raotm 2018- tm05 design productivity tools...design productivity •oem collaboration w/gotcs &...

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Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 1

RAOTM 2018- TM05 Design Productivity ToolsEnabling Technologies to reduce total cost to Design Develop and Deliver

Lokesh Kaushal

GOTC-Lead

PUBLIC Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved. 2

Automation Trends in Manufacturing

End users looking for added value beyond Machinery or Equipment, thus drives

OEMs to stay one step ahead…

1. Global Competitiveness :

Move from mass production to mass customization – FLEXIBILITY

2. Changing Risk :

Achieve compliance with increase regulations, by protecting IP - SECURITY

3. New technology :

Merge the Physical and Digital worlds to capitalize on value at stake provided by IoT - PROFITABILITY

PA

ST

The user expectations may not be easy, but they were tangible-move through “n” parts per hour, Energy optimization, Scheduled Maintenance etc… P

RE

SE

NT Today, user expectation is becoming

more complicated as Internet of Things (IoT) reached to plant floor

Priority change to reach Smart manufacturing goals


END USER

Productivity & Efficiency

Goals

CONNECTED ENTERPRISE SMART MANUFACTURING

3

Flexibility

Integration &

Standardization

Performance/OEE

After Market Service

& Support

Total Cost to Design,

Develop & Deliver

SMART MACHINES OEM EQUIPMENT

Faster Time to Market

Lower Total Cost of Ownership

Improved AssetUtilization

Enterprise Risk Management

CONNECTED ENTERPRISE BUSINESS VALUEWhy Should OEM’s Care about the Connected Enterprise?

OEM

Innovation to Drive

Differentiation


End User Trends

Ongoing sustainability / Equipment efficiency Reducing Water, Air, Gas, Electricity, & Steam consumption

Increased efficiency, improved yield

Producing wider offerings to their customers Scalable outputs / Flexible processes

Shifting to modular, skid-based plants Requiring delivery of FAT tested equipment

Reduce acquisition & integration costs

Consistency from Plant to Plant

More data off the Machines/Skids

Shrinking Engineering & Support Staff Need for knowledgeable maintenance staff & Systems Integrators

Need for remote access by third parties

4


….leading to OEM Trends

Modular Equipment Skid based with self contained control system

Standards based modular programming

FAT/SAT conducted prior to site installation

Design Flexibility & Productivity Consistency across platforms

‘Right-sized’ designs to save costs

Reusable Libraries / Objects

Remote Access & Support Access to operational data

Diagnosis and troubleshooting

Plug & Play equipment, including remedial servicing

Equipment Automation Optimized efficiency, performance, & yield

Intelligent equipment vs. manual “fine tuning”

5


Response: Machine and Equipment Builder Performance

OEMs shared the following…

Machine Builders today are challenged to differentiate themselves amidst global

competition and rapidly evolving technology

To achieve greater profitability OEMs must continuously improve their overall

operational performance

Commissioning

Global Service & Support

Reliability & Quality

Machine Performance

Design Design Productivity

Extensible Engineering

Scalability

Global Standards

Risk Assessment

Design for Sustainability

Develop Deliver Time to Market

Supply Chain Efficiency

Flexible Equipment Models

Simplified Integration

Design Optimization

6


Focusing on the need from a Customer perspective

Improve market value for the adopting customer/user

Optimize total business costs of the adopting customer/user

OEM business value = Market value - Business cost

“TCD = Total Cost to Design, Develop and Deliver”

Provide Business and Technical Value

“…. If a supplier cannot show the value they add, then why would anyone choose to do business with them, except on the

basis of price? ” Professor Theodore Leavitt, Harvard Business School

Defining “TCD”Total Cost to Design, Develop & Deliver

7


TCD3

OEM Examples: Improving total cost to Design, Develop, & Deliver


Total Cost to Design, Develop, Deliver

Increase OEM operational performance by helping to achieve greater profitability by improving

performance in three core areas:Design Develop Deliver

Design Productivity

• OEM collaboration w/GOTCs & GPTCs

• Leverage the multi-discipline process system

on a common control platform

• Simplify integration of Control components

• Product selection and Configuration tools.

