tf02 - the future of manufacturing in a connected world
TRANSCRIPT
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
The Future of Manufacturing in a Connected World
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Abstract
Integration of control and information on the manufacturing floor will be
essential for manufacturers to remain competitive. In this session,
Rockwell Automation® and Cisco will discuss how we are delivering
products, solutions, and services that use our industry-leading best
practices for networking and convergence for organizational efficiency.
Topics include: use cases and solution sets for the plant of the future –
automation infrastructure, security and compliance, mobility, video and
collaboration, industrial computing and cloud, remote expertise and remote
services, and energy management.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Today’s Discussion
Why we build Connected Enterprises
How to achieve a Connected Enterprise today with multi-capability
industrial architectures
Solution areas of Converged Plantwide Ethernet (CPwE)
Demo example
What steps to take to capture huge new value
Process, partners and products
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Why we build Connected Enterprises
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Rapid Adoption rate of digital
infrastructure:
5X faster than electricity and
telephony
50Billion“Smart Objects”
50
2010 2015 20200
40
30
20
10
Bil
lio
ns
of
Devic
es
2512.5
Inflectionpoint
Timeline
7.26.8 7.6
World Population
The Internet of Things is Enabling a
Connected World in Manufacturing
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
The Internet of Things (IoT)
Continuing Trend in Industrial Applications
6
“Things” are communicating using the same network technology as the Internet
EtherNet/IP (Internet Protocol)
“Things” become the catalyst for better understanding complex processes and
adapting to changes quickly Smarter Machines
Smarter machines can be better controlled thereby increasing efficiency
“Plant-wide Optimization”
Securing the architecture means data authentication and access control
become increasingly important “Unified Secure Infrastructure”
Faster Time to Market Lower Total Cost of Ownership
Improve Asset Utilization Enterprise Risk Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Supply
Chain
Headquarters
Distribution
Center
Smart Grid
Customers
Optimized for Rapid Value Creation
THE CONNECTED ENTERPRISE
SUSTAINABILITY
AGILITY
PRODUCTIVITY
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Supply
Chain
Headquarters
Distribution
Center
Smart Grid
Customers
Optimized for Rapid Value Creation
THE CONNECTED ENTERPRISE
8
Customer
Experience
$164B
Supply
Chain
$931B
R&D/Innovation
$503B
Smart Grid
$94B
Workforce
Enablement
$212B Plant Automation/
Output
$2086B
$4T Manufacturing Value at Stake
PRODUCTIVITY
SUSTAINABILITY
Smart Things Mobility Big Data Analytics Cloud Security
AGILITY
Source: Cisco IoE Value Practice Survey
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Network Convergence
…to a critical part of
the infrastructure
From basicconnectivity…
…to converged,
secure and
collaborative
operations
From disparate IT and OT networks…
…to open
standards
From proprietary standards...
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 10
MATERIAL & TRANSPORT
INDUSTRIAL “THINGS”
PLCS & SCANNERS
PRINTERS & LABEL SERVICES
SHOP FLOOR PERSONNEL
MACHINES & TESTERS
Real-time data: alarms, events, states, energy, diagnostics, …
FINANCIALS HR LOGISTICS QUALITY WAREHOUSE
Transactional information: orders, supply network, product design …
ERP
COMMON SECURE NETWORK INFRASTRUCTURE
OT
IT
IT-OT Convergence
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 11
COMMON SECURE NETWORK INFRASTRUCTURE
OT
IT
Collaboration
…is key to realizing The Connected Enterprise...
