problem - risks - reality - requirements - solution - highlights - benefits - references page 1 of...

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Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References

Savings and Expertise for your plantSavings and Expertise for your plant

ALL IN ONE SOLUTION FOR THE PROCESS INDUSTRY


Discover a new level of Data Safety for Automation Technology

in line with ISO 900x and FDA 21 CFR 11

Discover a new level of Data Safety for Automation Technology

Version Control Smart Compare

History Audit-Trail

Archiving

Check-In/Out

Access Control

e-Signature

Autom.Backupsemail Report

Reporting

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Consistent data management- was never as important as it is today

Consistent data management

Problem

Problem

Planning, maintenance

production: vital data is

changing all the time!

It doesn‘t matter whether

you produce cars, drinks or

pharmaceutical products

Reasons for changes: Product mods., bug fixescycle time optim., safety measures, “botched mods.“...

The problem

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Risk assessment for data management:

• How likely is it that something will go wrong?(FMEA = Failure Mode and Effect Analysis)

• How serious would the consequences be?

• How often does the risk arise?

• How many people could be affected?

• How much product could be affected?

• What are the financial implications?

• Are the effects immediate or chronic (long term)?

• What does the law require?

Risk assessment for data management

Risks

Risks

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Risks to be controlled and prevented

Risks to be controlled and prevented:

• Are the correct software releases operating the production?

• Do software changes effect quality and safety?

• Can unauthorised software modifications be detected?

• Are all systems software secured and accessible?

• Is there control over data access and handling?

• Can a replaced device be restored in acceptable time?

and, and ......

Risks

Risks

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• Filing on HDs and server

• Backup on CD, DVD (monthly, weekly)?

• LAN integration of PCs and workstations

• LAN enabled (SoftnetTM) programming software

• Formal work instructions and procedures

.... and your actions?

Which measures have been taken?

Reality

Which measures have been taken?

Reality

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Have you gained control?

Have you gained control?...

Reality

Reality

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.... or does this seem familiar?

• Where is the correct version?

• What exactly has been changed and why?

• Who has overwritten my changes on the server?

• What software version is our system really using at present?

• Why is it that nobody knows the answer...!!!

…. and now?Or does this seem familiar?

Reality

Reality

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Enormous efforts, poor quality,

lots of risks!

Action must be taken!

The current situation?

The current situation?

Reality

Reality

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• Server based, central project data storage withuser and access management

• Copy management between workstationsand server

• Automated program editor operations

• Version control and archiving

• Change management & documentation

• Change history, reporting and audit trail

The requirements

Requirements

The requirements:

Requirements

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• Scheduled automatic backup of controller and device programs, including change detection

• Automatic change notification via e-mail

• Efficient and speedy “disaster recovery”

• Documented change process in line with ISO 900x and FDA 21 CFR 11

• Proven solution with reference sites

The requirements

The requirements:

Requirements

Requirements

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PLC / PC SCADA / HMI / ROBOTS

FIELD DEVICES AND DRIVES FILES / DOCUMENTS

• Indramat• SEW• Lenze• Leutze• Datalogic etc.

• .bin, .xls, • .exe, .ppt,• .txt, .mdb,• .doc• E-CAD• Specifications etc.

„A well designed concept can manage the data of any application“

The type of data to be managed?

The type of data to be managed:

Requirements

Requirements

• Siemens• Rockwell• Schneider (Concept, Unity*)• 3S CoDeSys• TwinCAT• NC, CNC, DNC (840D…)• usw.

• WinCC, ProTool, PCS 7• InTouch• Citect• Ghost Images• ABB, KUKA• FANUC, ADEPT• usw.

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Vital data totally under control!

Vital data under total control!

