of that transformation.

For example, if your responsibility is to ensure the highest level of uptime and safe operation for a fleet of off-highway work trucks or an entire manufacturing organization of factory assets, you know it would be valuable to have parts and components in that equipment enabled to alert you when service or replacement is needed. So you would want to be sure that the enterprise was selecting a parts supplier with the ability to design, manufacture, integrate and easily service such components – a partner rather than a vendor, essentially. That would involve a meaningful conversation with colleagues outside of the operations silo.


Procuring the solution is just the beginning

But what about managing the never-ending data stream created as a result of liberating the information contained within the now-intelligent parts? Can you integrate it with other databases to generate insights and drive value? What about data security and privacy? Do you have people with the right skills working for you now; can they be trained or should new talent be recruited? What about paying for all of this?

These questions and many more inform what should become part of an ongoing cross-functional conversation within the enterprise. The idea of 24/7 connectivity can be very appealing, but the key to success is having a well-thought-out strategy to tie connected products to your specific core business and deliver those solutions to the end users who can benefit from them. That only comes from having a diverse group that is well informed and connected to the process because its members fully appreciate the stake they have in it. 


Our IoT roadmap to success started with customers

Our near-term IoT objective for our own OEM customers was to provide better reliability and higher performance for the components and systems they source from us (such as pumps, hoses, connectors). Built on a common platform, our IoT-empowered solutions all recognize and communicate with each other, simplifying deployment. The resulting Voice of the Machine offering makes it possible to identify what we call a serviceable event, determine the recommended next steps, and through our ebusiness capability, make it easy to remedy. That is Parker’s play in this stage of the evolution of the IoT revolution.

In our case, engaging expertise across the company when we began our journey was a nuanced process of change management. We had a lot of leaders already who had to be brought along because, while the focus in IoT may initially emphasize the “build” part of a new solution, the “operate,” “sell” and “service” elements of the solution are critical for a company like ours.   

That meant engaging our head of sales, CIO, the tech office and the P&L executives closest to the customer. Providing the support they need to achieve alignment means something different to each of these functions. To deliver on the promise of true collaboration that we ascribe to at Parker, we maintained close working relationships and a high degree of transparency as we worked on what our smart product offering would ultimately look like. And it remains a living, breathing organism to this day.

So what is the digital strategy to be for your company? What current and future customer use cases should you be envisioning today to improve your customers’ experience and who in your organization should be involved in shaping those experiences? It will never be too late to get the conversation started. 

To learn more about how to empower your operations with Parker’s Voice of the Machine™, visit our IoT website.


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When New Machines Have a Voice, What Will Old Machines Do? - factory - Parker Voice of the MachineLast year, PwC found that 85 percent of U.S. manufacturers are already delivering, or planning to deliver, products with IoT capabilities. Considering the promise of IoT, this should come as no surprise.

Manufacturers, including Parker, are moving quickly to IoT-enable their products because of the exciting new capabilities IoT technologies deliver. For example, equipping off-road industrial equipment with telematics systems that send data to a centralized fleet management platform provides the visibility fleet operators need to increase equipment utilization, reduce maintenance costs and increase safety.

Similar benefits are available for in-plant equipment. When subsystems, such as pumps and power units, are factory-equipped with sensors and network connectivity, plant operators suddenly have the visibility they need to improve efficiencies and reduce downtime.


Delivering value in manufacturing

When New Machines Have a Voice, What Will Old Machines Do?Deployed broadly, these capabilities deliver significant value in manufacturing. In fact, according to McKinsey, factories and other production environments have the potential to realize the biggest financial impact from the application of IoT. They predict the IIoT will generate an economic value of between $1.2 trillion and $3.7 trillion by 2025. This value will be created through new energy efficiencies, labor productivity, inventory optimization, and improved worker safety.

But, what happens when these IoT-enabled systems take their place alongside legacy systems? Do plant managers and engineers risk creating islands of intelligence within their plants that leave out the legacy systems that make up the bulk of their equipment and limit the return on their investment in IoT infrastructure? Or, will they be forced to replace critical legacy systems prematurely to expand the reach of their IoT initiatives?

Fortunately, the answer to both of these questions is no.  “First-fit” – meaning components or subsystems that have intelligence and connectivity designed into them – still receive the lion’s share of the attention when it comes to the future of IoT. However, in many cases there is an opportunity to retrofit legacy devices with IoT technology to allow them to take their place alongside first-fit components in smart machines and processes. In the short term, these retrofit opportunities may prove even more valuable than first-fit opportunities because they can be applied to aging equipment with a higher risk of failure or inefficient operation.

