Building Smart Machines for Digital Transformation

Transcription

1 Building Smart Machines for Digital Transformation Robert Hicks Regional Segment Lead - OEM RAOTM 2019, Bengaluru,

2 Agenda Smart Machines driving Digital Transformation Smart Machines - COMPLIANT Smart Machines - CONNECTED Smart Machines - COMPETITIVE

3 What is Industrie 4.0!! The Fourth Industrial Revolution!! INDUSTRIE 4.0 is the German strategic initiative to take up a pioneering role in industrial IT which is currently revolutionizing the manufacturing engineering sector.!! Professor Henning Kagermann!! President acatech!! National Academy of Science and Engineering!! Spokesperson of the Communication!! Promoters Group of the Industry-Science!! Research Alliance and Co-Chair of the!! INDUSTRIE 4.0 Working Group PUBLIC Copyright 2018 Rockwell Automation, Inc. 3

4 The Connected Enterprise Enabling the Industrial Internet of Things (IIoT) DIGITAL TRANSFORMATION CAPABILITIES Cloud On-Premise Edge Faster Time to Market SCALABLE PERFORMANCE & EXECUTION SCALABLE ANALYTICS ROCKWELL AUTOMATION IIoT INFRASTRUCTURE Integrated Architecture INTELLIGENT MOTOR CONTROL I/O & CONDITION MONTIORING CONTROLLERS MOBILITY & COLLABORATION VISUALISATION CONNECTED SERVICES SECURITY CUSTOMER OUTCOMES Lower Total Cost of Ownership Improved Asset Utilization SMART SENSORS SMART SAFETY COMPONENTS SMART CONNECTED ASSETS Ethernet/IP Enabled Network SECURE REMOTE ASSETS SMART MACHINES & EQUIPMENT Enterprise Risk Management PUBLIC Copyright 2018 Rockwell Automation, Inc. 4

5 SMART MACHINE DIFFERENTIATION RA, OEM & End User Collaboration Partnering on our OEM s Journey Scalable Analytics w/ PTC, Performance & Execution (MES) Solutions Focus on ROI & Creating New Revenue Streams PUBLIC Copyright 2018 Rockwell Automation, Inc. 5

6 What is a SMART Machine PUBLIC Copyright 2018 Rockwell Automation, Inc. 6

7 Smart Manufacturing Business Drivers Faster Time to Market Improved Asset set Utilization END USER OEM Flexibility Integration & Standardization Performance/OEE Enterprise Risk Management ent After Market Service & Support Lower Total Cost of Ownership Exceed Productivity & Efficiency Goals Innovation to Drive Differentiation Total Cost to Design, Develop & Deliver SMART MANUFACTURING SMART MACHINES & EQUIPMENT PUBLIC Copyright 2018 Rockwell Automation, Inc. 7

8 THE CONNECTED ENTERPISE Demands Smart Machines & Equipment Real-time Data Voltage, Kwh,Running Time, Temperature, Faults etc. Security PROTECT Securing the data flow Revenue NEW MODELS Monetizing OEM Wisdom Information CONTEXTUALIZATION Energy/Product or Line Speed/OEE Knowledge ANALYTICS How does line speed affect OEE? Wisdom OPTIMIZE Control speed to maximize OEE PUBLIC Copyright 2018 Rockwell Automation, Inc. 8

9 BUILDING A SMART MACHINES Creating differentiation for you and your customers PUBLIC Copyright 2018 Rockwell Automation, Inc. 9

10 BUILDING A SMART MACHINES Creating differentiation for you and your customers Scalable Performance OEE Dashboards PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 0

11 BUILDING A SMART MACHINES Creating differentiation for you and your customers Predictive Analytics and AR Maintenance Workflows PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 1

12 Building a Roadmap Assessing Key Drivers to Map an OEM s Journey Mechatronic Design Advanced Process Control Condition Monitoring Information & Reporting Mobility Scalable Analytics Smart Sensing Adaptive Motion Secure Remote Access Smart Safety Systems IP & Tamper Protection Modular Code & Virtual Design PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 2

13 Smart Machine Maturity Model Mapping current and future state Scalable Analytics Stage 1 Descriptive Stage 2 Diagnostic Stage 3 Predictive Analysis Stage 4 Prescriptive Analytics Mobility Stage 1 Local ViewPoint Thin Clients Stage 2 Secure, Remote Thin Clients Stage 3 ThinManager Administered clients Stage 4 User/Location Based Services Sensing Stage 1 Digital Input Devices Stage 2 I/O with Extended Diagnostics Stage 3 Networked Smart Sensors Stage 4 IIoT connected edge devices Secure Remote Access Stage 1 Local Access Only Stage 2 Secure Modem w/ VPN Stage 3 Virtual Support Engineer Stage 4 Validated CPwE Advanced Process Control Stage 1 Traditional PID Stage 2 Adv. Process Control (IMC, CC, MMC) Stage 3 In-Chassis Model Predictive Control Stage 4 Pavilion8 Server based MPC Condition Monitoring Stage 1 Overall Vibration Measurement Stage 2 Real Time Alarming using FFT & Banding Stage 3 Complex Waveform Analysis Stage 4 Machine Learning and Predictive Maintenance PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 3

