Industrial Automation and Modern Connectivity

Industrial Automation and Modern Connectivity

DMC Overview

Established in 1996, offices in Chicago, Boston, & Denver and customers

throughout the worldemployees &

growing

70+

Areas of Expertise

Matt PuskalaProject Director, Sr. Management

Technical: Factory Automation, PC, Web, and Database Applications

B.S. in Electrical EngineeringKettering University (GMI)

Joined DMC in 1999Student co-op

Presenter Info

Agenda1. Modern Connectivity

Overview2. Three Modern Connectivity

Storiesa. Automotive Storyb. Candy Storyc. Integrator Story

3. Security – Quick Tips

Define “Modern Connectivity” in the context of Industrial Automation.

Modern Connectivity: Definition

Traditional Automation LineModern Connectivity: Definition

PLCInterface

Factory Equipment

Any time you are connecting the factory line to other networks to allow data transfer (input or output).


• Intranet/Subnet• Internet

Any time you are connecting the factory line to other networks to allow data transfer (input or output).


• Servers and Databases• Enterprise Systems (MES, ERP)• Internet/Remote Access

Connections To:

Pros

?Modern Connectivity – Why?

ConsCost

ComplexitySecurity

1: Optimize ProductionModern Connectivity – Why?

Identification of productivity loss.

When?Tomorrow?Immediately?

1: Optimize ProductionModern Connectivity – Why?

Improve your process.

Data mining.

2: TraceabilityModern Connectivity – Why?

FDA Regulations

Recalls

3: ConvenienceModern Connectivity – Why?

Remote Support

Plant floor visibility at your desk

4: Standardize and Control the System InputsModern Connectivity – Why?

Recipe Management

RECIPE

Benefits:

• Consistency and Quality

• Reduce Product Change Over Time

Definition? Why? Goal?

Modern ConnectivityFactory System

Internet

Intranet

Introduce new ideas or new ways of looking at old ideas to help you get the most out of Modern Connectivity with your Industrial Systems.

Modern Connectivity - GoalFactory System

Internet

Intranet

Automotive Story

Continuous Improvement

Solving Mysteries!!1. Identify a big problem.2. Find the Cause.3. Find a Solution.

Continuous Improvement

Conveyor ->

Press 1

Station 1: Stamp

Part

Station 2: InsertSubPart

Station 5:Transfer to

Presses

Station 3: InspectInsert

Station 4:Stamp

Part

Press 2

Press 3

Press 4

Press 5

Example Continuous Improvement - Solving Mysteries

Continuous Improvement - Solving Mysteries

Conveyor ->

Press 1

Station 1: Stamp

Part



Presses


Station 4:Stamp

Part

Press 2

Press 3

Press 4

Press 5

Mystery: Transfer Faults

Transfer Faults

(dropped parts)

Mystery: Transfer Faults (Dropped Parts)Continuous Improvement - Solving Mysteries

SHIFT REPORT

Operator: Part:

Jim A27Fault: Count:

Transfer Fault 273E-Stop Fault 2Low Air Pressure Fault 0Press Jam Fault 5

Part A27: Smallest Diameter

Mystery: Transfer Faults (Dropped Parts)Simple Solution: Improve the part transfer!


SHIFT REPORT

Operator: Part:




Conveyor ->

Press 1

Station 1: Stamp

Part



Presses


Station 4:Stamp

Part

Press 2

Press 3

Press 4

Press 5

Mystery: Jammed Station 4

Jammed Stamping Press

DAILY FAULT COUNTS

Fault: Count:

Transfer Fault 9Press Jam Fault 132Low Air Pressure Fault 7E-Stop Fault 5


Conveyor ->

Press 1

Station 1: Stamp

Part



Presses


Station 4:Stamp

Part

Press 2

Press 3

Press 4

Press 5

Mystery: Jammed Station 4

DAILY FAULT COUNTS

Fault: Count:

Transfer Fault 9Press Jam Fault 0Low Air Pressure Fault 7E-Stop Fault 5

Add better part queuing.

Simple Mysteries:• Problem -> Cause• Paper data collection by operators

Complicated Mysteries?


Challenging Mystery: Inconsistent Production



Cause?:• Particular Part• Particular Fault• No obvious pattern


Challenging Mystery: Inconsistent ProductionReal Problem?: Inconsistent Data Tracking


SHIFT REPORT

Operator: Part:



Improve Inconsistent Data Collection? Continuous Improvement – Solving Mysteries

Through Automation!:

• Automated Data Collection

• Automated Reporting

Daily Emails of Reports to Engineers and Shift Supervisors


SHIFT REPORT

Operator: Part:




What was the cause?Unmasking the culprit



Conveyor ->

Press 1

Station 1: Stamp

Part



Presses


Station 4:Stamp

Part

Press 2

Press 3

Press 4

Press 5

Mystery: Inconsistent Production

Part Change OverDisabling presses.Reduction in throughput.



Continuous Improvement - Solving MysteriesAutomated Data Collection and Reporting

• Consistent Quality Data• Visibility

Technical Details?

