Intelligent Engineering
Our Intelligent Engineering solutions across products, plant and networks, combine our engineering expertise with advanced technologies to enable digital engineering & operations, develop autonomous products & platforms, and build sustainable energy and infrastructure
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Introduction
The adoption of TSN is revolutionizing industrial communication landscapes by bridging the gap between IT and OT networks. Initially developed for audio/video systems, TSN’s transition to industrial applications provides enterprises with robust, interoperable communication solutions. With the exponential growth of Industry 4.0 technologies, businesses increasingly turn to TSN to manage the complexities of converged networks requiring time sensitivity. TSN enables synchronized operations, real-time data exchange, and prioritized traffic handling, which is crucial for ensuring operational efficiency and reliability in mission-critical environments. By leveraging IEEE-defined TSN standards, organizations can achieve scalable and deterministic networking solutions, fostering seamless integration of IT-OT systems and ensuring readiness for future technological advancements.
Most industry OT-IT network architects still use proprietary industrial ethernet protocols such as Powerlink, Device net, CC-Link IE, Profinet, Ether Cat, Modbus TCO, and most frequently used OPC-UA for OT-IT Networks, enabling and managing communication within industrial equipment. However, with the advancement in rolling Private 5G networks at enterprises, there has been an increase in the adoption of Automotive Ethernet use cases. These business units increasingly turn toward converged networks with a holistic integration of Information and Operational Technologists, who are all set to change the status of the industrial communication landscape and create a bright foundation for the convergence of IT and OT networks.
Global Automotive Ethernet Market Overview
The global automotive Ethernet market is experiencing rapid growth driven by advancements in vehicle connectivity and autonomous technologies. Ethernet’s high bandwidth and low latency make it the backbone of modern automotive communication systems. The market is valued at USD 2.3 billion in 2024 and is projected to grow at a CAGR of 24.00%, reaching USD 12.86 billion by 2032. This growth is fueled by the increasing adoption of ADAS (Advanced Driver Assistance Systems), zonal architectures, and next-generation infotainment systems. TSN’s integration into automotive Ethernet networks is critical in addressing autonomous vehicles' stringent performance and reliability requirements, ensuring seamless data transmission between sensors, controllers, and actuators. By replacing legacy protocols like CAN and FLEXRAY, TSN offers a unified and future-ready communication standard for the automotive industry.
Core Features of TSN
Time-sensitive networking (TSN) is characterized by its ability to deliver reliable, real-time communication within complex network environments. By addressing the specific demands of time-critical applications, TSN introduces groundbreaking features that transform traditional Ethernet into a deterministic communication framework. These core features form the backbone of TSN’s functionality:
Enterprise businesses rapidly adopting Time-Sensitive Networking (TSN) include industries such as mining, utilities, automotive, rail, and aerospace. While Ethernet remains the most widely used networking technology, it traditionally operates on a best-effort basis, which can introduce unpredictability in data transmission. TSN, an evolution of Ethernet, enables deterministic networking, ensuring reliable and time-critical communication. Key features of TSN include:
TSN eliminates the need for physically separating critical and non-critical communication networks across IT and OT networks. It allows same-channel data communication across Operations Networks and IT enterprise networks that revolve around IIoT using the same communication network at Enterprises. TSN can be implemented in industrial devices by integrating switched endpoints, switches, and associated network system software. The advantage is that FPGA can be reconfigured based on new TSN Standards without much rework and effort.
Ethernet is the most adopted and widely accepted networking technology implemented, and it operates on a best-effort-based delivery mechanism to transfer packets across a network. It complies with Ethernet and Time-Sensitive Networking standards which enables Ethernet to become a deterministic networking technology.
