Internet of Things for Manufacturing

Transcription

1 Process Group Internet of Things for Manufacturing 100% Canadian owned.

2 Agenda IoT for Manufacturing Todays Theme Modern Infrastructure 9:00am to 9:15am - Welcome 9:15am to 10:00am - Introduction to IoT 10:00 to 10:15am - Rockwell s Connected Enterprise 10:15am to 10:30am - Break 10:30am to 11:20am - Modern Network Infrastructure 11:20am to 11:30am Break 11:30am to 12:30am Modern Control System Design for IoT based Systems and associated supporting services 12:30am to 1:30pm - Lunch Process Group Please feel free to ask questions Microphones are available during the sessions. We will be available for questions at the end as well. 100% Canadian owned.

3 Our IoT Partners Process Group Bridging the Gap Between IT and OT Controls Design Logical to Physical Networking 100% Canadian owned.

4 Internet of Things Process Group Goals of todays Seminar What is the Internet of Things? How does this apply to my manufacturing facility? How do I design my control systems to accommodate IoT? 100% Canadian owned.

5 Internet of Things What is the Internet of Things? Process Group Wikipedia defines IoT as: The Internet of Things (IoT) is the network of physical objects or things embedded with electronics, software, sensors, and connectivity to enable objects to collect and exchange data. The Internet of Things allows objects to be sensed and controlled remotely across existing network infrastructure, creating opportunities for more direct integration between the physical world and computer-based systems, and resulting in improved efficiency, accuracy and economic benefit. 100% Canadian owned.

6 Internet of Things How does this apply to my manufacturing facility? Process Group Analytics Cloud Diagnostics Internet WLC 100% Canadian owned.

7 Internet of Things How do I design my control systems to accommodate IoT? Process Group 100% Canadian owned.

8 Cisco Connected Factory and the Internet of Things David Jirku Consulting SE, IoT

9 Agenda Introduction Connected Factory Automation Security Use Cases Connected Routing Industrial Protocols Best Practices Partnerships Summary Cisco and/or its affiliates. All rights reserved. Cisco Confidential 10

10 The Internet of Things is the intelligent connectivity of physical devices driving massive gains in efficiency, business growth, and quality of life.

11 BILLIONS OF DEVICES IoT is Here Now and Growing! Billion Smart Objects Inflection point TIMELINE Adoption rate of digital infrastructure: 5X faster than electricity and telephony World Population 2015 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 12

12 Convergence Driving Adoption of The Internet of Things Sensors Real Time Analytics Personal Devices Robots Security Devices Sensors Everywhere Machine-to-Machine Pervasive Intelligence Automation Less Waste, More Efficiency, More Cost Savings Constant Improvements in Productivity Enhanced, Personalized Experiences Cisco and/or its affiliates. All rights reserved. Cisco Confidential 13

13 "If you went to bed last night as an industrial company, you're going to wake up today as a software and analytics company, Jeff Immelt CEO GE The impact of the IoT

14 Traditional IT IP-Rich TRADITIONAL IT

15 Core business IP-Rich TRADITIONAL CORE BUSINESS IT

16 IoT is Driving IT and OT Convergence

17 Report: Background: Northstar conducted a quantitative online survey of ~365 Senior Executives in the Canadian Manufacturing Sector

18 19 Productivity 19 Very Important Somewhat Important Not Very Important Not Important Q20 Productivity Importance 68% 26% 4% 2% Employee training Investing in technologies Automation Developed productivity improvement strategy Specialization of product offerering Lean, Six Sigma, other CI measures Outsourcing manufacturing Outsourcing support roles Q21 Top steps taken to improve productivity Have Taken Plan to Take 32% 32% 30% 28% 20% 28% 32% 19% 30% 17% 22% 41% 38% 37% 55% 71% Q23 Most Challenging areas with regards to managing and improving productivity 1. Shop floor operations 44% 2. Marketing and sales function 40% Q24 How do you monitor and measure the productivity of your shop floor manufacturing equipment and operations, shift by shift? Manual data collection, analysis and review Automatic data collection, analysis and review 49% 29% Not currently measured 22% Base: Total Answering (N=365) Q20. How important is productivity improvement to your company s business growth? Q21. What steps have you taken/plan to take to improve your company's productivity? Q23. In which of the following areas do you find managing and improving productivity most challenging? Q24 How do you monitor and measure the productivity of your shop floor manufacturing equipment and operations, shift by shift

