SV05 - New Strategies to Monitor, Optimize and Support your Machines - Leveraging the Cloud

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

PUBLIC INFORMATION

SV05 - New Strategies to Monitor, Optimize and

Support Your Machines Leveraging the Cloud


Opportunities for a Connected Enterprise The Transformation of Manufacturing

“… The Internet of Things is the third great wave of innovation after Ethernet and the Internet.”

Dr. Elgar Fleisch, Director of the Institute of Technology Management at the University of St. Gallen

Cloud Computing is a disruptive force in Manufacturing

Offers new capabilities, creativity and innovation for this industry

Step change in simplicity and cost of ownership for Manufacturing IT assets


The Transformative Value of IoT in Operations SaaS* Reduces Total Cost of Ownership and Simplifies Manufacturing IT

OpEx vs. CapEx Predictable Costs Flexibility

Service

Finance

Operations

Minimize Manufacturing IT Allow staff to Focus on Product /

Process Design Scalability

Engineering

Asset and Operations Performance Consumables Management and Ordering Multi-tenant Visibility for Your Supply Chain

Remote Service & Support < SMEs Supporting > Assets Predictive Maintenance

Extracting New Insights

Scale Up/Down Elasticity

‘0’ Infrastructure To Support

Trustworthy Exchange of Info

Business Model Flexibility

*Software as a Service


Cloud Computing Cloud Deployments Make Sense When…

There is a desire for long-term storage of manufacturing data

Local deployments are difficult

Assets are distributed across broad geographies

Access to data to be shared across corporations

Desire to add higher-level analytics or predictive algorithms

Common requirements are shared by many

Information Technology support costs are too high

There is a lack of local technical resources

“Shadow IT” projects need to be professionally managed

Enterprise data can be “mashed-up” with public or

syndicated data


Managing & Improving Your Manufacturing Assets Moving from Traditional Software Deployment to Software as a Service

5

Site 1 Site 2 Site n

Cloud Gateway

LAN Wireless

Cell Satellite

Automation Systems

Asset Performance Management

Performance Management Equipment and Process

Behavior and Optimization

Predictive Analytics Equipment and Process

Characterization Model Development

Predictive Maintenance


B

A

Supplier A

Machine Builder A

Support Org

Customer 1

Rockwell Automation Support

Utilities

Corporate Headquarters

Machine Builder B Machine Builder C

Supplier B

Prod/Proc Designers

Cloud

Gateway

Customer 2 Customer 3

Data Sources

Quality Org

Simple, Secure Data & Equipment Access for ALL Sanctioned Stakeholders

C

Weather Forecast


M2C* Gateway: Secure Data Transfer Scalable Software Service Tested on Multiple Hardware Platforms

Variety of Hardware Form Factors

Support Multiple Networks & Protocols LAN, Wireless, Cell, Satellite

GPS Support

Intelligent Data Management Gateways securely managed via Cloud Platform

Store & Forward, Aggregation, etc.

Data thinning/compression

* Machine-to-Cloud


Typical Machine-Level Cloud Gateway Hardware Platform

Small, DIN rail mount, industrial hardware platform

Linux, headless

Ethernet: Dual homed, Optional wireless

Cellular: 3G: Five Band UMTS/HSPA+, GPRS: Quad-Band,

GPRS Class 12

Serial

GPS support

Analog inputs, digital inputs, relay output

- 40 to +65 ○C, 12 to 48 VDC

8


Asset Performance Management Simple, Secure Remote Monitoring Solutions

9

Firewall

Cloud agent / gateway

agent enabled

hardware that is

deployed at the site

Connection to Cloud

via Internet or

cellular; secure,

compressed, and

encrypted

Internet connection

outbound only

communication

through Port 443

Cloud end point

accepts data only

from authenticated

gateways

On premise

Cloud

Agent

Email or text

notifications

• Data storage

• Live data dashboards

• Reports

• Alarming and

notification

• Trending

• Analytics

• Workflows


Rockwell Automation Cloud Platform Data Ingestion and Security Detail

10

Data Ingestion Historical (time series records)

Alarms (abnormal situations, different priorities)

Live (current temperature, pressure, current, voltage, etc.)

PowerFlex® 7000 drives (parameters specific to this hardware)

Cloud Agent

Collects data records, serializes and compresses them for

transmission to Azure storage

Manifest-based cloud agent configuration

Generated from system data model

Secure HTTPS / SSL secure outbound only

Encrypted storage account keys

Troll Bridge authentication

Excellent Reliability Store & forward mechanism

Flexible Variety of hardware form factors

Suite of connectors

Device / Process Data

Analytics

Troll Bridge Service

Data streams Encrypted keys token

enabled

Transient token


Cloud Application Platform Data Model, Objects, Types, Tags, Events, Workflows, Roles, Users…

11

Rich model for the data and application

Security associated with unified model

Common set of (web) services

Application services operating against the model

Time Series Services and history storage

Calculation

Scripting

Business Logic – Event Management and Notification

Common user interface (property grids, namespace explorer, …)

Common clients (Admin, Trend, XY Plotter, Excel Integration)

Cross-platform thin user interface

Workflow execution


Quickly Add Devices to Customer Hierarchy Email Notifications – By Device, Site and/or Global

12

Quickly add more assets by copy/paste/rename; automatically adds all dashboards/reports for this new asset!

