Transcript
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 1
Discrete MFG IoT Factory of the FutureAugust 28, 2013
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 2
Agenda
Manufacturing Trends
Factory of the Future Vision
Factory of the Future Journey
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 3
An Industrial Renaissance Has Begun
* “The Truth About Robotics White Paper,” Seegrid Corporation, Fall 2013** “US Manufacturing Nears the Tpping Point: Which Industries, Why and How Much, BSG April 2013*** “Manufacturing Moneyball: using big data and business intelligence to spur operational excellence”, Forbes 11,2011 **** From slide #77b – check sourrce
Robot Advancements,
Additive Printing
NPIConvergence
ManufacturingOnshoring
PlantFlexibility
Manufacturing Big Data
Converged Plant Networks
1M+ Industrial RobotsGlobally
Robot Advancements,
Additive Printing
MFG Flexibility Reduces NPI setup by 75%
PlantFlexibility
ManufacturingOnshoring
33% of NA Manufacturers Repatriating
Plants
NPIConvergence
33% NPIProcess
AccelerationManufacturing
Big Data
70% Have Big Data Plans to Improve Plant Operations
Converged Plant Networks
Unifying Networks:
18% IT TCOSavings
Manufacturing Sales are OutpacingGDP by 2x_______
$2 Trillion value Opportunityin Discrete Manufacturing
(the largest IoT opportunity)
U.S. Competitive Drivers
Source: “The next big thing in Manufacturing? On-Shoring”, Logistics Viewpoints; Michael Rackley, April 2013
InputCosts
Natural Gas75% Cheaper
WageGap
Asian WagesIncreasing
15–20%/year
Productivity U.S.
ProductivityRuns 3–3.5%
Higher
Supply ChainSimplicity
DomesticProductionReduces8 Weeks
of Inventory
ProfitCustomer Value Chain
Agility
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 4
Manufacturing Renaissance Enabled by the Factory of the Future
Sensors Everywhere | Machine-to-Machine | Pervasive Intelligence | Automation
RobotsPersonal Devices
Sensors Security Devices
Real Time Analytics
Factory of the Future — IoT Converged Plant Technologies
Cisco’s IoT Solutions — Simplify & Secure the Factory of the Future
Ruggedized Wireless AP
IndustrialRouters & Switches
Industrial Security Hardened Mobile M2M
Gateway
Access Points Designed to Mobilize your Factory
Network Solutions That Reduce Factory TCO &
Downtime
User & Control Level Factory Security
Industrial Plug-n-PlayOT/IT Connectivity
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 5
Industrial Equipment Manufacturer Reinvigorates US PlantsBefore $3B process/discreet Industrial Co
had neglected its US plants Heterogeneous PLC/Network
w/miles of blue hose & long outages
Quality issues (operator errors) from paper-based work orders
Plant security vulnerabilities were a board level concern
Solution Standardized on converged Cisco
and Rockwell network and PLCs
– VLANs ( physical segregation)
– Managed switches
– Cisco Firewalls
US PlantAverage OEE
2011 2012
50%Improvement
Results
US Plant Ave LineMean Time to Fix
2011 2012
Hours/Days to <30 Mins
After Quality Increase:
– Production and order integration via SAP and PLC integration
– Electronic Customer orders on HMI
Reduced Safety Downtime: Cut machine vs. whole line (keeping boilers warm etc…)
Reduced Electrical Downtime: Instantly locate problem vs. searching hours or days (i.e. grounds)
Now investing in US plants: Viewed as strategic investment
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Manufacturing is Cool Again