For example, air compressor inefficiency is a common source of wasted energy in manufacturing. New air compression systems have sensors designed into them that allow leaks within the system to be identified to eliminate inefficiencies. But legacy systems can also be instrumented with similar sensors to achieve the same objective.


Key to success of IoT retrofits

Key to the success of legacy system IoT retrofits is the ability to integrate the data from the retrofitted system with other systems, both new and old, to simplify IoT management. This is one of the values of the discrete approach to IoT provided by Parker’s Voice of the Machine™.

It allows each system to act as a standalone application through the Voice of Machine cloud platform and user interface. It also allows the data from the component or subsystem to be delivered to an existing cloud platform through cloud and edge-based integrations and presented in context with other machine data, regardless of whether that data was created by a Parker component or a component from another manufacturer.

In today’s increasingly connected world, it seems short-sighted to not have IoT capabilities included in new equipment that is being installed in either brownfield or greenfield environments. However, it’s also very limiting to restrict IoT to only new components or subsystems, particularly those whose operation have a significant impact on operating costs or productivity.

Parker and its distribution partners have the IoT expertise and toolset to help you develop a plan that focuses IoT on the systems or components where the greatest value can be realized, new or legacy, and create an integrated solution that maximizes return on investment.


Learn more about Parker's Voice of the Machine™ and how it can help your factory.


When New Machines Have a Voice, What Will Old Machines Do? - Jason Kreiner - Parker IotJason Kreiner, connected products platform manager, Parker Hannifin Voice of the Machine™





Other IoT focused articles:

Parker Teams Deploying IoT to Help Customers Improve Operations

Aggressive Measures for Industrial Cybersecurity

Defining the Value of IoT in a Connected World

Taking IoT to the Last Mile by Listening to the “Voice of the Machine”

You Have A Dashboard, So Now What?


When New Machines Have a Voice, What Will Old Machines Do?

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Aggressive Measures for Industrial Cybersecurity - by Venkat Perumalsamy, applications architect, Internet of Things, Parker Hannifin CorporationAs the technology that powers the Internet of Things (IoT) progresses, it’s changing the way industrial companies operate. But that technology brings security risks. Ransomware. Malware. Viruses. Account hijacking. Cybersecurity threats to the IoT are a reality that must be confronted. And as more devices are connected to the Internet, the possibility of further security breaches rises.

There are over 300 million new devices connected to the Internet every month. These devices go into a variety of industrial applications, from production machines and robotic equipment to assembly lines and mill and plant equipment. Embedded with software, sensors, actuators and network connectivity, the devices are designed to collect and exchange data.


Learn more by downloading our latest white paper: Staying Ahead of Industrial Cybersecurity Threats 

How IoT Analytics Can Optimize Productivity - White Paper Download - Parker Voice of the Machine

    Cybersecurity: A business priority

Many industrial and manufacturing companies have IoT strategies in place to capitalize on the data their machines can provide, but some are wary to move forward because of concerns over data security or loss of proprietary information. Just think of the impact cyber attacks can have on businesses.  Downtime. Productivity loss. Proprietary information loss. Damaged reputation to customers, partners and investors. In effect, cybersecurity touches virtually every aspect of business.


The Parker IoT platform: Voice of the Machine™

The Parker platform for secure IoT is Voice of the Machine™, an open, interoperable and scalable ecosystem of securely connected products and systems. It is designed to remotely monitor assets, keep critical systems productive and continually improve cybersecurity. Parker’s primary focus is at the component and sub-system level or what we refer to as Discrete IoT. This is a component-centric approach where component insights from analytics and models are the basis for higher-level decisions.


Aggressive Measures for Industrial Cybersecurity - by Venkat Perumalsamy, applications architect, Internet of Things, Parker Hannifin Corporation


High standards of cybersecurity

Parker takes a multifaceted approach to cybersecurity. It involves multiple steps in the collecting, transfer and storage of IoT data. It begins with the machines and the sensors or measuring devices built into them. Data gathered from the sensors is encrypted before it is transmitted to a cloud server or an internal onsite server where data is stored. To read or view the encrypted data, a secret key or password is required to enable the decrypting process.

Another measure Parker takes is the requirement of a digital certificate to access the data. The certificate is verified through a unique set of credentialing and identification steps for each device to enable connectivity. Parker can create distinct identities and credentials for each connected device.

