Internet of Manufacturing

Southwest 2017

Digitizing a

Manufacturing

Company

Who is SugarCreek?

• Largest private label bacon manufacturer and

sous vide processor in the US

• Founded in 1966, privately held

• >$650MM in revenue in 2016, on track to

exceed $1B in the next few years

• Primary products are raw bacon, precooked

bacon, bacon bits, sausage, meatballs and sous

vide cooked proteins

Who is SugarCreek?

• Over 2000 employees at 12 locations

• Six Manufacturing sites:– Washington Court House, OH: Raw pork bacon, turkey

bacon and bacon bits

– Dayton, OH: Precooked bacon

– Fontenac, KS: Precooked and raw bacon, bacon bits

– Cincinnati, OH: Assembly and packaging

– Fairfield, OH: Bakery, assembly and packaging

– Cambridge City, IN: Capable of manufacturing virtually

any precooked protein

Who is SugarCreek?

• Recent accolades:– 2017 Firebrand Award – Inductive Automation

– 2016 Plant of the Year - Cambridge City – Food

Engineering Magazine

– 2016 Food Processor of the Year – Refrigerated and

Frozen Foods Magazine

– 2016 Environmental Award – North American Meat

Institute

– 2015 Manny Award for Biggest Breakthrough – Cincinnati

Magazine

Technical Structure

CEO

Supply Chain VP

Operations

EVP

Engineering VP

CIO

ITOT

IT Objectives

• Be a proactive change agent in the business

• Provide a secure, stable and agile environment

• Manage costs as growth occurs

• Provide appropriate systems to manage the

business

• Enable collaboration

• Improve data access

IT Responsibilities

• Everything that plugs into the wall or connects wirelessly– Cell Phones, Desk Phones, TV’s, Laptops, Desktops, Tablets,

Scanners, Copiers, Cameras, Physical Security

• Network, Data Center and Servers

• Staffing – 20 Total – Support

– Developers

– Network and Server Personnel

– Management

IT Infrastructure

Network

Software Defined Data

Center

Network Environment – Pre

SDDC• 99% Virtualized using VSphere

• Conventional infrastructure using Cisco UCS, NetAp

p

• Microsoft Shop

– SQL Server

– Office

– Dynamics AX

• Primary Data Center in house, DR site at colocation

• Synchronous replication using NetApp to DR site

Network Environment – Post

SDDC• VMWare products provide the foundation for an agile

and automated network

• 99% Virtualized

• New Data Centers Running with NSX, Palo Alto on Virt

ual Layer, ACI on Physical Layer

• Running– VCloud Suite

• VSphere

• VROPs

• VRO

• VRA – Automation for developers

NSX

Vsan – Unstructured data and video

Airwatch (Cloud)

Horizon

NetApp – Enterprise data

Network Environment Benefits

• Provides Automation, Network and Developers

• Increases Utilization

• Improves Uptime and Recovery Time

• Reduces future Storage Costs

• Scalable, into the cloud as well

• Highly Secure – Micro segmentation and Next Gen F

irewalls

Network Environment Statistics

• 6 Servers in Management Cluster, stretched environm

ent between two data centers for HA, allows for

replicated Management cluster as backup

• Disaster Avoidance

– 13 physical servers each site

– 52 total sockets

– 9.5TB RAM total

– 300TB vSan Storage 120TB of that is all flash.

Where IT Meets OT

• Micro segmentation of plant floor networks

• Networks assigned to either production processes or

vendors

• All machines utilize Stratix managed switches with

Etherchannel redundancy

• No direct access to machines from outside their netw

ork

• VDIs configured as programming terminals

• Vendors/Maintenance remote into VDI for access to th

e machines on that network

Operational Technology

• Formed in 2017

• Responsibilities:– Getting the right data to the right people at the right time

– Connecting plant floor systems to IT infrastructure

– Developing standards for data

– Developing dashboards and reports for all levels of the

organization

– Technical lead for corporate continuous improvement

team

Ignition at SugarCreek

Ignition Metrics

• 12 Databases

• 100+ Devices– Rockwell (Logix, CompactLogix, Micrologix, SLC)

– Modbus TCP

– TCP/IP

– Siemens (S7-1500, S7-300)

• >15,000 tags

• 35-45 Clients open at any given time

• >50 reports (30 Scheduled)

Ignition Modules

• 18 Licensed modules– OPC Drivers (standard)

– Vision

– Alarming

– Reporting

– Mobile

– SepaSoft MES

• OEE Downtime

• Production

• Scheduling

Key Talking Points

• Designing intuitive dashboards

• Leveraging reporting for success

• Intelligent scan class utilization

• UDTs are your friend

• All alarms are not bad

• The importance of transaction groups

• Thinking outside of the box

Designing Intuitive Dashboards

Leveraging Reporting for

Success

• Do not limit reports to data collected by Ignition

• Schedule relevant reports to end users

• Make reports flexible

• Utilize dynamic data keys for conditional

formatting

All Alarming is Not Bad

• Alarm notification pipelines can be used for all

types of cool stuff…– Alerting sludge haul away companies for pickup

– Alerting vendors for replenishment

– Notifying employees when batches are complete

– And, obviously, for when machines go into alarm

• All pipelines are not created equal

Questions?

Thank You