Using Virtualization in Manufacturing Industries to Improve the Utilization and Availability of Resources and Applications

Transcription

1 Using Virtualization in Manufacturing Industries to Improve the Utilization and Availability of Resources and Applications Christopher Di Biase Principal Consultant Network & Security Services Copyright 2011 Rockwell Automation, Inc. All rights reserved.

2 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 2 Agenda 1. Overview and Drivers 2. Technology and Value 3. Virtualization and Factory Talk 4. Virtualization and the Cloud 5. Rockwell Products and Services

3 Most Important IT Priorities What are your organization s most important IT priorities over the next months? Increase use of server virtualization Information security initiatives Improve data backup and recovery Upgrade network infrastructure Manage data growth Major application deployments or upgrades Data center consolidation Business continuity/disaster recovery programs Large-scale desktop/laptop PC refresh Regulatory compliance initiatives Desktop virtualization Major database deployments or upgrades Mobile workforce enablement Improve collaboration capabilities Deploy unified communications / voice-over-ip (VoIP) Enterprise content management / document management Green initiatives Business intelligence/data warehouse initiatives Deploy unified computing solution Implement IT governance framework (e.g., ITIL, COBIT, ISO 27001, Increase use of IT outsourcing Increase use of "cloud computing services New data center construction Applications delivered via software-as-a-service (SaaS) model 28% 27% 27% 25% 24% 23% 21% 20% 19% 18% 18% 17% 17% 16% 16% 16% 14% 13% 13% 12% 12% 10% 9% 33% 0% 5% 10% 15% 20% 25% 30% 35% Copyright 2010 Rockwell Automation, Inc. All rights reserved. SOURCE: 2010 Enterprise Strategy Group 3

4 Server Virtualization Adoption, by Industry Server virtualization adoption, by industry. (Percent of respondents) Using server virtualization in a production environment Using server virtualization, but in a test environment only Have not yet deployed server virtualization, but plan to Have not deployed and have no current plans to Education (N=59) Manufacturing (N=74) Health Care (N=51) Professional Services (N=36) Government (State & Local, N=48) Financial (N=79) Communications & Media (N=27) Government (Federal, N=28) Retail/Wholesale (N=25) Transportation/Logistics (N=20) 71% 61% 53% 50% 48% 46% 44% 36% 21% 36% 20% 30% 20% 8% 22% 11% 23% 30% 41% 21% 16% 30% 12% 8% 8% 20% 11% 12% 14% 25% 14% 19% 10% 15% 9% 11% 4% 21% 28% 20% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Copyright 2010 Rockwell Automation, Inc. All rights reserved. SOURCE: 2010 Enterprise Strategy Group

5 Virtual Machines outnumber Physical 17,500,000 15,000,000 12,500,000 10,000,000 7,500,000 5,000,000 2,500,000 VM Cross Over Projected Physical Hosts Virtual Machines Source: IDC

6 ANSI/ISA 95 Functional Hierarchy Business Planning and Logistics Systems Level 4 Business Process Information Network Manufacturing Operations and Control Systems Level 3 Operations Information Network Data Collection, Operator and Batch Control Systems High Alarm Low Alarm Comm. Err. Level 2 Automation Network Equipment Control Systems Discrete Device Process Device Level 1 I/O and Sensors Discrete Manufacturing Process Device Continuous/ Batch Manufacturing Level 0

7 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Manufacturing System Considerations Virtualization is widely adopted by IT and growing in Manufacturing Manufacturing has some unique Considerations and Opportunities Long system lifecycle needed (10-20 years) Obsolescent hardware infrastructure Legacy operating systems no longer available Remote geographical locations, Limited space Disperse Operator Workstations Reliability for 24 x 7 x 365 Address with Virtualization Value Propositions System Longevity with HW/SW Abstraction Server Consolidation Deployment and Administration from Anywhere Centralized Desktop Support Availability (Reliability)

8 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 8 Agenda 1. Overview and Drivers 2. Technology and Value 3. Virtualization and Factory Talk 4. Virtualization and the Cloud 5. Rockwell Products and Services

9 What is Virtualization? Traditionally the OS and its applications were tightly coupled to the hardware they were installed on Virtualization breaks the link between operating system and physical hardware This allows the ability to change hardware without replacing the OS or applications Additionally multiple instances of an OS with independent applications can now run on the same hardware Application Application Application Operating System Hypervisor Copyright 2011 Rockwell Automation, Inc. All rights reserved. 9

10 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 10 Types of Virtualization Hosted or Desktop Bare Metal or Server App App App App App Application OS Hypervisor OS OS OS OS Host Operating System Hypervisor

11 Increased Longevity Typical computer refresh cycle is 3-5 years Typical industrial control system refresh cycle is much longer 15 to 20 years Computer replacements typically require software upgrades which are expensive and difficult Virtual hardware exposed to the guest OS does not change when physical hardware is replaced Each virtual hardware version is supported for three major releases of vsphere APP OS APP OS HW10 7 HW10 7 HW10 7 VMware ESX APP OS Copyright 2011 Rockwell Automation, Inc. All rights reserved. 11

12 Server Consolidation Many Server Machines Many Operating Systems Many Applications with Different CPU Usage High Maintenance of Server Infrastructure High Utility Cost (Electricity, Cooling) Copyright 2010 Rockwell Automation, Inc. All rights reserved.