Automation Robots Flexibility Wireless
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 7
Agenda
Manufacturing Trends
Factory of the Future Vision
Factory of the Future Journey
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Physically Segmented Network Converged Plant Network
Air Gapped Plant Security Plant & Controls Level Security
Resource Constraints Resource Mobility/Productivity
Factory of Future Goes Beyond Automation
Trapped & Siloed Data Real-time, Big Data
Mfg Operational Silo Mfg linked w/SC, R&D, Sales
Plant in Isolation Virtualized Production
Factory Today Factory of the Future
• TCO savings• Downtime reduction• Production flexibility
• Risk Mitigation• IP theft• OT to IT damage• Plant downtime
• Plant OEE increase• Plant cost reduction
(energy, inventories, maintenance)
• Operator productivity• Flexible manufacturing• OEE – Fast Response
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 9
Cisco Factory of the Future VisionIoT Factory of the Future
• Industrial Plug-n-Play OT/IT Connectivity creates access to the universe of factory data
• User & Control Level Factory Security to ensure protection from IP theft and malicious attacks
• Wireless Access Points that mobilize access to data, adding productivity to the factory workforce
• Network solutions that reduce factory IT TCO while simplifying the integration of the factory to the corporate systemsConverged Platform
ResiliencyFlexible
ProductionVisual
FactoryVisibility Manageability SpeedAutomationNew
Services
Converged Plant Security
OpenPort
RemoteAccess
MalwareProximalPhysical
IoT Factory of the Future
Converged Plant Wireless
Mobile Control Room
RemoteAccess
Wireless Machines
Mobile Task Management
Guest Worker Access
Converged Plant Information
VirtualizedProduction
Real-timeSupply Chain
EnergyManagement
TraceabilityERP/MES/
PLCIntegration
Predictive Maintenance
Collaboration in Factory
Apps
Cisc
o IO
T So
lution
s
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 10
Legacy Barrier to Overcome With Cisco Next Generation IP-Based OT/IT Platform
Current Plant Network Converged Plant Network
Gbps Link for Failover Detection
Firewall(Active)
Firewall(Standby)
Layer 3 Router
Layer 3 Switch Stack
Layer 2 Switch
Drive
Controller
Controller
DriveHMI
Controller
Drive
HMI
Distributed I/ODistributed I/O
Level 0–2
HMI
Cell/Area #1(Redundant Star Topology)
Cell/Area #2(Ring Topology)
Cell/Area #3 (Bus/Star Topology)
Cell/Area Zone
Manufacturing Zone Level 3
Demilitarized Zone (DMZ)
Demilitarized Zone (DMZ)
Enterprise ZoneLevels 4 and 5
Windows 2003 Servers• Remote desktop connection• VPN
FactoryTalk Application Servers• View• Historian• AssetCentre• Transaction ManagerFactoryTalk Services Platform• Directory• SecurityData Servers
Networking The Factory of the Future
Flexibly Meeting Demand Shifts
EnterpriseEthernet
ProprietaryEthernet
To next machine
I/O FieldbusMotion Net
Safety Net
STAR
FIBERRING
DAISYCHAIN
TRUNK/DROP
Multiple segmented plant networks (up to 6!)• Excessive cabling• Data integration complexity• Data routing limitations (not real-time)• Multiple data directories• Multiple topology rules, protocols,
configs
Increased Line Uptime
Reduced Network IT TCO by 18%
Current Plant Network Challenges
“I need a flat network so I can save money and get big data from machines without having to reprogram every PLC.”
