Getting the Right Data to the Right People Using Ignition

Most industrial and manufacturing facilities live in an environment where data is inexpensive, yet data analysis is nearly unmanageable. Challenges such as data silos and different formats prevent engineers from fully understanding processes and making appropriate decisions.

You need a platform that lets you integrate industrial hardware, including PLCs and sensors, with databases via custom dashboards and applications. This is where Inductive Automation’s Ignition can help. Ultimately, Ignition provides a clean way to organize facility SCADA systems and contextualize data across IT and OT.

Data Rich, But Insight Poor

Today, nearly every piece of equipment is loaded with sensors. Data dashboards are jam-packed with information. The cloud is constantly being updated with new readings. Because data and sensors are cheap and abundant, new information can be collected and stored more easily than ever before.

However, without context, this data is almost useless. Often, data becomes siloed and stored indefinitely. Unfortunately, few people, if any, know it exists or how to use it.

Engineers tend to choose their favorite metrics to track and may never get the full picture of what the data means. It’s hardly their fault. There is an abundance of data to track, and a few human brains cannot provide all of the context required.

As a result, trouble signals get lost in the noise. A few KPIs may get tracked. When an anomaly occurs, it can take longer to determine the cause, reducing throughput and efficiency. Chances are, the data was available to detect the issue earlier, and nobody knew about it.

Contextualization can catch issues early and turn reactive or preventative maintenance tasks into predictive maintenance tasks.

Delivering Data Appropriately

With all data available, how can plant engineers decide how to get the right information to the right people? Effective decision-making depends on accessing the right data sets for each role. Anything beyond that can add complexity without improving outcomes.

Another major obstacle is integrating OT and IT. This is further complicated by differences in manufacturers, software updates, and communication protocols. As facilities mature, this becomes especially difficult. New hardware is added to collect additional data, while legacy systems are patched or become unsupported. Integration and data transfer between these devices can be particularly challenging.

Beyond selecting the appropriate data to use and resolving integration issues, it is also necessary to display the data in an easy-to-use format. With the right tools, developers can create intuitive dashboards or custom applications that deliver the right data to the right person. This can be based on job function or on individual identity tied to system login information.

Ignition as a Solution

Inductive Automation’s Ignition platform solves these challenges when developing and implementing SCADA. Let’s examine a few of the key features:

• Data contextualization.
• Cross-platform capability.
• Customizable dashboards and applications.
• A scalable licensing plan.

Ignition allows all devices to be managed from one location, simplifying integration.

First, Ignition provides a system for data contextualization. With an infinite number of tags available, data can be classified and contextualized quickly. Furthermore, one licensed server supports an unlimited number of users, so data can be sent to individuals or groups without needing a bunch of complex licensing.

Additionally, the ability to integrate systems across platforms, manufacturers, and protocols is essential to a modern business. Ignition is the integration system that makes this possible. The platform allows data to flow freely between devices, regardless of whether they use SQL, Python, MQTT, OPC UA, or other protocols.

Ignition also allows users to quickly design and deploy intuitive, customized dashboards and applications. These dashboards and applications are web-based, meaning that they will work across all devices, from smartphones and tablets to PCs.

Cross-device compatible apps and dashboards make SCADA systems more manageable.

Finally, scalable licensing allows plant managers to select the appropriate license for their needs. No more top-heavy, high up-front costs; just a platform that grows with the business needs of the plant. Server-based pricing means a single licensed server can support an unlimited number of devices.

A Few Case Studies

Metaldom, a large steel producer, faced numerous challenges. Too much data was entered manually, and decision-making processes were too slow. This resulted in production problems that included system failures and unplanned downtime. Metaldom needed a way to integrate multiple machines and deliver the right data to the right people.

With the help of Ignition, the company converted its production systems from paper and Excel-based records to a fully integrated Manufacturing Execution System (MES). This included end-to-end traceability of raw material to finished steel. It also improved data visibility across the entire process, resulting in better communication between departments.

As another example, TreeTop had grown rapidly. This is a farmer-owned co-op that produces fruit juices and other fruit products. When scaling up quickly, automation became necessary to support that growth. The question was: “How efficient are the automation processes?”

For over 10 years, Tree Top has been using Ignition to control, record, and interact with its manufacturing equipment.

Ignition was able to help TreeTop track its KPIs and provide context to the data. Its systems were integrated, and data made sense to operators and engineers alike. They developed what they call “Plant at a Glance” to track key process variables through customized interfaces.

Getting Started

Ignition allows users to create custom applications and dashboards that provide context to the relevant data and process metrics. By doing so, troubleshooting time is shortened, and predictive maintenance is scheduled more efficiently. Operator errors are also reduced, and new production insights become available. For more information on how to simplify data contextualization in your facility, please contact the experts at Inductive Automation and ask how Ignition can help.

Alternatively, download a fully functional trial of Ignition. Within minutes, you'll be able to create industrial applications using the integrated Ignition Designer. You can also connect to data tags, PLCs, databases, and devices, and check out clients running on desktop or mobile devices.

All images provided by Inductive Automation.