14 Smart Machine Maturity Model Mapping current and future state Information & Reporting Stage 1 Data Collection Stage 2 Data Orchestration Stage 3 Real Time Information Dashboards Stage 4 Integrated Business Intelligence IP and Tamper Protection Stage 1 Password based protection Stage 2 Role-based IP protection Stage 3 License based IP protection Stage 4 Execution protection Modular Code & Virtual Design Stage 1 Modular Code & Offline Emulation Stage 2 Synchronize 3D Design and Code Development Stage 3 Bulk code generation & Machine Simulation Stage 4 Digital Twin Safety Systems Stage 1 Hardwired Stage 2 Extended Diagnostics Stage 3 Integrated Control and Safety Systems Stage 4 Connected Smart Safety Devices Mechatronic Design Stage 1 Belts, Chains & Pulleys Stage 2 Mechanical Line Shaft Stage 3 Electronic Line Shaft Stage 4 Independent Cart Technology Adaptive Motion Control Stage 1 Stand alone drive Stage 2 Network Interface Stage 3 Integrated Motion Stage 4 Adaptive Tuning PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 4

15 Smart Machines are COMPLIANT PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 5

16 Industrie 4.0: RAMI 4.0 A Connected Enterprise Relies on Existing Standards PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 6

17 Compliant Smart Machines Leveraging Existing ISA Programming Standards ISA 101 Effective displays Library of contextual display objects to drive productivity ISA S88 / TR88 Procedural control Pre-Built sequencers automate procedures to free operator to focus on process ISA 18.2 Standards-based alarming Effectively direct the operator s attention with alarms to improve the productivity, safety, and environment of your plant PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 7

18 Compliant Smart Machines Directly Integrate Compliant Safety, Power, and Condition Monitoring Integrated Safety (ISO / IEC 61508) Smart Machines combine safety and standard control and utilize contemporary safety solutions. CIP Safety provides safe speed, direction, position & Zone Control with functional safety designed in, opening a new window into the OEMs machine! How often is the systems tripped?! Where is safety impeding productivity?! Are safeguards being defeated? Power Monitoring (IEC 20140) Energy Monitoring products capture an exhaustive amount of data about your energy network, keeping you wellinformed on:! How much power you use! What your major loads are! When you use electric power the most! How much you pay for it! The quality of the power you use Condition Monitoring (VDMA 4582) OEMs can reduce unplanned downtime and perform predictive maintenance.! Measurement, signal processing and integration tools present the indicators of condition or fault!! Configurable for any machine, easily integrated to Logix over EtherNet/IP. Integrated detection, identification, and notification, and actions PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 8

19 Smart Machines are securely CONNECTED PUBLIC Copyright 2018 Rockwell Automation, Inc. 1 9

20 Smart Machines in a Connected Enterprise Secure, Remote Access Good, Better & Best (IEC62443) Good! Modems, eg Inhand, ewon, Prosoft, HMS! Inbound and/or Outbound! Secure VPN tunnels! Basic User Authentication! Basic Access Audit Trail! Basic End-User Control (On/Off) Better! RA s Secure Remote Access Platform! CPwE compliant! Outbound Only Comms (443)! SSL Certification/Fingerprint! Limit access by User and/or IP address! User Authentication! Remote Access Audit Trail! Remote Access Surveillance! Complete End-User control Best! RA/Cisco Reference Architecture! Globally recognized best practice! Validated Design for remote access! Enables secure plant-tobusiness network convergence! Security applied at all levels of the architecture PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 0

21 Smart Machines in a Connected Enterprise Security Holistic Defense-in-Depth (IEC 62443)!! No single product, technology or methodology can fully secure Industrial Automation and Control System (IACS) applications.!! Protecting IACS assets requires a defense-in-depth security approach, which addresses internal and external security threats.!! Physical limit physical access to authorized personnel: Cells/Areas, control panels,cabling, and control room!. locks, gates, key cards, biometrics. This may also include policies, procedures and technology to escort and track visitors!! Network security framework for example, firewall policies, access control list (ACL) policies for switches and routers, AAA, intrusion detection and prevention systems (IDS/IPS)!! Computer Hardening patch management, Anti-X software, removal of unused applications/protocols/services, closing unnecessary logical ports, protecting physical ports!! Application authentication, authorization, and accounting software!! Device Hardening change management, communication encryption, and restrictive access PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 1