With Cisco Reliably Converge Network with managed switches that offer:- Quality of Service (QOS)- VLAN vs. physical segments- Storm control- IGMP, NAT, DHCP, POE, etc.- Configuration Smart Ports- MAC ID Port Security- IEEE 802.1x Security- Rockwell/Cisco validated design
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Resiliency
Converged Platform
Flexible Production SpeedAutomation
VisualFactory
VideoCollaboration
Many Business Benefits of a Cisco Converged Plant Network
Reliably AutomateProduction Processes
1
• High speed • Lower
latencyand jitter
• QOS
Automation
IncreaseManufacturing Flexibility
2
• Flexibly shift sequencing and inputs vs. hard coding
• Change production recipes from managers office at click of a button
• Enable new product innovation
Flexible Production
EnableNext GenVisual Factories
4
• Provide next-generation, omni-channel customer experience seamlessly across all channels
• Develop fully interactive, secure, and automated banking tech
VisualFactoryVisibility ManageabilityManageabilityVisibility
Reduce PlantDowntime withManageability
“We reduced line downtime from
hours to minutes” Plant Engineer
3
• Greater visibility and manageability (“we’re flying blind today”)
• In operator tools for quick response
• Granular control over shut-downs
• Resiliency and faster recovery (REP)
Resiliency
6Platform to Enable NewServices• Mobility• Visualization• Machine monitoring• Physical security
NewServices
Speed NewProductIntroduction
5
• Ethernet speeds new line set up (e.g., ebugging 10 stations with 12 robots takes 2 days vs. 1–2 weeks)
• Collaborate between plant and R&D to speed NPI and ECNs
Speed
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 12
Case Study: Cisco Enables New Services to Improve PlantFlexibility, Productivity, and Worker Training
Harley-Davidson’s smart factory uses Cisco’s industrial Ethernet, wireless networks, and integrated video/digital signage to produce multiple models on same assembly floor while improving worker training Stakeholders view/make decisions
based on what’s happening on factory floor
New processes enable centralized location-driven “ubiquitous display”
Digital media content creates world-class “visual factory”
Video monitors relay real-time visual information to key stakeholders
People Machine People
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 13
Managed
-3%
Auto Converged Platform TCO Analysis
• Resiliency• Management• Big Data• Low Cost
WEAKWEAKWEAKWEAK
WEAKWEAK
MEDIUMWEAK
STRONGSTRONGMEDIUM
WEAK
STRONGSTRONGSTRONGSTRONG
Plus better performance with converged network(1 IO per PLC with vLANs)
Cisco Converged Platform: Better TCO Auto Example
EQ
UIP
ME
NT
CO
STS
(in
mill
ions
)
Profibus(Serial)
25
20
15
10
5
0 Ethernet(Unconverged,Unmanaged)
Ethernet(Unconverged,
Managed)
Ethernet(Converged)
$22.6 $21.8 $22.3$18.7
Example of Auto plant with 200 robotics cells – Lower Cost
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Reduce HW cost (3 switches to 1)Shrink cabinetsReduce wiring
Reduce design costReduce points of failure and unmanaged switch ports (E-tap)
Future:Cisco Converged Platform Will Lower TCO Even More with Device Level Ring (DLR)
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Cisco Converged Platform:Higher Uptime and Reliability
Removable SD card stores config for quick, plug & play replacement by anyone
Install and configure in Logix
Product
Installation and Replacement
Diagnosis and Troubleshooting
Management
Resiliency protocols (REP <50 msec recovery) avoiding application time out downtime
Rapid debug and troubleshooting with managed switches
- CIP in switches enables network visibility and mgmt in Rockwell apps
- Predefined Logix tagsHelp
Alarms
Configuration
Status
Trending
Coming: Integration w/ Rockwell Asset Center. See and recover from undesired config changes- Manage switch configs in same tool as other
machines and& devices on line
- See changes, see histories, back-up
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Converged Plant Security
Solution Capabilities• New class of industrial focused security solutions
- Identity and Policy• Centrally managed• Enforced at switch and AP level
- Coming: In-line protection of critical machines via deep packet inspection of application traffic
Today’s Challenge• Today’s control’s environments have “soft middles” • Increasing trend of disrupting critical infra controls
- Stuxnet: Siemens Controls (via USB)- Shamoon: Schneider (Telnet) client - Others: Flame, Duqu ,etc.
