TF02 - The Future of Manufacturing in a Connected World

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

The Future of Manufacturing in a Connected World


Abstract

Integration of control and information on the manufacturing floor will be

essential for manufacturers to remain competitive. In this session,

Rockwell Automation® and Cisco will discuss how we are delivering

products, solutions, and services that use our industry-leading best

practices for networking and convergence for organizational efficiency.

Topics include: use cases and solution sets for the plant of the future –

automation infrastructure, security and compliance, mobility, video and

collaboration, industrial computing and cloud, remote expertise and remote

services, and energy management.


Today’s Discussion

Why we build Connected Enterprises

How to achieve a Connected Enterprise today with multi-capability

industrial architectures

Solution areas of Converged Plantwide Ethernet (CPwE)

Demo example

What steps to take to capture huge new value

Process, partners and products


Why we build Connected Enterprises


Rapid Adoption rate of digital

infrastructure:

5X faster than electricity and

telephony

50Billion“Smart Objects”

50

2010 2015 20200

40

30

20

10

Bil

lio

ns

of

Devic

es

2512.5

Inflectionpoint

Timeline

7.26.8 7.6

World Population

The Internet of Things is Enabling a

Connected World in Manufacturing


The Internet of Things (IoT)

Continuing Trend in Industrial Applications

6

“Things” are communicating using the same network technology as the Internet

EtherNet/IP (Internet Protocol)

“Things” become the catalyst for better understanding complex processes and

adapting to changes quickly Smarter Machines

Smarter machines can be better controlled thereby increasing efficiency

“Plant-wide Optimization”

Securing the architecture means data authentication and access control

become increasingly important “Unified Secure Infrastructure”

Faster Time to Market Lower Total Cost of Ownership

Improve Asset Utilization Enterprise Risk Management


Supply

Chain

Headquarters

Distribution

Center

Smart Grid

Customers

Optimized for Rapid Value Creation

THE CONNECTED ENTERPRISE

SUSTAINABILITY

AGILITY

PRODUCTIVITY


Supply

Chain

Headquarters

Distribution

Center

Smart Grid

Customers

Optimized for Rapid Value Creation

THE CONNECTED ENTERPRISE

8

Customer

Experience

$164B

Supply

Chain

$931B

R&D/Innovation

$503B

Smart Grid

$94B

Workforce

Enablement

$212B Plant Automation/

Output

$2086B

$4T Manufacturing Value at Stake

PRODUCTIVITY

SUSTAINABILITY

Smart Things Mobility Big Data Analytics Cloud Security

AGILITY

Source: Cisco IoE Value Practice Survey


Network Convergence

…to a critical part of

the infrastructure

From basicconnectivity…

…to converged,

secure and

collaborative

operations

From disparate IT and OT networks…

…to open

standards

From proprietary standards...

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 10

MATERIAL & TRANSPORT

INDUSTRIAL “THINGS”

PLCS & SCANNERS

PRINTERS & LABEL SERVICES

SHOP FLOOR PERSONNEL

MACHINES & TESTERS

Real-time data: alarms, events, states, energy, diagnostics, …

FINANCIALS HR LOGISTICS QUALITY WAREHOUSE

Transactional information: orders, supply network, product design …

ERP

COMMON SECURE NETWORK INFRASTRUCTURE

OT

IT

IT-OT Convergence


COMMON SECURE NETWORK INFRASTRUCTURE

OT

IT

Collaboration

…is key to realizing The Connected Enterprise...

Standards, Academia, Industry

Initiatives


Industrial IP Advantage

12

A ‘go-to’ resource for educational

information about industrial network

communication and using standard Internet

Protocol (IP) for industrial applications

Community of like-minded companies –

Cisco, Panduit, and Rockwell Automation®

Receive monthly e-newsletters with

articles and videos on the latest trends

Network Design eLearning course available for TechEd Attendee promotional price! Sign up today at www.industrial–ip.org


Multi-Capability Industrial Architectures


Multi-Capability Industrial Architectures

Industrial

Customer

Drivers

• Faster Time To Market

• Lower Total Cost of Ownership

• Improved Asset Utilization and Optimization

• Enterprise Risk Management

Solution SetsScalable &

ComplementaryAutomation

Infrastructure

Security &

ComplianceMobility

Video &

Collaboration

Industrial

Compute

& Cloud

Remote

Support

Services

Energy

Management

Warning: The following slides have a lot of information that is better understood when downloaded after this event.