19 Adopting the Converged Industrial Network 70% of manufacturing executives are focusing on plant floor data initiatives to drive operational and business excellence IT Enterprise Empowering Decision Makers Aberdeen Group Reliability - Wired and Wireless - Lower Latency - QoS Real-Time - Analytics - Access to plant performance Manufacturing Floor Immediate Access to - IACS data (Historian) - Device, sensor and machine status Cisco and/or its affiliates. All rights reserved. Cisco Confidential 20

20 Enabling Connectivity Building to the Factory of the Future Real Time Supply Chain Asset Utilization Accelerated NPI New Business Models Productivity Energy Management Flexible mfg Flexible controls Flexible networks Resiliency (REP) Integrated management Near Zero Downtime Distributed Compute Machine-as-a-Service Remote Asset Mgmt Mobility 2.4/5Ghz Clean air Machine energy visibility reporting and analytics Connected Factory Applications Factory Security Industrial Identity Services Industrial Deep Packet Inspection IP Cameras Video Surveillance Management Converged Network Platforms Ruggedized Wireless Access Points Industrial Routers and Switches Hardened Mobile M2M Gateway Ruggedized Optical transceivers Things Parts Robots Torque Sensors Asset Tags IP HD Camera Drives Cisco and/or its affiliates. All rights reserved. Cisco Confidential 21

21 Internet and Industrial Network Evolution Cisco s Manufacturing Credentials People >>> White House, UN Launch Websites Multiprotocol Router Processes >>> Amazon and ebay Take First Orders Intelligent Switches; VoIP; VPN Data >>> Big Data Terminology 10 Gb EtherNet; 2M IP Phones Machines >>> IT and OT Converge Industrial Ethernet Everything >>> 1990s >>> 2000s >>> 2010s >>> Internet of Things Occurs Converged Ethernet; M2M Router Cisco is clearly the industry leader for IP telephony Toyota VP, 2006 Cisco stepped up without hesitation or restriction and got it done within 90 days. (TP Collaboration Solution) Proctor and Gamble Director, 2008 Standardizing [converging] plant networks has reduced costs, improved uptime General Motors Executive, 2010 Cisco helped us design a network that provides leadingedge industrial intelligence Bombardier (Trains) Cisco and/or its affiliates. All rights reserved. Cisco Confidential 22

22 The Manufacturing Journey How do we get there? Phase 3 Phase 1 Phase 2 Converged Plantwide Network Flexible, Multi-Service Platform Controls security Starting Point: Proprietary Serial Islands Unmanaged, unconverged Ethernet Richer sensor data Still siloed No security Converge siloed networks for IOT visibility & cost savings Controls Mobility Video & Collaboration Remote Monitoring CLOUD, FOG Software Defined Factories Increasing Value Cisco and/or its affiliates. All rights reserved. Cisco Confidential 23

23 IT-OT Convergence Transactional information: orders, supply network, product design ERP Financials HR Logistics Quality Warehouse IT Common Secure Network Infrastructure Industrial Things PLCs & Scanners Material & Transport OT Real-time data: alarms, events, states, energy, diagnostics, Machines & Testers Shop Floor Personnel Printers & Label Services Cisco and/or its affiliates. All rights reserved. Cisco Confidential 24 24

24 Cisco Connected Factory CPwE Connected Plantwide Ethernet Integrated into: A Converged architecture for ruggedized Industrial Ethernet and wireless networks Connecting Industrial Automation Control Systems (IACS) to wired and wireless devices Cisco s Standards-based industrial IP Ethernet wireless, switching platforms Cisco networking excellence delivered on an industrial platform Scalable, secure, real-time performance, predictability, and remote access Improves productivity, collaboration, efficiency, agility, operational experiences A Cisco Validated Design Tested and Validated Architecture Integration of Cisco and Partner IACS products Comprehensive support and service network Five year product warranty Lifecycle services with smart capabilities Developed and Delivered in conjunction with Rockwell Automation. Bringing together the best of IT and the best of Industrial Automation Cisco and/or its affiliates. All rights reserved. Connected Factory Automation Security Wireless Energy Management Cisco Confidential 25