• Today’s solutions not geared to protect against threats like APTs
PlantPhysical
RemoteAccess
Open Port
Malware
Proximal
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Factory of the Future Converged Plant Security:Identity and Location Based Security Approach
2012 Industry Cyber Attacks(Percent of Total Attacks)
Source: Internet Security Threat Report – 2013; Symantec Corporation, April 2013
PERCENTAGE OF TOTAL ATTACKS
Energy
Government
Sevices
Finance
Manufacturing
0% 5% 10% 15% 20% 25% 30%
• #1 attacked industry — 24% of total
• 2x increase against critical infrastructure
• 32% increase for MFG in last 6 months
Protecting the Factory of the Future
Intrusion Protection
Detection & Response
Remote Access
Firewall & VPN
Content Security
SPAM/ Web Filtering
Endpoint Security
Host IPS/AV Solutions
Converged Plant SecurityToday’s Plant Security
Network-Attached
Device
Nexus® 7000Switch
802.1X
ProtectedResources
IP Phones
Supplicant
Cisco®
Catalyst® Switch
Users,Endpoints
CampusNetwork
Guest User
ISE
• Growing business risk• Stolen IP (e.g., car design)• Downed production
(RasGas)• OT attack spread to IT
(Aramco 30,000 PCs)
• Defense in depth with:• ISE Policy• Switch enforcement• Central management of ACLs• Strong security across IT & OT
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Best SecurityPolicy-Driven Authentication & Authorization
Access Scenarios Identity Information Other Conditions Authorization(Controlling Access)
Manufacturing Device, Managed Asset
Security Camera G/WAgentless AssetMAC: F5 AB 8B 65 00 D4
Francois DidierCorporate Headquarters—Remote Access6:00 PM
Group:Manuf
Group:Facility
Group:Guest
Time and Date
Posture
Location
Device Type
Access Type
Broad Access
Limited Access
Guest/Internet
Quarantine
Deny Access
Track Activity for Compliance
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 19
Future: Industrial Security Appliance – PreviewExtend Cisco Security Model to Controls & Machine Security
Key Characteristics:
Ruggedized, DIN-Rail platform
FW, VPN, Application whitelisting, and DPI for Industrial Protocols
Ease of use — zero-touch deployment
By-pass (bump in the wire) and reliability
Security Information & Event Management (SIEM) integration (e.g., Prism and SIO)
Policy Management integration
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 20
Converged Plant Wireless
Today’s Challenges Solution Opportunities• Have to walk down line to see machine status• Manual, paper-based warehouse processes• Security concerns with wireless guest access• Plant downtime from line set up changes taking longer
due to needing to rewire
• Empower plant workers with mobile controls access• Automate warehouse processes with mobility• Drive integrated wireline and wireless security• Wireless machines for next gen manufacturing flexibility
Plant
Packaging and Shipping
Plant Worker
Guest Worker
Asset Management
Machine
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 21
Factory of the Future: Converged Wireless
Factory of the Future Converged Wireless: Mobilization & Collaboration for the Plant Workforce
Maximizing Workforce Productivity(Mfg Labor Output vs. Compensation)
• Manufacturing labor productivity continues to grow to an all time high as compensation hits a record level
• Manufacturers must continue to find ways to increase the productivity of these resources as they hit limits under legacy factory processes
*Bureau of Labor Statistics, “Economic News Release - 3/2012; Appendix Table 4. Durable MFG sector: Productivity, hourly compensation, and unit labor costs
1 2 3 4 5 6 7 8 9 1080
85
90
95
100
105
110
115
120
Converged Plant Wireless Impact
ImprovedUptime
Productivity: Save 10%-40%
Mobile VoiceCost Savings
Current Plant Challenges
Labor output per hour
Labor compensation
Managers are confined to control room; engineers need to make trips to/from office for equipment/communications
Today’s Plant
There is a free flow of people and resources across all areas of the plant
Converged Plant
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 22
Driving Productivity and Cost Savings on the Plant Floor Using Mobility
Source: Cisco® Customer Business Transformation Group
Metals and Mining Major Use Case
1
• Smelter operator needs to check process data to make adjustments
• Makes process change accurately and rapidly via mobile device
32
• Pulls up critical production data on hardened PDA
• Calls operator in another location to discuss change using soft-phone on PDA
Source: Cisco® Customer Business Transformation Group
Business Value• Eliminated three to four wasted hours walking to control room per shift per operator• >80% faster operator decision making• 50% reduction of physical control rooms
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 23
MachineControls
Video Monitoring ofPhysical Environment
NetworkManagement
• Operator able to see virtual HMI on iPad without having to walk down the line
• Can locate trouble spot with more granularity saving potentially hours in searching (e.g., “which of 50 grounds”)
Converged Platform Increases Uptime and Operator Productivity
Event Occurs:ALARM
Control Room Mobility
Jabber to Collaboratewith Expert
NOC
HQ
R&D
Contractor
SME
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Mobile HMI Example Value Model
Source: Motorola
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CISS-D / CPwE Architecture for Wireless
Cell / Area Zone Level 0 – 2
Drive
HMI
Cisco IE Cell/Area #(Ring Topology)
Controller
Discrete M. Wireline Access Configs Introduced w. CISS Rel.1.5
Cell/Area #1(Redundant Star Topology)
Drive
Controller
HMI DistributedI/O
Controller
Drive
HMI
Distributed I/O
Cell/Area # (Linear Topology)
Drive
HMI
STRATIX Cell/Area #(Ring Topology)
Layer 2Access Switch
withResilient Ethernet
Protocol
ControllerDiscrete Mfg. Wireline Access Hardened WiFi Factory
& Wireless sensors Ntwk.