13 Server Consolidation Different Applications with OS requirements Different Operating Systems Removes Dependency on Hardware Copyright 2010 Rockwell Automation, Inc. All rights reserved.

14 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Reliability: High Availability Automatic restart of virtual machine on host failure Resource Pool VMware ESXi VMware ESXi VMware ESXi Operating Server Operating Failed Server Operating Server

15 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Reliability: VMware Fault Tolerance Near bumpless transfer of control on host failure No Reboot Seamless Cutover VMware ESXi VMware ESXi VMware ESXi OperatingServer OperatingServer Failed OperatingServer

16 Client Virtualization Extend server virtualization benefits to clients: Software independence from hardware Lower Administration and Support Costs Rapid Desktop Deployment Lower Maintenance and Energy Costs Leverage VM Availability Features Integrated Secure Remote Access Offline Mode Wireless Access VMWARE VIEW SECURITY SERVER Centralized Virtual Desktops Remote Client Sample Uses Scenarios Thin Client With Wireless Desktop VMWARE VIEW MANAGER Laptop

17 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 17 Typical Hardware Architecture In the data center Storage Array (iscsi, FC, NFS) 2-4 Physical Servers 2 CPU, 32GB Redundant Gigabit Switches In the office and on the shop floor legacy desktops ruggedized laptops solid state thin clients Tablets (ipad / Android)

18 Server Considerations CPU Consolidation Ratios of 8 20 VM s per Server Memory Allocate by number of Virtual Machines Number of Servers (4) Operator 2 GB (1) Engr 4 GB (2) Multi Purpose Virtual 2 GB (1) Application 4 GB Virtualizing this system would require a minimum of 20 GB Memory With VMware Features such as vmotion, HA, and FT we recommend the use of 3 physical servers Verify all of your hardware is compatible by using the VMware Hardware Compatibility List at VMware.com Copyright 2011 Rockwell Automation, Inc. All rights reserved. 18

19 Storage Considerations Storage Options Fibre Channel NAS iscsi Direct Attached SAS Performance Factors Capacity / Price Disk types (SCSI, ATA, FC, SATA) Access Time; IOPS; Sustained Transfer Rate Reliability (MTBF) VMware Performance is gated ultimately by IOPS density and storage Space Copyright 2011 Rockwell Automation, Inc. All rights reserved. 19

20 Networking Virtualization requires additional networks to manage and isolate information traffic VM Network(s) Ie./ Assembly Line 1 VLAN, Assembly Line 2 VLAN Management / vmotion Storage Network (If applicable) Fault Tolerant Network So how many NIC s do I need on my server? In the scenario above, 4 Nic s per server If Fault Tolerance was a requirement, 8 Nic s Gigabit Switches are required Networks should be isolated by VLAN s The NICs connected to the Servers act as Trunks into your vswitches Copyright 2011 Rockwell Automation, Inc. All rights reserved. 20

21 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 21 Agenda 1. Overview and Drivers 2. Technology and Value 3. Virtualization and Factory Talk 4. Virtualization and the Cloud 5. Rockwell Products and Services

22 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 22 FactoryTalk System Example Active Directory FactoryTalk Directory Primary HMI Secondary HMI Asset Centre Historian VantagePoint Batch Engineering Workstations Operator Workstations

23 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 23 FactoryTalk System Example Active Directory FactoryTalk Directory Primary HMI Secondary HMI Asset Centre Historian VantagePoint Batch Engineering Workstations Operator Workstations

24 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 24 Agenda 1. Overview and Drivers 2. Technology and Value 3. Virtualization and Factory Talk 4. Virtualization and the Cloud 5. Rockwell Products and Services

25 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25 What about Clouds? Active Directory Primary HMI FactoryTalk Directory Secondary HMI Engineering Workstations Asset Centre Historian VantagePoint Batch Operator Workstations Thin clients

26 A Common Definition Cloud Computing IT Resources and Services that Are Abstracted from the Underlying Infrastructure and Provided On Demand and At Scale in a Multitenant and ElasticEnvironment A Style of Computing Where Massively Scalable IT-Enabled Capabilities Are Delivered As a Service to Multiple External Customers Using Internet Technologies Source: Gartner Defining and Describing an Emerging Phenomenon June 2008 Anywhere, Anyone, Any Service Copyright 2011 Rockwell Automation, Inc. All rights reserved.