Standards, Academia, Industry
Initiatives
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Industrial IP Advantage
12
A ‘go-to’ resource for educational
information about industrial network
communication and using standard Internet
Protocol (IP) for industrial applications
Community of like-minded companies –
Cisco, Panduit, and Rockwell Automation®
Receive monthly e-newsletters with
articles and videos on the latest trends
Network Design eLearning course available for TechEd Attendee promotional price! Sign up today at www.industrial–ip.org
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Multi-Capability Industrial Architectures
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Multi-Capability Industrial Architectures
Industrial
Customer
Drivers
• Faster Time To Market
• Lower Total Cost of Ownership
• Improved Asset Utilization and Optimization
• Enterprise Risk Management
Solution SetsScalable &
ComplementaryAutomation
Infrastructure
Security &
ComplianceMobility
Video &
Collaboration
Industrial
Compute
& Cloud
Remote
Support
Services
Energy
Management
Warning: The following slides have a lot of information that is better understood when downloaded after this event.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Automation InfrastructurePain Points:
Getting data from everywhere to the right place at the right time in the right context…seamlessly
Difficult to scale, maintain, and troubleshoot the physical infrastructure
Value Prop:
Common network infrastructure, brownfield ready and future proof
Outcome:
Faster time to market/new product introduction (NPI)
Ability to change production capabilities without having to totally reconfigure the
machines/operations
Reducing changeover times and lowering downtime
Keeping infrastructure components and cabling securely in place
Solution:
Stratix™ family of automation network infrastructure products
Environmental protection of infrastructure components
Converged Plantwide Ethernet (CPwE) architectures
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Security and CompliancePain Points: Availability of the industrial automation control systems (IACS) including:
Unwanted access to intellectual property and to the physical infrastructure
Unwanted activity on the network and modifications to applications
Value Prop: Risk and downtime avoidance; enabling the Connected Enterprise
Outcome:
Permitting communication only between entities for which there is a need
Protecting the ability to view, edit, and use specific pieces of control
system content (e.g., logic, formulations, recipes, HMI displays, etc.)
Controlling access to the physical infrastructure and automation systems
Managing policies across applications, networks and systems
Solution: Defense in depth security approach including:
Stratix 5900™ Services Router
Physical access control and cable lock-in/block-out
Holistic security capabilities documented in CPwE reference
architectures
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
MobilityPain Points: Connectivity to mobile people, assets, and tools is hard to move
Value Prop: Operations and maintenance productivity improvement
Outcome:
80% faster response in decision making
Solution:
Stratix™ 5100 Wireless Access Point
Architectures to manage radio frequency interference in plants
CPwE document “Deploying 802.11 Wireless LAN Technology
within a Converged Plantwide Ethernet Architecture” includes
wireless access equipment connectivity use cases
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
WLC – Wireless LAN controller
AP – Access point
WGB – Work group bridge
WGB 5..12
AP
Fixed PAC
FactoryTalk® Application
Servers
Wireless
PAC
FTView
ME
FTView SE
Core
switch
Distribution
switch
Fixed I/O
Wireless
I/O
WGB
1..4
Wireless
I/OWireless
PAC
… …
AP (Backup)
AP (RADIUS)
5 GHz
2.4 GHz
Cell/Area ZoneLevels 0-2
Industrial Zone
Level 3 - Site Operations
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Video and CollaborationPain Points:
Ease of use for video and audio integration with the control system
Cost to deploy and configure video
Value Prop: Converged network – video and controls with Quality of Service (QoS)
Outcome:
Reduce frequency of downtime, and especially micro stops
Reduce mean time to repair (MTTR)
Solution:
Cisco Video Surveillance Management (VSM) solution
IP cameras
Video collaboration for remote expertise and remote support
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
ENCODER
TELEMETRY / PTZ
JOYSTICK
IP CAMERA MEDIA SERVER
MEDIA SERVER
OPERATIONS
MANAGER
ANALOG
VISUALIZATION
SERVER
VSM CLIENTS &
VIDEO WALL
FACTORYTALK VIEW
HMI & CLIENTS
MOBILE CLIENTS
DATA PLANE
CONTROL PLANEAPIANALOG
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Industrial Compute and CloudPain Points: Deployment cost and complexity of application delivery and maintenance
Value Prop: Compute resources where they are required – at the edge, in the cloud,
or in between
Outcome:
Reduce cost to deploy 30-50%
Collect and process increased data from the production environment
Execute more optimization applications in the production environment
at a lower cost
Flexibility to add new intelligence and applications easily
Solution:
IOx – compute at the edge (Fog)