Enterprise Zone Level 4 - 5
Manufacturing Zone Level 3
Manufacturing Di-Militarized Zone
Catalyst 3750-X
Catalyst4500/6500
Enterprise / Campus Core
Patch ManagementTerminal Services
Data ShareApplication Server
AV ServerASA 55xx-X
(Active)ASA 55xx-X(Standby)
Real–Time ControlFast Convergence
Traffic Segmentation and ManagementEase of Use
Site Operations and ControlMulti-Service Networks
Network and Security ManagementRouting
Application and Data shareAccess Control
Threat Protection
Enterprise/IT IntegrationCollaboration
WirelessApplication Optimization
• Wide Area Network (WAN)• Physical or Virtualized Servers• ERP, Email• Active Directory (AD), AAA – Radius• Call Manager, etc.
Plant Firewalls:• Inter-zone traffic segmentation• ACLs, IPS and IDS• VPN Services• Portal and Terminal Server proxy
Web DNS FTP
CatalystSwitch Internet
Layer 2Access Switch
withResilient Ethernet
Protocol
Cisco5500 WLC
CiscoWLC
AnchorCiscoWLC
SiSi SiSi Future ReleaseFuture
Release
Future Release
Discrete M. Wireless Access Opt. & Adv. Security
Asset ManagementHMI Server
Manufacturing ExecutionHistorian
Cisco PrimeNetwork Services
Remote Access ServerISE 34xx
Catalyst2960-X
Catalyst2960-X
Catalyst2960-X
Catalyst2960-X
IE2000
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Converged Plant Operations
Today’s Challenge Capabilities
Plant
Product Development
Finance Plant
Sales
Supply Chain
• Real time visibility into machine level performance(“what is happening in the plants now”)• Enable move to build to order versus build to stock
production models (real time flexibility, ATP)• Automated and Proactive Maintenance can impact
factory profitability by as much as 30%
• Only 19% of manufacturers state they have an effective link between plant and business KPIs*
• Only 4% of factories in the machine tool industry monitor their equipment*
• High machine unplanned downtime and maintenance cost from “blind” fixed schedule maintenance
*IDC Manufacturing Insights 2012; N=83
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Converged Plant Operations Impact
ReducedEnergy
Use
Factory of the Future Converged Plant Operations: “The Last Mile” of Enterprise Process Integration
Today’s Plant Converged Plant
Reduced Maintenance
Cycles
Order to Production10% DSOs
NPI Cycle Time
20-50%
Factory of the Future: Converged Plant Operations Trend in Plant Production Models
Source: IDC Manufacturing Insights 2012. N=81
Make to order
Make to stock
Plant
Plant
Supply Chain
Sales
Product Development
Finance
Plant
Plant
Supply Chain
Sales
Product Development
Finance
Engineering to order
Assembly to order/Build to order
100%90%80%70%60%50%40%30%20%10%
0%
21%
39%
29%
11%
9%
34%
35%
22%
Today 5 Years
Jour
ney
tow
ard
Mak
e-to
-Indi
vidu
al
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New Visibility/Connectivity Real Time Analytics Multi-Level App & Data Access
Alarm alerts operator of peak load utility penalties threshold
Checks MES real time prod vs. plan & energy threshold
Reduces variable speed drive to avoid peak
Operator checks co-gen capacity Raises output to avoid peak load
Real-time gap visibility – adjusts supply chain, MRP, and factory build
plan to shift prod to plant with capacity w/o
impacting ATP or inventory
Leverage Cisco collaboration tools to
quickly decide and act cross silo
Business Value Plant Productivity: Reduce energy costs (typical first year -— 20% with new Software/Devices/Ethernet NW)