25 Catalyst Switch Internet IDMZ NTP Server Secure Managed File Transfer Server Data Share Remote Desktop Gateway PI-to-Pi Server AV Server FactoryTalk AssetCentre, Vantage point, MIS FactoryTalk View Server, Clients & View Studio FactoryTalk Batch FactoryTalk Historian RSLinx Enterprise Industrial NTP Server Active Directory Remote Access Server RSLogix 5000 ISE 34xx PSN Guest WLC Anchor Web DNS FTP Catalyst 3750-X Catalyst 3750-X Catalyst 4500E Catalyst 3750-X DMZ ASA 55xx-X (Active) Si DMZ Outside Failover Inside Catalyst 4500/6500 Si Active Directory, MFT, Factory Talk App servers ISE 34xx PAN, MnT, Enterprsie WLC Anchor Catalyst 3750-X Cisco 5500 WLC Level 3 ASA 55xx-X (Standby) Catalyst 3750-X Enterprise Zone Level 4-5 Industrial Demilitarized Zone Industrial Zone Level 3 Si I/O WGB HMI A P Controller Cell/Area # (Linear Topology) Drive Drive Industrial Wired LAN Access supported in CPwE baseline Controller HMI WGB Cell/Area #1 (Redundant Star Topology) A P I/O I/O Layer 2 Access Switch with Resilient Ethernet Protocol Controller Cisco IE Cell/Area # (Ring Topology) Drive HMI HMI Layer 2 Access Switch with Resilient Ethernet Protocol Controller STRATIX Cell/Area # (Ring Topology) Industrial Wired LAN Access Configurations Introduced w/ CPwE - REP A P WGB Drive Trusted Partner Laptop I/O I/O WGB Controller A P Cell/Area # (Wireless Topology) A P X Controller Industrial Wireless LAN CPWE Cell / Area Zone Level 0 2 A P Industrial / Corporate / Trusted Partner Laptop A P I/O I/O WGB WGB Drive I/O HMI Cisco and/or its affiliates. All rights reserved. Cisco Confidential 26

26 Enabling Connectivity Building to the Factory of the Future Real Time Supply Chain Asset Utilization Accelerated NPI New Business Models Productivity Energy Management Flexible mfg Flexible controls Flexible networks Resiliency (REP) Integrated management Near Zero Downtime Distributed Compute Machine-as-a-Service Remote Asset Mgmt Mobility 2.4/5Ghz Clean air Machine energy visibility reporting and analytics Connected Factory Applications Factory Security Industrial Identity Services Industrial Deep Packet Inspection IP Cameras Video Surveillance Management Converged Network Platforms Ruggedized Wireless Access Points Industrial Routers and Switches Hardened Mobile M2M Gateway Ruggedized Optical transceivers Things Parts Robots Torque Sensors Asset Tags IP HD Camera Drives Cisco and/or its affiliates. All rights reserved. Cisco Confidential 27

27 Architecture Solving Real Customer Pain Points Factory Automation Factory Wireless Factory Security Factory Energy Customer Pain Point Example Quotes Inflexible weeks to reconfigure production line Long search time Each cable run $1500 and rewire 2X/yr We basically have no factory security once in a plant. Now a Board concern. Need to lower energy use 25% by 2015 but can t get any data Cisco Value Prop Build any bike any line Reduce debug - hours to minutes! Unified wireless for IT & OT applications Identity based access Secure remote monitoring See real time energy Outcome Increase OEE (e.g., 75% to 89%) Increase output 95% lower OPEX Risk reduction New business models Lower costs 10 to 20% Cisco and/or its affiliates. All rights reserved. Cisco Confidential 28

28 Manufacturers Using IOT Technologies to Enable an Industrial Renaissance Unifying Networks: 18% IT TCO Savings Converged Networks Plant Networks Converged Plant Robot Advancement, Advancements, Additive Printing Plant Flexibility MFG Flexibility Reduces NPI setup by 75% 70% Have Big Data Plans to Improve Plant Operations Manufacturing Big Data Big Data * The Truth About Robotics White Paper, Seegrid Corporation, Fall 2013 ** US Manufacturing Nears the Tipping Point: Which Industries, Why and How Much, BSG April 2013 *** Manufacturing Moneyball: using big data and business intelligence to spur operational excellence, Forbes 11, 2011 **** From slide #77b check source NPI Convergence Manufacturing Onshoring On-shoring 33% NPI Process Acceleration 33% of NA Manufacturers Repatriating Plants Cisco and/or its affiliates. All rights reserved. Cisco Confidential 29

29 Cisco: Connecting Manufacturers Processes Data People Things Data Center/ Cloud Cisco and/or its affiliates. All rights reserved. Cisco Confidential 30