Industrial Data Center
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
Switch w/IOx
Servers
• Single
• Redundant
Industrial Data Center
• Essentials
• Essentials +
• Custom
Enterprise data centers
Private/ publiccloud
Industrial Data Center
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Remote Support Services
Pain Points:
Cost to monitor and maintain remote assets (e.g., unnecessary “truck rolls”)
Skills gap leading to insufficient workers to maintain and fix automation systems
Value Prop: Proactive engagement by engineers leveraging contemporary
collaboration tools
Outcome:
Faster response to avoid impending outages
Narrowing of the skills gap through outsourced services
More data for production optimization
Solution:
TechConnect℠ monitoring and managed services
M2M connectivity – Internet Protocol, cellular
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
Rockwell Automation®
Monitoring Cloud
Firewall
Assets
On premise
On premise
RA monitoring end point
Dashboards
Email notification
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Energy Intelligence
CIP Energy on EtherNet/IP
Energy Aggregator and
Low-Power
Energy Aggregator and
Energy Management
PowerMonito
r™
Cisco EnergyWise™
Energy ManagementPain Points:
Energy cost is becoming critical to meet sustainability and profitability goals
Little visibility into where energy is being consumed in the context of manufacturing
Value Prop: Architecture that delivers secure and sustainable automation
Outcome:
Reduce energy cost by 5-30% with better control over smarter equipment
Energy correlated to asset lifecycle
Solution:
Energy intelligence leveraging Cisco EnergyWise,
CIP Energy, and Panduit SmartZone technologies
Field area network
Automation
Infrastructure
Security &
ComplianceMobility Video & Collaboration
Industrial
Compute & Cloud
Remote
Support ServicesEnergy Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Multi-Capability Industrial Architectures are Achievable Today
VantagePoint/
FT EnergyMetrix Power
Monitoring and
Dashboards
Camera Feed
NAT /
Connected
Routing
8193750x and UCS
(behind board)
VSM,
IPICS,
FTVie
w, ISE
Image
s
Add a Switch to
the REP Ring
Guard
I/O™
PTZ Camera
Wireless Tool
Controller
?? ??
“Machines”
Video
Standalone
Fanuc
Robot Cell
GuardLogix
®
AP
Mobile
Tablet
FT View SE w/ Integrated
Video and Robot Diagnostics
Remote Diagnostics
Video
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Multi-Capability Industrial Architectures – Value Impact
Value Impact
where customers
see value
• Lower
downtime
• Faster line
expansion
• Faster NPI
• Risk reduction
(board level
issue)
• Enablement of
new PoF
business models
• Faster MTTR
• Faster decision
making
• Productivity
• Faster MTTR
• Faster NPI
• Faster ECNs
• Lower costs 30-
50%
• Lower downtime
• IOT data
enablement
• Faster MTTR
• Faster NPI
• Faster ECNs
• Lower downtime
• Lower scrap
• Quality
• Lower energy
costs by 5-30%
Industrial Fabric
Solution SetsScalable &
Complementary
Automation
Infrastructure
Security &
ComplianceMobility
Video &
Collaboration
Industrial
Compute
& Cloud
Remote
Support
Services
Energy
Management
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Steps to Take to Capture Huge New Value
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Integrated, Pre-Tested Solution Architectures From Cisco and
Rockwell Automation® Can Ease Skill Gaps and Accelerate Value
Plus lowers costs for plant design and network engineers
Lifecycle Services
Industry Leading Partners
Business Risks Reduced
Faster Deployment
Better ROI
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Delivering the right information
to the right person (or
machine) at the right time
ProcessConnecting people
in more relevant,
valuable ways
People
Turning data into more useful
information for decision
making
DataPhysical devices and objects
connected to the Internet and
each other for intelligent decision
making
Things
The Internet of Everything (IoE)Networked Connections of People, Process, Data, Things
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 27
The Connected Enterprise
EXECUTION MODEL
Analytics
Secure, Upgrade
Working Data Capital
Optimize and Collaborate
Assessment
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Where are You on Your Journey Today?
Automation
Infrastructure
Security &
ComplianceMobility
Video &
Collaboration
Industrial
Compute &
Cloud
Remote
Support
Services
Energy
Management
Assessment
Secure,
Upgrade
Working Data
Capital
Analytics
Optimize and
Collaborate
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Rockwell Automation® and Cisco Can Help You
Capture the Value Opportunities – Next Steps
Discovery Workshop with “OT” and IT
• Business challenges
• Best practice sharing
• Use case brainstorming
and prioritization
• Connected Enterprise
Execution Modeling
TCO or OEE Opportunity Quantification
• Quantify top value
opportunities for senior
management (TCO, OEE,
and overall benefit
models)
Proof of Concept Design
• Run POCs in a Showcase
manufacturing facility to
prove the value and
technology
End State Architecture Assessment
• Document future state
architecture (e.g., 3 to 5
years out), gaps with
today, change
management, and phased
plan to get there