Use Case — Energy Management Use Case Example
Challenge Real time operator decision making tools across multiple variables, applications, and sites in a complex supply chain (many factors to simultaneously consider)
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 29
Hi Tech MFG – Converged “Opportunity to Plant Floor Production” ProcessChallenge• Manual sales processes delayed order to prod
response and was prone to manual errors
• Orders are passed to inside sales person creating transcription issues, dirty orders, and 4-day delay in order processing time
• Lack of visibility to order details at customer site
• No access to configurator, order promise, status of existing orders all limit ability to close business
Solution• Fully integrated process from Opportunity to
ATP to Order to Plant Floor Production
• SFDC integrated with Oracle EBS, configurator and plant floor visibility via plant floor Andon screen
• Eliminates order entry errors, reduces order processing time, electronic order is immediately confirmed with ATP engine and visible at plant floor
Sales:Remotely track orders
from opportunity to configuration to ATP to
order status
Inside Sales:Eliminates manual order
entry - focus on new business creation
Factory:Real-time order
visibility; reduce dirty orders; electronic
orders
Management:Real-time reportingof sales, order and
production performance
Opportunity to Production ProcessResults
• $3M in annual sales increase
• DSO reduction of 2%
• 75% reduction in Order Entry Cycle Time
• Reduced dirty orders reduced
• Improved NetPromoter Scores
• 6 FTE inside sales productivity gain
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 30
Unlocking Factory Data ThroughOT/IT Unified Architecture
DeviceNetwork PLC MES/
ScadaHistorian DMZ ERP
Data Velocity:
Data Quality:
Data Security:
Real Time (<1 second roundtrip) Push every 2 to 9 HoursNightl
y?
Today up/down data flow not real
time:
??
Auto-configuring of
tags and profiles
Open, unmanaged ports. USB ports ???
No network visibility or resiliency (reducing
data quality)
PLC backplane limits real time pass through
(“every 9 hours”)
Vulnerabilities to man in
middle, USB, PC, HMI
client attacks
Segmented physical networks
required hard coded
mappings
Segmented physical networks
required hard coded
mappings
Vulnerabilities to man in
middle, USB, PC, HMI
client attacks
Segmented physical
networks limit data
availability and quality
Batch updates to
send upstream
every 20 to 30 minutes??
??
Segmented physical
networks limit data
availability and quality
No security or block all but limited data
feeds
No security or block all but limited data
feeds
No security or block all but limited data
feeds
Not real time
Poor data quality from plant & lack
of device taxonomy
Device Network PLC MES/
ScadaHistorian DMZ ERP
Data Velocity:
Data Quality:
Data Security:
Real Time (<1 second roundtrip) X seconds?
X seconds?
X seconds?
Today up/down data flow
not real time:
??
Auto-configuring of tags
and profiles
Still need integrated
controls security
Full visibility
and resiliency protocols
VLAN 1 stop
routing by passes
any bottleneck
s??
Still need integrated controls security
Converged Plant NWs
Less hard coded
integrations than with
segmented NWs
Less integration than with segmented physical networks
Batch updates to
send upstream every 20
to 30 minutes??