Solution

Version Control Smart Compare

History Audit-Trail

Archiving

Check-In/Out

Access Control

e-Signature

Autom.Backupsemail Report

Reporting

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A closed loop control for data flow

Work process

A closed loop control for data flow:- developed from practical experience -

Archive Server

WorkstationsDevices

Solution

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Eindeutige Datenablage

Work bench:CommanderEasy-Mode

• Easy to use with the Commander Easy Mode

• Project components, including all versions

• Instant access to change history

• Filing order and structure as required

Direct overview:

Solution

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• Search function for the project tree and master data• Overview of all components which are „under construction“• Indication of the PG- and AG- Actuality• Backup- and Restoring on push of a button

Eindeutige Datenablage

Transparency and functionality:

Work bench:CommanderPower Mode

Solution

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Detailed changes - S7

Version control

• Locating all changes by using „Smart Compare“

• Additional commenting features

Complete version control:

Solution

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

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Detaillierte Unterschiede - S7

• Detaillierte Darstellung aller Änderungen

• Zusätzliche Kommentierung

Eindeutige Versionierung:

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

Solution

Version control

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Detailed changes - WinCC

Version control

Solution




S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

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Detaillierte Unterschiede – PCS 7


• (SFC Smart Compare)


Version control

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

Solution

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Detaillierte Unterschiede – PCS 7


• (CFC Smart Compare)


Version control

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

Solution

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Detailed changes - InTouch

Version control

Solution




S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

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Detaillierte Unterschiede - Schneider




Version control

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

Solution

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Detaillierte Unterschiede - Citect




Version control

S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

Solution

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Detailed changes - Word

Version control

Solution




S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

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Detailed changes - KUKA

Version control

Solution




S7

WinCC

InTouch

CitectWord

... and more

Schneider

PCS 7

KUKA

CodesysTwinCat

Rockwell

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• Electronic change records – audit trail

• „Smart Compare“ between any two versions

Components history

HistoryAudit-Trail

Component history

Solution

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Central data vault

Archiving

• User administration with account policies

• Automated file and directory management of all copying procedures (check-in/ -out)

Central data vault

Solution

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Access controle-signature

• Unique user administration and management

• Electronic signature of specific actions

User security policy

User security policy

Solution

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ReleaseProcedure

• Release procedure according to the four-eye-principle for new versions:

• Electronic Signature• Escalation Management• Deputy Regulation• Email Notification• Audit Trail for all actions

Release procedure - Workflow

Sicherheitsrichtlinien für Benutzer

Solution

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Automated Backups

Automatedbackups

Automated, scheduled device data backupvia LAN (device upload via PLC-Saver)

• Backup of PLC programs (including Soft-PLC), SCADA or HMI, robot controllers, NC, etc.

• Backup of recipes, setpoint values and parameters (for S7: according to selected words or variables)

• Backup of any files via shared network resource or FTP

• Change detection between backup and archived version

• Backup and change report via email

• Support of manual program backups for non LAN accessible devices

Solution

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Automated change report

Change report via email

Automated change report:

• Email report

• “Smart Compare” of any change

Solution

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• Audit trail of all activities• Predefined and user defined selections and filtering • Time-stamped to local- and UTC time• Print functions and export to CSV-file

Project State and reporting

Audit-TrailReporting

ProjectState and Reporting

Solution

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Highlights of VersionWorks®

Highlights

• Archiving of program- and data files on a server with secure user-, access- and copy management

• Support of all PC based data types

• Version control and archiving

• Change history and audit trail

• Scheduled automated backup of controller and device programs including change detection

• Automated change notification via e-mail

• Efficient and speedy “Disaster recovery”

• Documented change process and audit trailin line with ISO 900x and FDA 21 CFR 11

• Proven solution with reference sites:

170 companies approximately 2000 user administer approximately 20.000 devices

Highlights

Highlights of VersionWorks®

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What do we gain by this?

Benefits

Benefits

What do we gain by this?