Coral of TSN Standards
TSN leverages many IEEE standards to manage and address various issues and add-on network functionalities. These standards, some active and others under development, ensure robust and deterministic networking for critical applications. Below is a summary of key TSN standards:
Seamlessly integrating TSN capabilities into Communications for Enterprise (C4E) businesses can help deliver the significant necessary network improvements
OT and TSN Networks
TSN capabilities can enable the co-existence of different types of traffic on the same network depending on its operational needs. Enabling such OT connectivity and network devices to be successfully deployed and managed and ensuring interoperability and conformance with the IEEE-defined TSN standards is essential and is the most critical piece toward Private 5G Networks (P5G) from an IR 4.0 Network Integration. C4E Network Automation from an IR 4.0 automation consisting of real-time detection, monitoring, tracking and closed-loop decision making, IoT Sensor integration and Enabling Automation for C4E domains - such as Intelligent Factory Automation and Scada/IoT Utilities Sensor Integration, Aero IoT Sensor integration, Rail Scada/IoT Sensor Integration, AGV Automation, Automotive Sensor Integration. TSN offers deterministic, real-time communication that allows different OT/IT equipment to work seamlessly.
Applications of TSN in C4E Industries
1. Automotive
There is an increasing demand forecast for the adoption of Automotive Ethernet systems in the automotive industry in the coming years. Some of the key features driving the need for TSN Networks in this industry include:
- High data rates: Enable high-speed, high-volume data communication management.
- Low latency: Provides minimal delay for real-time systems, such as AD/ADAS feature enablement and quick decision- making capabilities powered by machine learning.
- LIDAR and RADAR inputs: Supports 2D, 3D, and video-based decision-making.
- Lane Assist Programs: Enhances driver safety and convenience.
- V2X feature enablement: Facilitates vehicle-to-everything communication for improved connectivity.
- High reliability: Offers robust noise immunity for uninterrupted communication.
- Lightweight, space-efficient, and cost- effective cabling: Reduces overall vehicle weight and cost.
- Standardization: Based on well-established standards from reputable standards bodies.
- Zonal controller integration: Streamlines autonomous driving architecture.
- Replacement of legacy protocols: Phases out protocols like CAN and FlexRay for internal automotive communications.
- Deterministic communication: Ensures seamless and predictable performance for infotainment systems.
Unlike non-automotive Ethernet, automotive Ethernet cables use PAM3/PAM4 modulation to achieve high data rates and reliability. Here’s an example of the adoption of TSN Ethernet implementation at automotive domain.
Ref. Architecture for TSN Ethernet in SDV
2. Mining
- Real-time data analytics using IoT sensors and RF drones.
- TSN’s low-latency capabilities improve underground communication and safety.
- Scheduling algorithms manage delay constraints in multi-hop communication networks.
3. Utilities and Energy
- Integration with IEC 61850 for power substation automation and prepaid meter deployment
- Enhanced cybersecurity and synchisation protocols for smart grids.
- Precise-Time Protocols ensure accurate time synchronization across equipment.
4. Aerospace and Rail Networks
- Integration of TSN in SCADA systems for seamless operations.
- Real-time data sharing between IoT sensors for predictive maintenance.
About the Author
Joe Issac
Joe has 28 years of experience in the IT & Telecom Domain including Network Engineering & Communication Service Providers Business verticals. He has been associated with CTO Office-based functioning and heading early technology adoption into solution conceptualization, design & development and taking it to global T1 & T2 customers. He has built about 14+ platforms & products for customers and internal developments for NG- OSS/BSS, Green Energy Management Platform, Radio Network Emulators, Cloud Car & Software Defined Vehicle. He led various customer projects as the chief architect, where he was involved in architecture inception definition, development & rollout of telecom products for T1 & T2 customers across the globe. His expertise is in areas of homegrown and COTS tools in areas of Telecom B/OSS, SDN NFV, Disaggregation of Telecom & Automotive domains - Softwarisation, Containerisation & Virtualisation of Wireless & Wireline Systems, Telco Cloud, Edge Networks, 5G & 6G ORAN Radio Networks, Network Automation - Resource & Service Orchestration, RT & Non-RT RIC Controller, Interface Specs Packet Core implementations & Automotive domain - Cloud Car & Software Defined Vehicle. He is a senior member at IEEE ; member at ACM and a contributing member to various technical forums such as FB-TIP, ORAN Alliance, TSDSI-SDO, TMF, ETSI, LF- ONAP, Akrino ,OAI, SOAFEE, CENT-OS & Ubuntu Automotive SIG & an invited speaker at many of these forums.