30 Cisco and Rockwell: Automation Partnership Common Technology View Support use of open, unmodified standards, with intelligent networking features in automation networks through ODVA, ISA and others Collaborating on Reference Architectures Tested and validated design and implementation guidance and best practices for a converged network architecture People and Process Optimization Develop process guidelines for help with convergence, facilitate training and dialogue with IT and Manufacturing Product Collaboration Developed Industrial Ethernet switch incorporating the best of Cisco and the best of Rockwell Automation Cisco and/or its affiliates. All rights reserved. Cisco Confidential 31

31 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 32

32 Real Time Status of Production Dashboard Cisco and/or its affiliates. All rights reserved. Cisco Confidential 33

33 Thank you.

34 Accelerating High Performance Operations 35

35 30% 10% REDUCTION IN CAPITAL EXPENDITURES IMPROVED TIME TO MARKET 30% 4% REDUCTION IN INVENTORY IMPROVED PRODUCTIVITY 36

36 <14% MANUFACTURERS In North America have tied their machines to the enterprise network. SOURCE: Industry Week 6 Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

37 Government Initiatives Visions for fueling manufacturing leadership Technologies Innovations that redefine and create new value opportunities Advanced Manufacturing Partnership 2.0 Industrie 4.0 Made in China 2025 Manufacturing Innovation 3.0 Usine du Futur IoT Security CPS SMART MANUFACTURING ENABLED BY The Connected Enterprise AVAILABLE Today and FOUNDATIONAL to Achieving These Visions Industry Consortiums Assemble and promote best practices Industry Standards Drive interoperability and commonality 38

38 THE CONNECTED ENTERPRISE Optimized for Rapid Value Creation Production Headquarters Customers Smart Grid Supply Chain Field-Based Assets Distribution Center Copyright 2016 Rockwell Automation, Inc. All Rights Reserved

39 Rockwell Automation s Integrated Architecture is A High Performance Architecture Scalable Multidiscipline Control Built Upon Contemporary Technologies Manufacturing Intelligence Machines & Process Safety INTEGRATED CONTROL AND INFORMATION Diagnostics & Prognostics Secure Reference Architecture Track / Trace, Genealogy $ Integrated Architecture Intelligent Motor Control Services & Solutions

40 The Connected Enterprise Implementation & Transformation 387, 000 SKUS 20 PLANTS UP TO 200 SKUs AVG ORDER 20 YEARS AVG PRODUCT LIFE PRODUCT TYPES Stock + Configure to Order Engineered to Order 42

41 Our Situation THEN We did not have clear visibility into every plant s operation Best practices or greatest difficulties were tough to compare or contrast since they were defined by different sources of information or points in the process Making confident decisions off of known good data was hard to do

42 Our Situation NOW We have clear visibility into every plant s operation Best practices are easy to identify and execute upon using consolidated analytics Making better, more profitable decisions using real-time data is easy to do

43 PLANT FLOOR MANUFACTURING OPERATIONS MANAGEMENT ENTERPRISE The Connected Enterprise Implementation at Rockwell Automation INDUSTRIAL THINGS ERP FINANCIALS HR LOGISTICS QUALITY WAREHOUSE Scalable computing Mobility Secure Network Infrastructure Multi-disciplined Control & Information Smart Assets MATERIAL & TRANSPORT MACHINES & TESTERS IT OT Rockwell Automation Cloud platform Common Industrial Protocol (CIP) Manufacturing execution mgmt.: Multidiscipline control & information: Logix Data collection CONTROLLERS & SCANNERS PRINTERS & LABEL SERVICES SHOP FLOOR PERSONNEL 45

44 The Connected Enterprise Rockwell Automation Transformation Inventory 120 days to 82 days CapEx 30% per year in capital avoidance Delivery Mid-80s to 96% Lead Times Reduced 50% Time to Want 82% to 98% Quality 50% reduction in PPM Productivity 4% to 5% per year Rockwell Automation Journey Video 46

45 INDUSTRIAL IoT Enhances THE CONNECTED ENTERPRISE that delivers transformational value in productivity and global competitiveness I n n o v a t i o n $ Faster Time to Market Lower Total Cost Improved Asset of Ownership Utilization Enterprise Risk Management Copyright 2014 Rockwell Automation, Inc. All Rights Reserved. 47

46 PUBLIC