22 Protecting your Smart Machines Smart Machines Utilize Defense-in-Depth Security Practices Content Protection Protect viewing, editing, execution, exchanging data and use of specific pieces of control system content.! (NEW)Execution Protection! (NEW) Secured Data Exchange! Password-based Source Protection! License-based Source Protection! FactoryTalk Security Tamper Detection Detect & Record unwanted Activity & Modifications to the application! (NEW) Component Change Detection! Logix Change Detection Audit Value! Controller Change Log! Security Server Validation! High integrity Add-On Instructions Hardening the Network Control Access to the network, Detect unwanted access and activity! Stratix 5900 Services Router! Stratix 5950 Security Appliance! Disabling unused ports / services! Logix data access control! Stratix MAC ID security / ACLs! Logix controllers trusted slots! CLX secure comm card (EN2TSC) PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 2

23 Smart Machines are COMPETITIVE PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 3

24 Leverage New Technology Examples on reducing development and delivery costs Kinetix Tuningless Features Smart Machine drives tune themselves!! Load Observer dynamically estimates the load torque & provides a feedback signal to cancel its effect! Adaptive Tuning w/ Tracking Notch Filter compensates for unknown & changing load conditions on the fly Automatic Device Replacement Premier Integration at its finest. Three step process enables seamless device replacement.! DHCP Port Persistence! Firmware Supervisor! ADC Automatic Device Configuration Instrumentation Integration Provide an immediate and measurable impact on asset availability, operational efficiency, and energy management.! Reduced integration cost of disparate systems! Safe monitoring of energized devices on operator screens. PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 4

25 Modular, Scalable Performance & Information Partnering with OEMs Smart Machine vision High MES > ERP (Performance, Quality, Production Tracking, etc.) Plant OEE & Performance Analytics Plant MES (Scalable MES/FT Production Centre) Progressive Functionality Line OEE & Performance Analytics Machine OEE Performance Reports Line (MES Lite ) (FT Historian / FT VantagePoint / RAPID) Machine + (FT ViewSE/ViewPoint/SQL iewpoin Express) OEMs are being asked to provide connectivity and to increase scope Low Machine Line Plant Enterprise Machine (PVP7/FT ViewPoint) PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 5

26 Mobility & Portability Reducing downtime through better Information Accessibility Securely access, enter data, & control your FT View app from a web browser! No client software to install or maintain! Real-Time and Historical Trending! ViewPoint is now HTML5!! Support for ios and Android Connect from and mobile device! Mobile portal Responsive UI adjusts content dynamically! Ad Hoc dashboard or trend creation! Excel Reports, Advanced Reports Trend, & XY Plot charts Safely and securely deliver your CONTENT to any combination of DEVICE, USER and LOCATION! Centrally manage users and devices! Increases Security Provides Location-Based Mobility! PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 6

27 Scalable Analytics Partnering with OEMs Smart Machine vision Optimization Orchestration / Presentation Machine Performance Device Health More to Come PRESCRIPTIVE What Should I Do? PREDICTIVE What Will Happen? DIAGNOSTIC Why Did it Happen? DESCRIPTIVE What Happened? MACHINE LEARNING Edge On-Premise Cloud PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 7

28 Analytics Transforms Data to Action BASIC ANALYTICS ADVANCED ANALYTICS ACTION HUMAN INPUT DESCRIPTIVE Historical Data DIAGNOSTICS Historical PREDICTIVE Future PRESCRIPTIVE Future Action WHAT HAPPENED? WHY DID IT HAPPEN? WHAT IS ABOUT TO HAPPEN? WHAT CAN I DO TO AVOID IT? Motor Fault Motor Fault High Current Motor will Fault Motor Fault, Decrease Load Almost out of gas Check engine light appears Shows miles until empty GPS Navigation PUBLIC Copyright 2018 Rockwell Automation, Inc. 2 8

29 Smart Connected Machines Leveraging Scalable Analytics Platforms to Deliver Outcomes Solutions Expertise Predictive Maintenance Asset Health System Performance Infrastructure Security Power Control / Software Infrastructure Analytics Devices PF52x/PF75x PFx000 PLCs On-Machine Database Networks Virtual Compute EDGE

30 Don t wait to differentiate TIPS for SUCCESS Identify opportunities and build ROI Start small with scalable solutions Implementing a Smart Machine will bring POSITIVE impact to your business Use modular, standards based control Partner with trusted technology providers Continuously Improve! PUBLIC Copyright 2018 Rockwell Automation, Inc. 3 0

31 Thank you