Technical Details – FactoryTalk Metrics

• Data Collection• Reporting• Preconfigured Reports and Wizards• Open System

Technical Details – FactoryTalk MetricsPLC 1

PLC 2

PLC 3

Reports

PLC 1

PLC 2

PLC 3

Reports

Technical Details

TagsSystem StatePart Created

Part NumberFault NumberOperator

PLC 1

Good PartRejected PartRejection Cause

TagsSystem StatePart Created

PLC 1

RunningFaultedSetup (Change over)Test ModeStarved (Up Stream Problem)Blocked (Down Stream Problem)

PLC 1

PLC 2

PLC 3

Technical Details

Technical Details

Report Expert

Built in basic reports. Viewable by Web Browser Viewable by Web Browser

Full Power of MS SQL Server Advanced/Complex ReportsSMTP Server

• Why? - Optimize Production

• How? – FactoryTalk Metrics and Advanced Customizations

• Automated Emailed Reports• Visibility!

Automotive Story Recap!

Candy Story

Recipes produce variety on a single machine

Recipes

Innovate

New Crossover Recipe: Global Implementation

Global Platform Variety

1998:USA Plant 1

2007:China Plant

2012:USA Plant 3

2010:India Plant

2002:USA Plant 2

2000 2005 2010

New Crossover Recipe: Global Implementation

5 Months$100,000+

Cost of Implementation?

Ready for the next new product?

Better way?!!

• Single Website• Uniform Recipe Management System• Keep Existing Control Hardware and

Software

A Better Way!

1. Log In To the Website2. Select Plant3. Select Production Line4. Select Existing Recipe and

EditOR

Create New Recipe

New System Update Recipe?

Technical Details?

Technical Details - Overview

IntranetWebsite

USA Plant 1

USA Plant 3

India Plant

Custom Service

Technical Details

IntranetWebsite

USA Plant 1

USA Plant 3

India Plant

Custom Service

DNN: a Content Management System (CMS)

Built on the Microsoft Stack:• ASP.NET• SQL Server Database

Technical Details: Intranet Website

Proven Pre-existing Functionality:• Security• User Management• Hundreds of Third Party

Tools

Why Content Management System?

• Easy to Add Pages and Features

• Up and Running Fast

Why Content Management System?

Technical Details

IntranetWebsite

USA Plant 1

USA Plant 3

India Plant

Custom Service

Intranet Website

DNN Tables

Custom Recipe Tables

Custom Functionality

Technical Details

IntranetWebsite

USA Plant 1

USA Plant 3

India Plant

Custom Service

15.315.23.1.2.3

Legacy System

Technical DetailsPLC

Select Recipe:1

Interface

Tags

Recipe NumberSugar (kg)Gelatine (kg)Water (L)Flavor 1 (kg)Flavor 2 (kg)

New System

Technical DetailsPLC Select Recipe:

1

Interface

Tags

Recipe NumberSugar (kg)Gelatine (kg)Water (L)Flavor 1 (kg)Flavor 2 (kg)

1

Custom Service

5.315.23.1.2.3

Technical Details

5.315.23.1.2.3

Custom Service

1

PLCDNN Tables

Custom Recipe Tables

OPC Server

USA Plant 1

USA Plant 3

India Plant

Technical DetailsOPC Server:• Standard: Support for 100s of

Industrial Platforms• 1996• OPC: “OLE for Process Control”• OPC: “Open Platform for

Communications”

Candy Story Recap!• Why?

• Standardize and Control the System Inputs

• Convenience• How? – Cost-Effective Custom

System• Flexible – Feed Multiple Platforms

Integrator Story

43

Onsite Commissioning - Chemical

I/O IssuesOnsite Commissioning - Chemical

InterfacePump 1

System

REV FWD

Pump 5

REV

I/O Issues:• Hundreds of

I/O Points• Trial and

Error Debugging


Slow 2 Person Job


Controls

Pumps100’

Onsite Commissioning - Chemical Days?

WEEKS?

Onsite Commissioning - ChemicalSimple Idea!


Controls

Pumps

Controls

Technical DetailsInterface

System: Pumps Valves Feedback

PLCs

D͞Mobile Interface E͞



• Why? – Convenience• Remote Desktop Protocol – Simple and Cost

Effective!

Integrator Story Recap

Security Considerations

Security is Complicated

1. Three Quick Recommendations2. Some Resources

Security Considerations

• Any time any change is made!• Archive or software repository is best.

Recommendation #1: Back Up Control Software

• Use VPN for External Access• Be wary of WiFi• Remove internet access all together?

Recommendation #2:Isolate from Outside

• Consider using internal Subnets and Firewalls

Recommendation #3: Isolate from Inside

Resources

1. Recommended Practiceshttps://ics-cert.us-cert.gov/Recommended-Practices

https://ics-cert.us-cert.gov/Recommended-Practices



Resources

Recommended Best Practices“Improving Industrial Control Systems Cybersecurity with Defense-in-Depth Strategies”https://ics-cert.us-cert.gov/sites/default/files/recommended_practices/Defense_in_Depth_Oct09.pdf

https://ics-cert.us-cert.gov/sites/default/files/recommended_practices/Defense_in_Depth_Oct09.pdf





Resources

2. List of Vulnerabilitieshttps://ics-cert.us-cert.gov/ics-archive/

https://ics-cert.us-cert.gov/ics-archive/



Recap!

Modern Connectivity and Industrial Automation:• Defined

• Why?• Optimize Production• Traceability• Convenience• Standardize and Control

the System Inputs

Factory System

Internet

Intranet

Recap!

Stories:

Factory System

Internet

Intranet

Recap!

Security

Factory System

Internet

Intranet

Thank You!