Pressed
Pressed
Unlocking Business
Value Through
Industrial Data
Management
Author: Shefali Patel
Contributing authors: Jeremiah Stone, Scott Duhaime and Venkat Eswara
Contents
03 The Opportunity and Potential of Industrial Big Data
05 Industry Mega Trends and Challenges for Big Business
08 GE’s Approach: Maximizing Value from Machines and Enterprise Data
12 Rethinking Data Management—Control to Cloud
14 Customer Case Studies
16 Conclusions
With lower cost of sensors, we can now tools proliferate, they are changing how At GE, we are developing a better
measure many things that we could we behave, automate machines and reap way—a better way to manage industrial
not before, and therefore control our benefits of digitization.1 big data that triggers insights. We are
technology more precisely and less However, despite the promise of big in the early stages of a long journey
expensively than ever before. Utilization data, companies struggle to exploit its of discovery and invention, taking a
of Internet technologies has made it value. Why? Abundant data by itself solves longer-term view to strategic data
easier to access data. Data can help us nothing. Its sheer volume and variety management and its technologies that
make better predictions and take smarter exceeds human capacity to configure it translate to business advantage.
actions. We can be collectively objective, efficiently. Inherent challenges tied to
rather than individually subjective. We can evolution and integration of information
do so in areas where we formerly acted
based on intuition and assumption rather
and operation technology make it difficult
to glean intelligence from unorganized
Abundant data by
than by data and analysis. As big data data, compromising digital literacy. itself solves nothing.
What if invisible insights into your business became visible? What if terabytes of data pulsing through your operations were
captured and stored securely in the field and in the cloud so that it could be accessed in real time? Imagine an enterprise
world with a single source of truth—a panoramic view of your entire fleet and operation with the ability to zoom into
powerful telescopic detail in a cost-effective way, and a workforce focused on resolving issues, innovating and collaborating
across silos.
This paper is about Industrial Data Management: its challenges and opportunities, with a central focus on foundational technologies that
lay the groundwork to win in the future of the Industrial Internet.
Source: Goldman Sachs Global Investment Research, John C. McCallum Research, TCG Advisors
Industry and
Customer Challenges
Taken together, these trends are carrying us forward. They are also
creating new challenges for business leaders. We have grouped them
into technology, business and organizational challenges.
Technology challenges
Islands of disparate data challenges. When the data is Technology integration
scattered throughout plant and the
Keeping up with a flood of Management of industrial technology
enterprise, integrating and analyzing
information is difficult. Most has traditionally been split between
it manually becomes resource-
companies struggle with data deluge two separate fields: information
intensive and tedious. This has an
driven by lower cost storage, sensing technology (IT) and operations
opportunity cost. By the time
and communications technologies. technology (OT). IT worked from top
data is organized, its value
But a few have figured out how down, deploying and maintaining
may have been lost and the
to exploit their data. Big data data-driven infrastructure largely to
personnel too fatigued to derive
that is neither structured nor management side of business. OT
any insights.
contextualized is strenuous built from ground up, starting with
to cost-effectively store and machinery, equipment and assets,
analyze in its entirety through To extract meaning and and moving up to monitoring and
traditional computing approaches. value from data, new industrial control systems. With
systems are required to smarter machines, big data and
What causes handle the challenges the Industrial Internet, worlds of IT
data islands? posed by the volume, and OT are converging. Traditional
velocity and variety of enterprise data management, such
Data islands are created as a
as ERP or CRM, is being dwarfed
byproduct of operational and project these big data sets.
by operations data due to sheer
moment-in-time decisions not
made in the context of a larger data
strategy. Layering of legacy systems Islands of Disparate Data
conjoined with newer technologies
and lack of governance for data When everything’s an island, it’s hard to be intelligent
systems also results in data-
related islanding of internal
departments and work groups.
It can lead to limited purview
and inhibit collaboration. Data
gets siloed, whether it is enterprise
data, equipment data inside an
organization, or data across
different organizations.