Learn more by downloading our latest white paper: Staying Ahead of Industrial Cybersecurity Threats 



Aggressive Measures for Industrial Cybersecurity - Venkat Perumalsamy, Applications architect, Internet of Things, Parker Hannifin Corp

This blog was contributed by Venkat Perumalsamy, applications architect, Internet of Things, Parker Hannifin Corporation




Additional insight into Parker's Voice of the Machine:

Aggressive Measures for Industrial Cybersecurity

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How IoT Analytics Can Optimize Productivity - Mining Shoving working at night - Parker Voice of the MachineFrom our personal devices to medical systems and online shopping, it’s clear we live in a digital world—and the rapid progress of that world is driven by data. The collection and application of data are everywhere. It’s why there’s been substantial investment in the Internet of Things (IoT) across all major industries. But collecting data is not enough. A precise analytics strategy is necessary to fully understand the data.  Because real value can only be obtained from data when it can be analyzed, interpreted and used to generate the insights that improve productivity.
How IoT Analytics Can Optimize Productivity - White Paper Download - Parker Voice of the Machine
Learn more by downloading our latest white paper: Using Analytics to Build Customer Solutions 
How IoT Analytics Can Optimize Productivity  - Taking IoT to the last mile infographic - Parker Voice of the Machine
  The Parker approach: Discrete IoT
Generally, the Industrial IoT is employed to monitor the relative health and productivity of equipment. Insights are required at the machine level so that machines can self-report the difference between optimum and actual performance. But the machines, of course, are made up of components, so generating insights at the machine or system level requires visibility at the component level. This is where Parker expertise applies. Parker has over a century of experience in motion and control technologies. Through its platform called Voice of the Machine™, Parker’s efforts in IoT are concentrated at the component- and subsystem-level, or what we refer to as Discrete IoT. Parker Discrete IoT produces distinct component insights that become the basis for machine, higher-level system and even fleet-level productivity improvements.
Generating insights from digital twins
To realize the most value from IoT, Parker focuses on contextualizing the data collected from machines. Models of the overall system and the individual components are created and leveraged to generate insights. Not unlike the way their actual counterparts are assembled, digital twins of components are connected to build digital twins of systems. The insights identified from these models reveal opportunities for customers who can then make improvements to existing processes and systems. With model-validated insights from Voice of the Machine™, decision-making, planning, and management of operations are more precise and more productive.
How IoT Analytics Can Optimize Productivity - Digital Twins infographic - Parker Voice of the Machine
Discrete IoT informs decision making
When precise machine data is analyzed in the context of higher-level operational goals, sound decisions can be made. For example, think of all the factors that go into deciding when to schedule maintenance on a factory machine. What is the production schedule? Is planned downtime coming up? How much will it cost to replace a component? What is the loss of performance cost compared to the cost of replacement? How long will the machine be down?  How much will a worn component affect performance? Answering these questions is key. But just as critical is analyzing the right data that generates actionable insights about the machine itself.
To learn more about how to empower your operations with Parker’s Voice of the Machine™, visit our IoT website 
How IoT Analytics Can Optimize Productivity  - Tim Franke. solutions architect, Internet of Things Parker HannifinThis blog was contributed by Timothy Franke, solutions architect, Internet of Things, Parker Hannifin Corporation
Additional insight into Parker's Voice of the Machine:

How IoT Analytics Can Optimize Productivity

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 If you’re familiar with Parker, you know we’ve been manufacturing components and subsystems for industrial equipment for a long time. One hundred years to be exact.

You also know the world is much different today than it was 100 years ago—or even five years ago for that matter.

One of the biggest recent advancements in industrial manufacturing is the proliferation of sensors on all types of industrial equipment, from connectors, hose and tubing to pumps, motors, actuators and filters. Data from these sensors creates enormous opportunity to transform the way industrial equipment is operated and maintained.

While much of the focus of Internet of Things (IoT) technology has been on “enterprise-level” IoT systems, these systems are unable to collect data from the component level. To borrow a phrase from telecommunications, industrial IoT has failed to travel the “last mile,” limiting its overall value.

 Proprietary protocols, security concerns, and the overwhelming volume of data being generated have all prevented operators from covering this last mile and gaining the insight they need to predict failure and optimize performance at the component level.

That’s where our 100 years of experience comes in. Our depth of technical knowledge gained from working across hundreds of thousands of applications, has been instrumental in our effort to effectively address the challenges of discrete IoT. For example, we know exactly where to integrate sensors for optimal insights, what data to collect, and how to present it to maintenance, repair and operations professionals in the way that is most useful to them.

But experience alone isn’t enough to travel the last mile. Addressing the challenges of discrete IoT also required focus and commitment.

Several years ago we initiated a centralized strategy within Parker to ensure the IoT-Empowered products and subsystems we were developing across our businesses would all use the same communications standards and best practices to deliver interoperability and security.