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Quality improvement due to VersionWorks®

Benefits

Quality improvement due to VersionWorks®

• Complete version control and archiving of all data and software releases as a foundation for “disaster recovery”

• Exact reproducable production conditions

• Association and traceability of software releases and product batches

• Secure user and access administration

• Electronic signature for all relevant actions

• Documented change process and audit trail in line with ISO 900x and FDA 21 CFR 11

• Automated change check and e-mail reporting

Benefits

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Cost reduction due to VersionWorks®

Benefits

Cost reduction due to VersionWorks®

• Reduction of production down time

• Prevention of down time and bad product, due to accidentally activated old software

• Prevention of financial loss, due to loss of vital data

• Prevention of loss of know-how, due to personnel changes/movement

• Quick training of new personnel

• Time saving for the searching of valid Software releases

• Extreme improvement of daily procedures and routines

• Short amortization time (ROI)

Benefits

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Referenzen - Automobilindustrie

References

References

DaimlerChryslerRastatt, Wörth, Mannheim

AudiIngolstadt

BMWDingolfing

BMWLandshut, Leipzig

BMWRegensburg

BMWMünchen

DaimlerChryslerBerlin, Bremen

DaimlerChryslerGermersheim

DaimlerChryslerMettingen

Automotive Industry

FordKöln

VolkswagenBrüssel (BELGIEN)

VolkswagenHannover, Braunschweig

VolkswagenWolfsburg

FAW-VWChangchun (CHINA)

Automotive Associated Industries

BehrMühlacker

BroseCoburg

Continental TevesFrankfurt

Continental TevesMechelen (BELGIEN)

Continental TevesCulpeper (USA)

Continental TevesMorganton (USA)

CorningKaiserslautern

KS AluminiumNeckarsulm

LuKBühl

Mann + HummelMarklkofen

DaimlerChryslerSindelfingen

Shanghai GMShanghai (China)

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References – Food Beverage/Parma

References

References

BavariaLieshout (HOLLAND)

Beck’sBremen

CarlsbergNorthampton (UK)

DanoneOchsenfurt

IndagEppelheim

KrombacherKreuztal

Langnese-IgloReken

Molkerei Alois MüllerFischach

Food and Beverage Industry

NestléHamburg-Wandsbek

NestléBiessenhofen

Nordwest GetränkeSoest

TetraPakGlinde

VeltinsMeschede

WagnerNonnweiler-Braunshausen

WarsteinerWarstein

Pharmaceutical and Chemical Industry

BASFMinden

Boehringer IngelheimIngelheim

FreseniusSt. Wendel

MerckGernsheim

NovartisBasle (SWITZERLAND)

RocheMannheim

RochePenzberg

Salutas PharmaMagdeburg

Wacker ChemieBurghausen

WellaWeiterstadt

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References - Various

References

References

Steel and Metallurgy Industry, Machine builder and various Industries

AluNorfNeuss

AlstomBirr (SWITZERLAND)

DatevNuremberg

Eckart-WerkeVelden

EKO StahlEisenhüttenstadt

Forbo LinoleumAssendelft (HOLLAND)

Franz Viegener IIGroßheringen

Gebr. HellerNürtingen

KnaufImmingham (UK)

Kocher-PlastikSulzbach-Laufen

MieleGütersloh

NECSAPelindaba (SOUTH AFRICA)

Salzgitter FlachstahlSalzgitter

SAPSt. Leon-Rot

Sekurit Saint-GobainHerzogenrath

Schott RohrglasMitterteich

Schweizer ElectronicSchramberg

StihlWaiblingen

VA Tech ElinLinz (AUSTRIA)

Neumag SaurerNeumünster

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BIConsulting Inc.Miami, USA9050 Pines Blvd. Suite 480Pembroke Pines, FL 33024Tel.: +1 (954) 272-6120Fax.: +1 (954) 885-6503E-mail: [email protected]

Contact Information

BIConsulting C.A.Valencia, VenezuelaCentro Comercial Paseo TarbesPlanta Alta, Oficina PA-4Valencia, VenezuelaTel.: +58 (241) 8242139Fax.: + 58 (241) 8242139E-mail: [email protected]

problem - risks - reality - requirements - solution - highlights - benefits - references page 1 of...

Documents

problem risks

reality requirements

reality slide

problem slide

solution highlights

benefits references

data management risks

data access