This fragmentation makes data
discovery difficult and presents
Unplanned Downtime Wasted Analytics Lost Productivity Missed Opportunities
complex technical and organizational
volume and variety. But most together and find common ground
of this data is still in the dark. IT to develop a new infrastructure.3
and OT, developed separately
with independent systems
architectures, need to come
Business challenges
New sources of revenue There is a need to link analytical to be able to monitor assets in real
systems to operational systems. time and ensure all assets (across all
and profitability
Today, most business analytics do plants) are performing at an optimal
With a highly volatile market not support any connection back to level. They need increased visibility
environment and costs of the originating systems of the data. and better insights that can be acted
maintaining aging infrastructure, Analytics are on an island, as well, upon. This enables them to detect
companies are continually inhibiting the ability to take action in anomalies and fix issues before
challenged to sustain their a reliable and effective way due to they occur, yielding no
profitability by finding new sources the onus on the individual to connect unplanned downtime.
of revenue. Manufacturers are the worlds in their brain and connect Asset Performance
seeking ways to lower capital the systems and workflows via their Management and operations
expenditures, and they need own initiative optimization software can
a single source of the truth to
provide operators with
help them make the right decisions
Asset-level visibility answers on what equipment
for improved performance, while
Improved capacity utilization is one is most important, how it
mitigating risk from
of the great benefits of state-of-the- should be maintained and how
unexpected incidents.
art information systems. To achieve unexpected failures can
production targets, operators need be avoided.
Organizational challenges
Aging workforce and of younger employees. Preparing attacks pose a range of threats—
for this impending change by using from personal devices to corporate
knowledge capture
digital technologies can ease IT systems—making individuals and
Aging of the workforce is impacting the transition.3 institutions vulnerable to financial
a number of industries. Retirement and physical harm.
of experienced workers is
Cyber security There is growing awareness and
expected to create a skills gap.
As billions of assets get smarter, paranoia among stakeholders, and
While younger generations of
network and store information an urgency to mitigate these risks.
workers will bring new skills, it
on the cloud, they will be exposed Vendors are deploying solutions
is crucial that the knowledge
to digital privacy risks. Just in the to prevent these cyber events and
and experience accumulated
last year, there have been several protect against digital crime. As we
by more senior workers is
cases of data breaches causing invest in digital technologies, cyber
captured and made accessible
significant damage to all parties security capability must be part of
to the new workforce. Inability to
involved (companies and their supply the selection criteria.
institutionalize this knowledge can
be detrimental to the apprenticeship chains, as well as consumers). Cyber
GE’s Approach: Maximizing
Value from Machines and
Enterprise Data
Industrial Internet technologies can turn the challenges
discussed earlier into opportunities for improved productivity.
Many industrial companies have already
started their digital journeys towards
Reaching maturity involves five
stages with corresponding technology
5 stages of Industrial
Industrial Internet maturity. Technologies components that allow an enterprise to Internet maturity:
including enterprise data management connect, monitor, analyze, predict and connect, monitor, analyze,
and predictive analytics that we have optimize their assets and operations.
been deploying for our customers are This can be accomplished on the premises predict and optimize
now seeing double-digit performance and in the cloud, depending on the current
gains across the following sectors: power configuration of your data architecture.
generation, oil and gas, transportation and
health care.
Value
data storage, data visualization and
Analyze
analytics. This foundation of the
Industrial Internet starts with Monitor
data management. Connect
Historically, it was possible for a single
machine or a handful of machines to
receive and store data. However, the Capability
545 MILLION
4 BILLION
samples per hour
samples per shift
13 BILLION
samples per day
9 MILLION
samples per minute
4 TRILLION
samples per year
152,000
samples per second
Figure 1
Next, let us review underlying technical capabilities
and the business outcomes of data historians.
Historian: Built for the Industrial Comparing the Disk Space Effiency
Internet and Big Data Solutions of an RDB vs. GE Historian†
35
Effective bytes per sample
30
Process Data 25
Client based 20
15
10
6
5
Files 1.3
Stores 0
Analysis
Archives RDB Historian Historian
Context (no compression) (1%compression)
RDB and Historian. Results will vary depending on the raw data set used and the
Server Data Web based RDB schema employed.