Automation InfrastructurePain Points:

Getting data from everywhere to the right place at the right time in the right context…seamlessly

Difficult to scale, maintain, and troubleshoot the physical infrastructure

Value Prop:

Common network infrastructure, brownfield ready and future proof

Outcome:

Faster time to market/new product introduction (NPI)

Ability to change production capabilities without having to totally reconfigure the

machines/operations

Reducing changeover times and lowering downtime

Keeping infrastructure components and cabling securely in place

Solution:

Stratix™ family of automation network infrastructure products

Environmental protection of infrastructure components

Converged Plantwide Ethernet (CPwE) architectures

Automation

Infrastructure

Security &

ComplianceMobility Video & Collaboration

Industrial

Compute & Cloud

Remote

Support ServicesEnergy Management


Security and CompliancePain Points: Availability of the industrial automation control systems (IACS) including:

Unwanted access to intellectual property and to the physical infrastructure

Unwanted activity on the network and modifications to applications

Value Prop: Risk and downtime avoidance; enabling the Connected Enterprise

Outcome:

Permitting communication only between entities for which there is a need

Protecting the ability to view, edit, and use specific pieces of control

system content (e.g., logic, formulations, recipes, HMI displays, etc.)

Controlling access to the physical infrastructure and automation systems

Managing policies across applications, networks and systems

Solution: Defense in depth security approach including:

Stratix 5900™ Services Router

Physical access control and cable lock-in/block-out

Holistic security capabilities documented in CPwE reference

architectures

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote


http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/4/4c/US_Department_of_Homeland_Security_Seal.svg/360px-US_Department_of_Homeland_Security_Seal.svg.png&imgrefurl=http://commons.wikimedia.org/wiki/Image:US_Department_of_Homeland_Security_Seal.svg&h=359&w=360&sz=82&hl=en&start=1&usg=__g68ZxZ1Czwnbm-C8k0D2deynJXk=&tbnid=fqr03iu-bFLMmM:&tbnh=121&tbnw=121&prev=/images?q=department+of+homeland+security&gbv=2&hl=en

http://images.google.com/imgres?imgurl=http://upload.wikimedia.org/wikipedia/commons/thumb/4/4c/US_Department_of_Homeland_Security_Seal.svg/360px-US_Department_of_Homeland_Security_Seal.svg.png&imgrefurl=http://commons.wikimedia.org/wiki/Image:US_Department_of_Homeland_Security_Seal.svg&h=359&w=360&sz=82&hl=en&start=1&usg=__g68ZxZ1Czwnbm-C8k0D2deynJXk=&tbnid=fqr03iu-bFLMmM:&tbnh=121&tbnw=121&prev=/images?q=department+of+homeland+security&gbv=2&hl=en


MobilityPain Points: Connectivity to mobile people, assets, and tools is hard to move

Value Prop: Operations and maintenance productivity improvement

Outcome:

80% faster response in decision making

Solution:

Stratix™ 5100 Wireless Access Point

Architectures to manage radio frequency interference in plants

CPwE document “Deploying 802.11 Wireless LAN Technology

within a Converged Plantwide Ethernet Architecture” includes

wireless access equipment connectivity use cases

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote


WLC – Wireless LAN controller

AP – Access point

WGB – Work group bridge

WGB 5..12

AP

Fixed PAC

FactoryTalk® Application

Servers

Wireless

PAC

FTView

ME

FTView SE

Core

switch

Distribution

switch

Fixed I/O

Wireless

I/O

WGB

1..4

Wireless

I/OWireless

PAC

… …

AP (Backup)

AP (RADIUS)

5 GHz

2.4 GHz

Cell/Area ZoneLevels 0-2

Industrial Zone

Level 3 - Site Operations


Video and CollaborationPain Points:

Ease of use for video and audio integration with the control system

Cost to deploy and configure video

Value Prop: Converged network – video and controls with Quality of Service (QoS)

Outcome:

Reduce frequency of downtime, and especially micro stops

Reduce mean time to repair (MTTR)

Solution:

Cisco Video Surveillance Management (VSM) solution

IP cameras

Video collaboration for remote expertise and remote support

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote


ENCODER

TELEMETRY / PTZ

JOYSTICK

IP CAMERA MEDIA SERVER

MEDIA SERVER

OPERATIONS

MANAGER

ANALOG

VISUALIZATION

SERVER

VSM CLIENTS &

VIDEO WALL

FACTORYTALK VIEW

HMI & CLIENTS

MOBILE CLIENTS

DATA PLANE

CONTROL PLANEAPIANALOG


Industrial Compute and CloudPain Points: Deployment cost and complexity of application delivery and maintenance

Value Prop: Compute resources where they are required – at the edge, in the cloud,

or in between

Outcome:

Reduce cost to deploy 30-50%

Collect and process increased data from the production environment

Execute more optimization applications in the production environment

at a lower cost

Flexibility to add new intelligence and applications easily

Solution:

IOx – compute at the edge (Fog)

Industrial Data Center

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote


Switch w/IOx

Servers

• Single

• Redundant


• Essentials

• Essentials +

• Custom

Enterprise data centers

Private/ publiccloud



Remote Support Services

Pain Points:

Cost to monitor and maintain remote assets (e.g., unnecessary “truck rolls”)

Skills gap leading to insufficient workers to maintain and fix automation systems

Value Prop: Proactive engagement by engineers leveraging contemporary

collaboration tools

Outcome:

Faster response to avoid impending outages

Narrowing of the skills gap through outsourced services

More data for production optimization

Solution:

TechConnect℠ monitoring and managed services

M2M connectivity – Internet Protocol, cellular

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote


Rockwell Automation®

Monitoring Cloud

Firewall

Assets

On premise

On premise

RA monitoring end point

Dashboards

Email notification


Energy Intelligence

CIP Energy on EtherNet/IP

Energy Aggregator and

Low-Power

Energy Aggregator and

Energy Management

PowerMonito

r™

Cisco EnergyWise™

Energy ManagementPain Points:

Energy cost is becoming critical to meet sustainability and profitability goals

Little visibility into where energy is being consumed in the context of manufacturing

Value Prop: Architecture that delivers secure and sustainable automation

Outcome:

Reduce energy cost by 5-30% with better control over smarter equipment

Energy correlated to asset lifecycle

Solution:

Energy intelligence leveraging Cisco EnergyWise,

CIP Energy, and Panduit SmartZone technologies

Field area network

Automation

Infrastructure

Security &


Industrial

Compute & Cloud

Remote



Multi-Capability Industrial Architectures are Achievable Today

VantagePoint/

FT EnergyMetrix Power

Monitoring and

Dashboards

Camera Feed

NAT /

Connected

Routing

8193750x and UCS

(behind board)

VSM,

IPICS,

FTVie

w, ISE

Image

s

Add a Switch to

the REP Ring

Guard

I/O™

PTZ Camera

Wireless Tool

Controller

?? ??

“Machines”

Video

Standalone

Fanuc

Robot Cell

GuardLogix

®

AP

Mobile

Tablet

FT View SE w/ Integrated

Video and Robot Diagnostics

Remote Diagnostics

Video


Multi-Capability Industrial Architectures – Value Impact

Value Impact

where customers

see value

• Lower

downtime

• Faster line

expansion

• Faster NPI

• Risk reduction

(board level

issue)

• Enablement of

new PoF

business models

• Faster MTTR

• Faster decision

making

• Productivity

• Faster MTTR

• Faster NPI

• Faster ECNs

• Lower costs 30-

50%

• Lower downtime

• IOT data

enablement

• Faster MTTR

• Faster NPI

• Faster ECNs

• Lower downtime

• Lower scrap

• Quality

• Lower energy

costs by 5-30%

Industrial Fabric

Solution SetsScalable &

Complementary

Automation

Infrastructure

Security &

ComplianceMobility

Video &

Collaboration

Industrial

Compute

& Cloud

Remote

Support

Services

Energy

Management


Steps to Take to Capture Huge New Value


Integrated, Pre-Tested Solution Architectures From Cisco and

Rockwell Automation® Can Ease Skill Gaps and Accelerate Value

Plus lowers costs for plant design and network engineers

Lifecycle Services

Industry Leading Partners

Business Risks Reduced

Faster Deployment

Better ROI


Delivering the right information

to the right person (or

machine) at the right time

ProcessConnecting people

in more relevant,

valuable ways

People

Turning data into more useful

information for decision

making

DataPhysical devices and objects

connected to the Internet and

each other for intelligent decision

making

Things

The Internet of Everything (IoE)Networked Connections of People, Process, Data, Things


The Connected Enterprise

EXECUTION MODEL

Analytics

Secure, Upgrade

Working Data Capital

Optimize and Collaborate

Assessment


Where are You on Your Journey Today?

Automation

Infrastructure

Security &

ComplianceMobility

Video &

Collaboration

Industrial

Compute &

Cloud

Remote

Support

Services

Energy

Management

Assessment

Secure,

Upgrade

Working Data

Capital

Analytics

Optimize and

Collaborate


Rockwell Automation® and Cisco Can Help You

Capture the Value Opportunities – Next Steps

Discovery Workshop with “OT” and IT

• Business challenges

• Best practice sharing

• Use case brainstorming

and prioritization

• Connected Enterprise

Execution Modeling

TCO or OEE Opportunity Quantification

• Quantify top value

opportunities for senior

management (TCO, OEE,

and overall benefit

models)

Proof of Concept Design

• Run POCs in a Showcase

manufacturing facility to

prove the value and

technology

End State Architecture Assessment

• Document future state

architecture (e.g., 3 to 5

years out), gaps with

today, change

management, and phased

plan to get there

TF02 - The Future of Manufacturing in a Connected World

Technology

Transcript of TF02 - The Future of Manufacturing in a Connected World