Configure email notifications by customer – you can get either or both when a problem occurs and clears


Cloud Application Security

13

Object level security

Role-based Access Control List (ACL)

ACL can be inherited from the parent

Authentication via federated security

Google IDs

Yahoo IDs

Azure Active Directory

Server-side users (managed by us or you)

Other providers can be added


Data Visualization, Reporting and Analytics Live Data Dashboards

14

Dashboard(s) can be developed to customer

specifications, by Rockwell Automation or

customer

Standard tool is derived from FactoryTalk ®

VantagePoint ® Mobile

FactoryTalk® View ME HMI screens can also be

replicated and ported to the cloud environment

Can also leverage SQL Server Reporting Services

and Microsoft Power BI

Available on any web browser or mobile device

with an internet connection

and the right credentials


Data Visualization, Reporting and Analytics Alarms, Notification, Trending

15

Alarms from monitored system pushed to the

cloud as high priority data

Alarms may also be generated in the cloud

platform from “rules” applied to the data

stream

Notification via email or text can be

configured to match the customer’s

preference

Trending of any stored data points over any

time period

Pre-defined reports created to match

customer specifications


Predictive Maintenance for Manufacturing Currently in Prototype / Proof of Concept Status

16

Manufacturing

Intelligence

80%

Predictive

Analytics

250%

Machine Plant Floor

Predictive Analytics Equipment and Process

Characterization Process Optimization

Predictive Maintenance

Predictive maintenance: Monitoring the condition of a machine to predict when maintenance

should be performed to avoid unplanned downtime

Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.


PowerFlex® 7000 Remote Monitoring Service What Happens When an Alarm or Fault Is Triggered?

The alarm or fault appears immediately in the cloud application and our

support center in Cleveland, OH

Notification delivered to customer via agreed to method

Automatically creates a service ticket in Rockwell Automation Tech Support

system (SAP) and sends a notification to an MV Drive service engineer

Rockwell Automation Remote Support will respond to this alarm within a

30-minute guaranteed Service Level Agreement, 24 x 7 x 365

This means, within 30 minutes, we have:

Acknowledged the alarm

Contacted the customer through a predefined method

Begun to troubleshoot the drive

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 19

PowerFlex 7000 Remote Monitoring Service Visualization Examples


New Business Model – Supplying Consumables Innovation in a conservative industry

20

M.G. Bryan,

Fracking Truck

Manufacturer


Rockwell Automation Solution –

Asset Performance Management (APM)

21

Fleet performance screen: search by truck type,

name, location

Detail screens: match the HMIs on the control

system on the truck

Order screen: Auto-populates required parts and

generates order email for the customer

Support most mobile devices

At YE16, more than 50% of

Global 1000 companies will

have stored customer-

sensitive data in the public

cloud” Gartner 2011


Anticipated and Achieved:

High-value, differentiated solution for M.G. Bryan and its

customers

Real-time visibility of truck, fracking KPIs and location

Supply usage-based consumables to trucks

Create accountability for truck maintenance

Ensure maintenance is performed

Avoid over/under Preventive Maintenance

Zero Infrastructure to maintain – scales from one truck to

4000 trucks

Same solution for new trucks and for truck retrofits

APM Benefits and Value to M.G. Bryan

22

Not Anticipated, but Achieved:

Significant warranty savings

New terms/warranties with key suppliers

Remote troubleshooting

Empowering a larger set of ‘knowledge workers’ with real

time and historical data

Equipment: performance, quality, maintenance

Process: efficiencies

Enabling potential new business models

Enabling the potential for Rockwell Automation to help

improve systems and processes

“When you combine our new information system with the flexibility and scalability of cloud computing, we’ve really

opened the door for a wide range of operations management solutions for our own vehicles and those we sell.”

Josh Rabaduex, Director of Engineering, M.G. Bryan


Enterprise Performance Management Global Manufacturing Re-invention

23

Global

Food & Beverage

Manufacturer


The Cash Machine of the Oil & Gas Industry Removing the Potential for Error

24

Trigg Technologies

L.A.C.T. Unit

Manufacturer


The Cash Machine of the Oil & Gas Industry Asset Performance and Transactions

25


Remote Asset Performance Management Liquid Natural Gas Terminals

26

Supermajor O&G

Building & Managing

LNG Retail Stations


Product Serialization Minimize Counterfeiting and Diversions of Specific Foods & Medicines

27

Brand Protection Global Dairy

Company


vMonitor®

The Connected Oilfield

28

OptiLift - NF Natural Flow

OptiLift - ESP Electric Submersible Pump

OptiLift - PCP Progressive Cavity Pump

OptiLift - RPC Rod/Sucker Pump

OptiLift - GL Gas Lift

OptiLift - PL Plunger Lift

OptiLift - WM Well Monitoring

Digital Oil Field


Remote Asset Performance Management Software as a Service Order Components

Application Configuration Model Development

Dashboard Development Business Rule Configuration

Workflows

Non-Recurring-Eng Costs Per Site/Asset*

Cloud Gateway Hardware Cloud Gateway Software

APM Platform commissioning Optional

Wireless Hardware GPS Hardware

SaaS Subscription Fee**

All ‘Compute’ infrastructure All ‘Data Storage’ infrastructure

Provisioning additional infrastructure APM Platform (per Asset)

Support SLA

Optional Cellular data contract

Rockwell Automation application support

** Invoiced quarterly, annually (minimum 3-year contract) * Can be built into the subscription service


Other Cloud Related Sessions

www.rockwellautomationteched.com

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Thank you!

SV05 - New Strategies to Monitor, Optimize and Support your Machines - Leveraging the Cloud

Technology

rockwell automation

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rokteched opportunities

manufacturing assets

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syndicated data

assets predictive maintenance

secure data equipment