Figure 2 Figure 3
Data access: On-premise to cloud This also allows IT managers creative options for long-term
Another two considerations for IT leaders are: a) the cost of storage. For instance, one customer, who keeps 30 days of
moving large data files across the network and b) long-term data historical data at the plant level, aggregates all plant data onto
storage requirements, specifically determining where the final a central Historian temporarily, and then moves all this data to
resting place of data should be. an HDFS cluster for their “data at rest” strategy. This approach
GE Historian solves for both these problems. has financial benefits. A terabyte that costs $5,000 to store
in a traditional manner may cost $1,000 in an HDFS cluster.
Per our previous discussion on data compression, consider With the server-to-cloud collector capability, the costs of highly
moving uncompressed archives of 10 GB or more across various compressed GE Data Historian file drops from $20,000 to $5,000
networks, say from a control network, through a firewall, into in HDFS.
a DMZ (demilitarized zone) or a business network, then again
across another firewall boundary, into an external facing network
or public Internet for cloud storage. Then consider the 10x
compression of GE Historian and the impact to your network of
Time to value: From calendar time
transferring 1 GB of archive files. to watch time
Beyond efficiency, GE Data Historian has a number of native Within the Enterprise Historian, the time-series data is stored
ways to move the data. From one Historian to another, one in an HDFS. The near-linear scalability of Hadoop allows our
can use a server-to-server collector for streaming data. Moving Enterprise Historian platform to scale out as the volume
from premise-based Historian to cloud-based time-series of data grows over time. Up to 20+ years of industrial big data
open source, Historian offers a server-to-cloud collector. To generated from the installed base of equipment can be stored
move larger files, one could use the Historian HD ingestion service online and mined on demand, replacing months of manual effort,
to move the tag configuration and archive data onto a Hadoop to explore much smaller data sets.
Distributed File System (HDFS) data lake on-premise or in
the cloud.
Industrial Data Management is the foundation for the Industrial Internet and goes beyond historian
time-series data. To effectively and efficiently deliver next-generation analytics and applications,
Industrial Data Management uses time-series data generated from machines and equipment in
conjunction with structured data such as enterprise resource planning (ERP), customer relationship
management (CRM), geolocation, semi-structured data such as machine logs and digital inspection
data, and unstructured data such as content (images, manuals, video, etc.). This is critical to bringing
a complete contextual and situational analysis for the assets. In addition, it becomes the basis to
empower personas beyond process engineers, such as data scientists and enterprise operations, to
unlock the value using advanced data management and analytic capabilities.
We are learning a lot along with our Figure 4 below depicts how data Critical to this journey is to bring a wide
customers as we redefine GE as a data- management capabilities can traverse array of data together and relate it into
driven business. Beyond just assets, the enterprise—single-site, on-premise a common structure such as a data lake
our customers are looking at how to installations to multi-site, cloud-based in Predix™, our cloud platform for the
manage their data across the enterprise solutions. The cloud-based solutions go Industrial Internet, as shown in
and run analytical queries that provide beyond semi-structured time-series data figure 4. Business-level analyses based
immediate tangible insights to operations to include structured transactional system on statistical models can then be
and improve business metrics. To achieve data, and unstructured web and machine performed with Enterprise Historian
better business outcomes, digital industrial data, merging these data streams into a solutions as the foundational data layer,5
companies like ours are rethinking how single view. Evolving the use and capability as shown in figure 5.
they manage the data in the field in order of data historians to be cloud-based, is
to maximize the value of the analysis in central to rethinking data management.5
the cloud.5
ERP / CRM
Operational State Data (e.g., temp) Asset Life Data (e.g., cycles to failure)
Asset Performance
Management
Data Lake and Predix Cloud Performance Models Life Models
Operations Optimization
Business Optimization
Figure 5
Customer Case Studies
At GE’s Remote Monitoring and Diagnostics Higher-quality analytics engineers with less historical knowledge
(RM&D) Center in Atlanta, we are Data-driven decisions are correct and are more effective, improving productivity
leveraging our Data Historian capabilities optimal. We can now use larger data sets by nearly $9 million.
to collect data generated from 1,600 to create rules, thus reducing rule errors on Enabled growth
gas-fired turbines around the globe. unseen issues.4 Digitized knowledge is allowed to focus
The total output of these turbines can more on creation of new digital products
Increased customer satisfaction
support the annual energy needs of over and services.