WinClient and WebUI
Solumina Interfaces:
Solumina has two interfaces that can be used in iSeries
- WinClient
- Web UI
Case Study 1
WinClient
WinClient: The WinClient is widely used by:
The Solumina WinClient used various roles in the organization. One is a Process planner and Quality engineer.
Quality Engineer
A Quality Engineer uses the WinClient to
- Author rework instructions.
- Create or edit action plans.
- Create inspection blocks in Process Plans and work orders.
- Create, edit, and monitor corrective actions and Create or edit engineering changes.
Process Planner
A Process Planner uses WinClient to setup, organize, and manage manufacturing Process Plans. For example, it is used to:
- Create and revise Process Plans.
- Alter work orders.
- Supersede and update Operational Flow Diagrams.
- Manage bill of materials.
- Engineering change management and Create release packages.
Case Study 2
WebUI
The Solumina Web Ul is accessed by logging onto the web-based system. It is most commonly used by
to input data and view work order instructions and statuses.
Shop Floor Technician
- The Shop Floor Technician uses the WebUl to review:
- Work order and operation dispatches and Notes and Holds to see what needs to be worked on.
- The Shop Floor Technician also uses the WebUl to execute work orders.
Shop Floor Supervisor
- Shop Floor Supervisors use the WebUI to get a summary of what is going on in the Shop Floor to resolve issues, keep work running smoothly, and effectively use resources.
- Shop Floor Supervisors can easily get an idea of:
- Operations on time and late
- Open holds
- Open discrepancies and
- Pending crew assignments
Quality Technician
- The Quality Technician uses the WebUI to look up information on open and closed discrepancies such as
- Status
- Assignee
- Workflows
- Serial number(s) and affected unit(s) and
- Scheduled end dates
Quality Technician
- Quality Technicians also use the WebUI tolook up open and closed Quality buyoffs including information such as
- Associated work order and operation where buyoff is located
- Serial/lot of unit(s)
- Due dates
- Required quality/inspector certifications and Holds
- Supplier Quality uses the WebUI to Manage source and receiving inspection
- Review As-inspected History and Review calculated supplier rating and metrics
Common roles in Solumina
Case Study 3
QTECH - Quality Technician
At QTECH, a mid-sized aerospace manufacturer, the role of the Quality Technician is vital for maintaining high product quality and ensuring compliance with industry standards. The technician utilizes the Solumina dashboard to streamline quality management processes and improve operational efficiency.
Buyoffs
The Solumina dashboard features several key tools that assist the Quality Technician in their duties. One of the most important components is the Buyoffs View, which enables the technician to track the approval status of products following inspection. This view provides essential details, including whether an item has been approved or rejected, the results of quality checks, and timestamps for when the buyoff was completed, ensuring traceability and accountability throughout the inspection process.
The Buyoff Display Information records various details for each inspected item, such as the part number, inspector's name, comments or notes related to the inspection, and a digital signature for approval. This thorough documentation helps maintain a clear record of quality evaluations.
Discrepancies View
Another crucial feature of the dashboard is the Discrepancies View, which organizes any quality issues identified during inspections. The technician can easily monitor the status of each discrepancy, whether it is open, under review, or resolved. This view also facilitates root cause analysis by linking to investigations aimed at understanding underlying issues.
The Discrepancies View in Solumina is essential for effectively managing quality issues. It includes filtering options that allow the technician to sort discrepancies by severity, date reported, or personnel responsible for resolution. This functionality helps prioritize actions based on urgency and impact.
For each discrepancy, the displayed information includes a unique Discrepancy ID, a detailed description of the issue, its location, the reporting date, the assigned personnel, and the current resolution status. It also outlines any corrective actions taken, providing a comprehensive overview of the situation.
Note : The QTECH Case study Images are sourced from iBASEt.