27 Product Stack Adoption + Value Copyright 2011 Rockwell Automation, Inc. All rights reserved. 27 Journey to a Cloud Infrastructure Stage 3 IT as a Service BUSINESS AGILITY Stage 1 IT Production COST EFFICIENCY Stage 2 Business Production QUALITY OF SERVICE Business Continuity & Disaster Recovery Operations Management Cloud Services Delivery Desktop Virtualization Higher layers of the product stack delivers on business values Server Virtualization Core virtualization platform is the foundation

28 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 28 Private Cloud for the Manufacturing Zone Hybrid Cloud APP Loads APP Loads APP Loads Management VMware vsphere Management VMware vsphere Manufacturing Zone Private Clouds Enterprise Zone or Public Clouds

29 Copyright 2010 Rockwell Automation, Inc. All rights reserved. 29 Agenda 1. Overview and Drivers 2. Technology and Value 3. Virtualization and Factory Talk 4. Virtualization and the Cloud 5. Rockwell Products and Services

30 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 30 Products Supported RSLogix 5 RSLogix 500 RSLogix 5000 RSLogix Architect FactoryTalk View SE FactoryTalk View ME FacotryTalk View Studio RSNetworx FactoryTalk Metrics FactoryTalk ProductionCentre FactoryTalk Transaction Manager RSView32 RSLinx Classic FactoryTalk AssetCentre FactoryTalk Vantage Point FactoryTalk Gateway RSLinxEnterprise FactoryTalk Historians FactoryTalk Batch Emonitor

31 VMware Ready Products RSLinx Classic RSLinx Enterprise Product CY2009 CY2010 a a FactoryTalk AssetCentre FactoryTalk Batch FactoryTalk Historian Site Edition FactoryTalk VantagePoint FactoryTalk Gateway FactoryTalk View SE FactoryTalk View Studio RSLogix5000 a a a a a a a a

32 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 32 Windows 7 XP Mode support FactoryTalk View Studio for FactoryTalk View Enterprise v6.00 FactoryTalk View Studio for Machine Edition v6.00 RSView32 Works v7.50 FactoryTalk Activation Manager v3.30 FactoryTalk Services Platform (FTSP) v2.30 RSLinx Enterprise v5.30 RSLinx Classic v2.57 PanelBuilder32 v3.82

33 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Virtual Appliance Model Availability = 99.99% Security = High Performance = 500 msec SLA Definitions App OS App OS App VMware Infrastructure Virtual Datacenter OS OS An uplifting of a virtualized workload VM = Virtualized Hardware Box App = Virtualized Software Solution Properties: Comprised of one or more VMs (may be multi-tier applications) Encapsulates resource requirements on the deployment environment Distributed in industry standard Open Virtualization Format (OVF) Built by: ISVs / Virtual Appliance Vendors IT administrators SI/VARs

34 Copyright 2010 Rockwell Automation, Inc. All rights reserved. Virtual Appliance Deployment Software Vendor Corporate Customer Studio Sell and Distribute Deploy & Configure Patch Repository

35 Rockwell Virtualization Progression November 2009 November 2010 VMware Ready November 2009 VMware Ready RSLinx RA Products Classic Supported with VMware RSLogix 5000 RSLinx Enterprise RSLogix 5 RSLogix 500 RSLogix FactoryTalk 5000 View SE FactoryTalk View Studio RSLogix Architect RSNetworx FactoryTalk Batch FactoryTalk AssetCentre RSLinx Classic & Enterprise FactoryTalk Vantage Point Design & Production Configuration Management Factory Talk Gateway FactoryTalk Historian SE ASSESS MANAGE / FactoryTalk View SE & ME RSView32 Factory Talk Gateway MONITOR FactoryTalk View Studio FactoryTalk Batch Quality & Compliance FactoryTalk Transaction Manager DESIGN/PLAN FactoryTalk AUDIT Metrics FactoryTalk AssetCentre FactoryTalk Vantage Point FactoryTalk ProductionCentre IMPLEMENT FactoryTalk Historian SE & Classic Emonitor Virtualization Infrastructure Services + Virtual Appliance Planning and Testing Asset Management Data Management Performance & Visibility

36 Network & Security Services: Lifecycle Approach to Services and Support Copyright 2011 Rockwell Automation, Inc. All rights reserved. ASSESS MANAGE / MONITOR HOURLY CONSULTING AUDIT DESIGN/PLAN IMPLEMENT Because Infrastructure Matters

37 Copyright 2011 Rockwell Automation, Inc. All rights reserved. 37 Rockwell Automation Services and Support ASSESS Assess the current state of the security program, design, policy Assess the current state of the network design, implementation Assess the current state of a manufacturing data center DESIGN/PLAN Design and plan a network infrastructure Design and plan security program, policy, infrastructure, business continuity plan Design and plan a virtual infrastructure IMPLEMENT Installation, procurement and configuration of a network Implementation of a security program, infrastructure design, policy training Installation, procurement and configurations of a virtual infrastructure AUDIT Audit current architecture compared to governing body (ODVA, IEEE, ANSI/ TIA) Audit security program compared to governing body (NERC CIP, ISA -99, NIST , NIST MANAGE/MONITOR Manage, maintain and monitor uptime and issues on the network and SANs environment Managed Security Services (Incident response, disaster recovery, monitoring)

38 Copyright 2011 Rockwell Automation, Inc. All rights reserved. Questions?