Our customers are experiencing our
60 million homes. The data feeds a central
greater speed and consistency in addition Subjecting machinery data
GE Historian cluster. A team of more than
to savings through higher-quality analytics, Subjecting machinery data to analysis
20 M&D engineers analyzes this data to
data-driven analysis and decisions. and data mining operations has yielded
assist customers in enhancing their asset
The questions posed and the answers significant amounts of productivity
reliability and performance 24/7/365. This
available to this team via the GE Historian for GE and business benefits to GE's
data is then fed into a big data Historian
infrastructure have generated customer customers through better management
running in a Hadoop file cluster, where this
savings estimated at more than of their equipment (avoiding unplanned
team runs complex analytics across 100
$100 million. downtimes). To date, the team has led
million fleet operating hours.4
Elevated team effectiveness 15 patents on the Enterprise Historian
Digitized knowledge reduces training needs system and adjacent technologies.4
Business outcomes of and increases staff flexibility. Experienced
engineers with valuable knowledge
GE Historian at our RM&D can now be more productive, and new
Center include:
Increased productivity
We have reduced decision times and
minimized effort spent managing data.
GE Remote Monitoring and Diagnostics Center
This time to find cross-fleet patterns and
creating test rules, which used to be in
weeks or months, has reduced to minutes
or hours.
Reduced costs
Independent software development costs
have been reduced by $3 million.
Industrial companies have begun an exciting digital journey. At the heart of this transformation is the power of data analytics to unlock
new sources of value. However, the challenges of big data, threat of digital disruption and changing workforce dynamics are real. In order
to exploit the fast-moving technology wave of the Industrial Internet, companies need to think strategically and holistically
about the foundational elements of their data architecture, starting with Industrial Data Management.
GE has invested in a software solutions portfolio to provide our customers the building blocks of achieving Industrial Internet maturity.
On-ramping with cost-effective data management technologies that can aggregate, store, analyze and visualize terabytes of data pulsing
through assets and systems across the enterprise is a critical foundational step. These technologies give business leaders and operators
a single source of truth to improve asset-level visibility, cross-operation performance, knowledge capture and employee collaboration.
Having these capabilities in the field and in the cloud sets up the enterprise to extract value from insights that would have otherwise
remained hidden within islands of dark and disparate data.
We have deployed data management, predictive analytics and advanced control systems that are yielding operational improvements
and increased productivity for our customers. As a first mover of the Industrial Internet, our mission is to continue to lead the market
with our technologies, our domain experience and an unparalleled ecosystem of partners.
References
1 McAfee, Brynjolfsson. "Big Data: The Management Revolution," Harvard Business Review, 2012.
2 "Gartner Definition of Big Data." http://www.gartner.com/it-glossary/big-data
3 Annunziata, Bell, Buch, Patel, Sanyal. "Powering the Future: Leading the Digital Transformation of Energy," 2015.
4 Puig, Lu, Interrante, Pool, Aggour, Botros. Enterprise Historian for Efficient Storage and Analysis of Industrial Big Data, 2013.
5 Littlefield. "Will the Data Historian Die in a Wave of IIoT Disruption?" LNS Research, 2015.
http://www.geautomation.com/blog/rethinking-data-management-and-cloud-horizontal-data-value-chain-part-1
6 Stone. "Rethinking Data Management and the Cloud: Horizontal Data Value Chain, Part 1," GE, 2015.
http://blog.lnsresearch.com/will-the-datahistorian-die-in-a-wave-of-iiot-disruption
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