??
Less integration
s than with
segmented physical
NWs
Policy, identity, easier central
management
Policy, identity, easier central
management
Policy, identity, easier central
management
Memory resident real time processin
g
Large SI integration and data clean up work still needed
• Batch applications can delay MFG visibility for hours• Segmented physical networks require mappings and
hard-coded integrations• Significant security risk (e.g., man in the middle,
DMZ vulnerabilities)• Limited visibility to data flow/availability
• Converged network simplifies data path• Integrated management provides real time
data flow visibility• Single, unified architecture creates near real-time
visibility to MFG performance• Joint architecture addresses security risks and
removes barriers
Traditional Factory Connected Factory
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 31
SAP Windpower Converged Application Example
Integrates different sources of real time data all the way to sensors in the end machine
Used by both machine manufacturer and operator
See source of problems real time to:– Lower costs (e.g., dispatch technicians
with spare parts needed)– Get more efficiency (e.g., reduce “hard”
downtime)
SAP is a leader in big data and real time analytics with HANA Cisco is working with SAP to enable better quality and quantity of data to allow faster reaction and better decisions
SAP Windpower Video
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 32
Agenda
Manufacturing Trends
Factory of the Future Vision
Factory of the Future Journey
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The Factory of the Future Journey:How to Get There
Unmanaged, Unconverged Ethernet
Converged Plantwide Network
Multi-Service Platform
Step 1
Step 2
Step 3
Starting Point: - Fieldbus
- Proprietary- Serial
• Real time distributed control
• Resiliency
• Richer sensor data
• Converge separate physical networks with managed switches
• OT Ethernet Upgrade — line equipment moves to Ethernet to reduce TCO and add flexibility
• Converge OT/IT Networks to further reduce plant TCO, unlock big data
• Factory of the Future — virtualized production, real-time IT/OT monitor/management
The Journey
• Manufacturing Strategy• Business Case• Proof of Concepts / Showcases• Plant Architecture Design• Implementation
Cisco’s Capabilities
• Controls security
• Control Room Mobility
• Video & Collaboration
• Remote Monitoring & Control
• CLOUD, FOG• Software Defined
Plant Networking
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 34
Factory of the Future: Cisco Validated Converged Plant Design Accelerates Time to Value
Lifecycle Services
Industry-LeadingPartners
Business Risks Reduced
Faster Deployment, Better ROIQ. Top barriers to implement your factory of
the future strategy
Source: IDC Manufacturing Insights 2012. N=81
PERCENTAGE OF COMPANIES
Processes not consistent across
multiple sites
Low maturity/lack of production technology
Change management
Finding skilled people
No factory of future strategy
Difficultyin demonstrating
ROI / Cost
74%
73%
73%
71%
61%
58%
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 35
Rockwell Automation and Cisco Partnership Best of Both Worlds to Change the Industry
Best of Cisco Cisco IOS™ Catalyst™ switch architecture and feature set CLI and Device Manager Secure integration with enterprise network
Best of Rockwell Automation Common Industrial Protocol (CIP) interface to Rockwell Automation Integrated
Architecture™ RSLogix 5000™ for configuration via Add-on Profile (AOP) Predefined logic tags for diagnostics FactoryTalk™ view faceplates
Best for the Plant Floor Compact flash for “zero-config” replacement Industrial environmental ratings Default configurations for Industrial Automation Easy to maintain
A Unique Product in the Market…
…Integrating the Enterprise and Manufacturing Environments
© 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 36
Cisco Can Help You Capture Value Opportunities
Discovery Workshop with OT and IT
• Business challenges• Best practice
sharing• Use case
brainstorming and prioritization
• Run POCs in a Showcase manufacturing facility to prove the value and technology
• Document future state architecture (e.g., 3 to 5 years out), gaps with today, change management, and phased plan to get there
• Quantification of top value opportunities for senior management (TCO, OEE, and overall benefit models)
POC Design
TCO or OEE Opportunity Quantification
End State Architecture Assessment
top related