We also realized that our products must co-exist with products from other manufacturers. One of the core principles of our centralized IoT initiative is “the value of any IoT solution is directly proportional to its interoperability.” We employed an open, exchange-based architecture that enables interoperability with third-party products, applications and platforms. We also worked with the OPC Foundation and the Industrial Internet Consortium to support interoperability across IoT devices and platforms.

 Security and ease-of-use are other core principles. We baked in best-practice data encryption in motion and storage to create an end-to-end secure ecosystem and employed a common visualization scheme to ensure a consistent experience across our solutions.

The result is an open, secure, interoperable and scalable ecosystem of connected products and services that help you improve business productivity by unlocking the last mile of IoT.

We call it Voice of the Machine™.


To learn more, visit www.Parker.com/IoT or talk to your Parker representative.

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Defining the value of IoT in a connected world - field sprinkler system - Parker Voice of the Machine

There’s volumes of material that focus on the technology behind IoT. However, a more significant discussion should be had around the value IoT delivers. While that value must begin with end users of the technology, it can’t stop there. To ensure future success, IoT must cascade and deliver value to equipment manufacturers and distributors as well.

In this stage of IoT development, value relates primarily to the visibility and insights IoT applications provide and the performance and uptime improvements they enable. In manufacturing and production environments with discrete IoT, such as that provided by Voice of the Machine™, the key business driver for IoT adoption is likely to be equipment uptime, as this addresses one of the major issues virtually every industrial company faces. 

Quantifying value

In manufacturing and production environments, downtime in one piece of equipment can impact an entire process. According to the ARC Advisory Group, 43 percent of downtime is unplanned, and this type of downtime creates a production capacity loss of 5 percent annually. In addition, repair costs are 50 percent higher for equipment that is run to failure compared to equipment that is serviced in advance. 

Yet companies can be reluctant to make investments today based on promises of value that may not be fully defined. So why is IoT’s “value” so hard to recognize? The reasons include too much focus on technology and not enough collaboration between operations technology (OT) and information technology (IT) professionals.

Focusing on the short-term value of IoT is fundamental to overcoming the resistance to adoption that exists within some organizations. It also shifts the discussion around IoT from, “here is some cool technology we are going to add to your equipment or process,” to “let’s talk about what equipment is most likely to fail, how frequently that equipment fails, and how many pieces of that type of equipment are in your overall operation.” 

The answers to those questions then become the basis for quantifying the value for a specific application. They also create the opportunity to bring OT and IoT professionals together around a common business goal: improving profitability by focusing technology in ways that directly impact costs and productivity, such as discovering when component or subsystem performance is deviating from established metrics.  

Once there is alignment on the broad goal, issues of whether the solution is OT- or IT-based become easier to resolve and organizational barriers that can complicate IoT deployments become easier to navigate.

Discrete IoT value chain - Defining the value of IoT in a connected world   Enabling value

With many IoT solutions, equipment distributors will play a key role in selling, integrating and supporting IoT technology. The Voice of the Machine cloud platform and data visualization tools simplify the task of implementing IoT solutions, allowing Parker’s distribution partners to better meet their customers’ demand for connectivity and intelligence.

In 2017 PwC surveyed U.S. manufacturers regarding their current and planned activities related to IoT and found that while 38 percent were offering IoT-driven products and services, only 14 percent had created IoT go-to-market strategies. As PwC states in their report on the survey, Monetizing the Internet of Things, “this suggests that some companies are offering IoT products and services without a clear strategy to market those products.” The potential result of this gap between product development and marketing is that companies will fail to see the expected return on their IoT investments. 

Defining the Value of IoT in a Connected WorldRather than focusing on the technology, the marketing strategy must present a clear and quantifiable value proposition that speaks to core business problems that OT and IT professionals can rally around. In addition, manufacturers can streamline IoT development by working with partners, such as Parker, that have deep experience in sensor and motion technology and an established platform for converting raw data into actionable intelligence.  

By taking the steps to focus IoT on applications with bottom-line business benefits, end users, distributors and manufacturers all benefit. As users get comfortable with the technology, and realize a measurable return, pockets of resistance diminish and additional applications will be more likely to proceed. Distributors with IoT capabilities will be positioned to elevate and strengthen their relationship with their customers while manufacturers can create a competitive advantage for their offerings.

At Parker, we’re helping make this possible by delivering discrete condition monitoring solutions for equipment in production operations and telematics solutions for mobile assets—and by providing our partners and their customers with the tools to support IoT applications. 

Learn more about Voice of the Machine on our website.  

Jeff Smith - Defining the value of IoT in a connected world



   Article contributed by Jeff Smith, business development manager, Internet of Things






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