Therefore, Quality Technician at QTECH, supported by the Solumina dashboard, is crucial in upholding the company’s commitment to quality. The dashboard's features facilitate efficient monitoring and management of buyoffs and discrepancies, enabling quick resolutions and ensuring compliance with industry standards. This integration ultimately enhances QTECH’s quality assurance processes and overall operational effectiveness
Business Benefits
Implementing Solumina MES (Manufacturing Execution System) brings numerous business benefits to manufacturers, especially in industries such as aerospace, defense, electronics, and medical devices.
Enhanced Operational Efficiency
- Solumina MES streamlines manufacturing processes, reducing waste and improving cycle times, leading to a 15-25% increase in productivity.
- By eliminating inefficiencies, the system minimizes downtime by 10-15% and ensures optimal use of resources.
- Integrating quality management features helps manufacturers maintain high standards and comply with industry regulations, which can result in a 30-50% reduction in defects and rework, further reducing manufacturing costs by 10-20%.
Real-Time Decision-Making
- Solumina MES provides real-time insights into production processes, allowing faster decision-making and more effective problem-solving.
- This transparency helps identify bottlenecks, which contributes to a 20-30% improvement in lead time and on-time delivery, and significantly reduces inventory carrying costs by 20-30%.
Scalability and Flexibility
- Solumina’s adaptable architecture allows companies to scale their systems as they grow, incorporating new products or processes with minimal disruptions.
- The MES enhances the compliance process by up to 20-30% faster, ensuring timely adherence to evolving regulatory standards.
Enhanced Workforce Management
- Through performance tracking and training integration, Solumina MES enhances workforce efficiency, aligning employee skills with operational needs to achieve a 15-25% boost in overall productivity.
- This approach also minimizes data entry errors by 50-70%, streamlining administrative processes.
Continuous Improvement and Cost Savings
- Solumina enables companies to foster a culture of continuous improvement, achieving a 5-15% annual improvement. Additionally, maintenance costs see a 10-20% reduction, enhancing operational sustainability and profitability.
Conclusion
In summary, MES Solumina, offers a transformative MES solution tailored for complex discrete manufacturing industries such as aerospace, defense, electronics, and medical devices. Its modular architecture, real-time data integration, and seamless compatibility with enterprise systems provide manufacturers with the tools essential to enhance operational efficiency and agility.
By focusing on quality management, workforce optimization, and advanced analytics, Solumina enables organizations to maintain compliance, improve product quality, and drive continuous improvement. Ultimately, Solumina empowers manufacturers to achieve operational excellence through informed decision-making, optimized processes, and maximized productivity.
About the Authors
Rekha R is a Software Engineer with a Master of Technology (MTech) in Computer Science and Engineering. She brings over four years of experience in the manufacturing systems and quality management domain. She possesses practical expertise in implementing MES solutions such as Solumina and a solid background in Robotic Process Automation (RPA), design, and development. Rekha’s career has primarily focused on design and development, where her innovative approach to complex manufacturing and quality processes enhances operational efficiency and product quality. Her specialized skills drive the development of cutting-edge solutions in dynamic environments.
Prasad Patnam is a Software Developer at Cyient Ltd and a dedicated professional in manufacturing systems and quality management. He has a strong background in implementing Manufacturing Execution System (MES) solutions, particularly Solumina, which has significantly enhanced operational efficiency and product quality within complex manufacturing environments. Prasad specializes in React.js and front-end development and holds a Bachelor of Science degree. He excels in creating responsive, user-friendly web applications and has expertise in JavaScript frameworks and state management libraries like Redux, enabling him to effectively transform complex requirements into intuitive code.
Padmanabham V is a Software Developer with experience in Solumina, a top software solution for manufacturing operations management, where he has integrated advanced functionalities to streamline processes and enhance data management. His work leverages microservices architecture and web technologies to improve scalability and flexibility, addressing the dynamic needs of clients in the manufacturing sector. He has contributed to various projects, including Windchill, Common Authoring, Configuration, Transformation, Utilities, and Services. Padmanabham holds a Master of Computer Applications (MCA) degree and is proficient in Java, J2EE, Spring, Spring Boot, microservices, web services, Hibernate, and Angular.