Challenge & Context

Industrial manufacturing companies require reliable and efficient monitoring and control of their processes, necessitating the development of innovative and cost-effective solutions. The advent of the Industrial Internet of Things (IIoT) has made it possible to collect and analyse vast amounts of data. However, ensuring the reliability and accuracy of the data collected from a diverse range of smart,  small-sized interconnected factory devices remains a challenge. To address this issue, the i4QP introduces Reliable Industrial Data Services (RIDS), a comprehensive suite of 22 innovative and cost-effective solutions. These solutions cover the entire data cycle, including sensing, communication, computing infrastructure, storage, analysis, and optimization. 

With i4Q RIDS, industrial data can be efficiently managed, enabling real-time monitoring and control of manufacturing processes. It also provides simulation and optimization tools for continuous process qualification, quality diagnosis, reconfiguration, and certification, ultimately ensuring high manufacturing efficiency.

The journey towards achieving Zero-Defect Manufacturing (ZDM) presents several challenges. One such challenge is gathering data from common devices and industrial machines, while ensuring real-time data processing, seamless integration with existing platforms and services, support for common industrial standards and interfaces (e.g., OPC UA, MQTT, etc.), and accurate data visualization and monitoring to identify trends and detect potential abnormal behaviours in advance. 

Among all the pilots in the i4QP, BIESSE, a renowned manufacturer of joinery, furniture, windows, doors, and wood building components since 1969,  faced a specific challenge. They needed to ingest data and events from multiple woodworking machines communicating via the OPC UA protocol, which is the de facto standard in the automation market and Industry 4.0. This data needed to be directed to i4Q RIDS for further processing and analysis.

Specifically, BIESSE described their business pain as follows: 
“On woodworking machinery, it is very challenging to keep the health of components under control, which can affect machine downtime, customer satisfaction, and costs.The i4QP aims to handle a large amount of data provided by OPC UA servers and the smart sensors on our CNC machines. Thanks to the implementation of i4Q RIDS, BIESSE can provide its customers new diagnostic tools and Industrial IoT services, to remotely monitor and manage their manufacturing systems more efficiently and to predict anomalies in advance.”

To achieve this objective, the FIWARE OPC UA IoT Agent has been proposed as a bridge to handle communication between the OPC UA machines and the NGSI interface of a FIWARE – Orion  context broker. Additionally, a new companion tool called the O2K-Connector has been developed. This tool is designed to efficiently transmit data from the OPC UA field to the Apache Kafka-based i4Q RIDS, also known as the “i4Q Message Broker”, simplifying  data distribution to other i4Q services.

Figure 1 . Technical Framework

Figure 2 . Architecture

Benefits & Impact

​The IoT Agent OPC UA is a transformative solution carrying substantial promise for industrial users, with an impact that resonates across various fronts.

Currently, the IoT Agent OPC UA has amassed a considerable user base within the industrial sector. Numerous customers spanning various industries have already recognized its value, establishing it as a preferred choice for enhancing operational efficiency and data integration. This user base encompasses both  small and medium-sized enterprises (SMEs) and large industrial players. Its adoption is not limited by the size of the enterprise but instead caters to a diverse array of industrial needs.

Looking ahead, the anticipated number of users is expected to grow substantially. The versatility and adaptability of the IoT Agent OPC UA position it as a future-proof solution. As industries increasingly recognize the significance of IoT and data-driven decision-making, it is likely that more users will turn to this solution for their needs.

The high impact of the IoT Agent OPC UA primarily resonates with industries striving to harness the power of the Industrial Internet of Things (IIoT). Sectors such as manufacturing, energy, logistics, and healthcare are poised to experience significant benefits. These industries deal with complex machinery and data-intensive processes, making seamless IoT integration essential for enhancing efficiency, achieving cost savings, and maintaining competitiveness.

This solution also holds significant importance for Europe, as it is being actively used in multiple Horizon 2020 R&D projects. These projects aim to advance European industries by incorporating cutting-edge technologies, and the IoT Agent OPC UA plays a central role in achieving these objectives. Its significance extends beyond individual companies, serving as a key contributor to the growth of the European industrial landscape and, consequently, the betterment of society as a whole. By facilitating efficient data exchange and integration, the IoT Agent OPC UA fosters innovation, competitiveness, and sustainability, aligning with the broader objectives of the European Union’s Horizon 2020 initiatives.

Added value through FIWARE

FIWARE have needed utilising for an extended period, harnessing the advantages of this innovative technology to enhance solutions. FIWARE, with its Open Source and Standards-based approach, has consistently delivered substantial value to our endeavours.

FIWARE has empowered the pilot to seamlessly achieve interoperability and scalability. Its standardized NGSI (Next Generation Service Interface) data model facilitates the integration of various data sources and systems, streamlining the process of collecting, processing, and sharing information. This interoperability ensures that our solutions can adapt and grow alongside evolving technological landscapes, future-proofing our investments.

One of the key value-adds created through FIWARE is the capacity to unlock the full potential of data. FIWARE’s context management capabilities allow us to not only collect data but also contextualise it. This means that data is not just a collection of numbers but is imbued with meaning, enabling smarter decision-making and deeper insights. Additionally, the ability to dynamically manage context ensures that our solutions can adapt to changing conditions and requirements in real-time, leading to increased operational efficiency and an improved user experience.

Furthermore, FIWARE’s ecosystem offers a wide array of pre-built, reusable components and enablers. This expedites development, reduces costs, and mitigates the complexity of building and maintaining our solutions. The rich ecosystem also fosters innovation by providing a foundation upon which developers can rapidly prototype and deploy new features and services.

FIWARE’s future readiness is another compelling reason why it is not only the right technology for  current pilot but also for future solutions. Its active engagement in European initiatives like Horizon 2020 ensures that it remains at the forefront of technological advancements. FIWARE’s commitment to open standards and continuous evolution ensures that it can seamlessly integrate emerging technologies such as IoT, AI, and blockchain, making it a versatile and future-proof choice for projects and solutions. In essence, FIWARE serves as a reliable and innovative partner, consistently adding significant value to our efforts and positioning us for success in the rapidly evolving digital landscape.