Scalability

• Scalable product platforms suited for

process applications : control, HMI,

Drives, I/O, Safety & IC, etc.

• Scalable industry standard batch (S88)

Global Standards & Risk Assessment

• Support of common programming languages

• Products designed for global compliance

Design for Sustainability

• Optimize and reuse standard blocks

Minimize Time to Market

• Reduced wiring resulting in lower system costs and

assembly time

• Reduced programming effort with LBSM, Process

Library & Simple Sequencer, and Accelerator

Kits

Supply Chain Efficiency

• Preferred parts availability

• Off-the -shelf components

Flexible Equipment Models

• Standard modular library to increase design

efficiency

• Ability to use different languages through HMI

language switching

Simplified Device Integration

• Quick and Seamless integration of system

components using Add-On-Profiles and

Faceplates

Commissioning

• Simplified skid integration into plant-wide automation systems

• Link real time reporting from equipment to the IT infrastructure with standard EtherNet/IP

Machine Performance

• Information-enabled solutions for fasterMES integration

• OEE availability and enhanced security

Global Services & Support

• Services – Phone, On-site & Training• Global Parts Availability & Repair • Consulting – Safety, Networks, Sustainability

Remote Access• Simple and Secure Connectivity • Real-time Alarming• Data Collection & Reporting• Scalable, Cost Effective Solution


DESIGN: Make Life Easier…

Sizing and selection tools simplify your life and help save you money


to Select, Develop, Commission and

Maintain Portions of Your Project

Popular

Configuration

Drawings: Guidance

for product selection

- based product

capacity


Controller Selection

Guidance for controller selection based on function and cost while

verifying network performance


Servo Drive and Motor Selection

Guidance for drive and motor selection based on application requirements (motion profile

and mechanics). If you undersize, it is not possible to achieve required speeds. If you

oversize, you paid too much!


Aux. Component Selection a and Combined Proposal

Guidance for component selection along with provision of the complete

proposal


DESIGN:Scalable Control Platforms

Process Skids• Small, self-contained systems that are

tested prior to shipment and easily

integrated into overall production facility

PlantPAx Process Automation System• Scalable architecture from small single unit to large multi area applications

• Easily integrate systems across the plant, mill or manufacturing facility with

one architecture

User defined Systems Small to large Distributed PlantPAx Systems

Single Server /

Single Client

Single Server / Multi

Client

(Process Area)

Multi Server / Multi Client

For Large applications

(Multi Area/ Plant)Local HMI, SCADA

(OEM Machine, Balance

of Plant, etc) Small process

applications

(Process Unit)

Medium sized process

applications (Process

Unit)

OR


DESIGN: Automation Design Environment

Scalability

Multi-Disciplined

Common Infrastructure

Intuitive Workflow

Single software platform:


Suite of Control & HMI objects to

accelerate project engineering

Built-in troubleshooting features

Fully documented & supported by RA

Tech Support

PlantPAx Standard Library“Out of the box”

DEVELOP:Reusable Process Library


DEVELOP:Add On Profiles

Add devices directly from RSLogix 5000 design environment

Use text based Electronic Data Sheets

Provides configuration, input, and

output tags, and configuration screens

1

Fully configured profiles for devices you plan to integrate into a Logix based processor.

These configurations are graphical in nature and create the structure (tags) used to

communicate to the device.

Easily integrate EtherNet/IP devices into Logix


DEVELOP:Application Code Manager

1

• Combine control, visualization, historical, and alarm management

into one library object

• Centralized repository for easy access and version management

PUBLISH LIBRARY OBJECTS

• Easily generate your standardized application code in bulk to

configure projects

• Users doesn’t need to understand the library object dependency

structure; the tool manages the dependencies per the librarian’s

rules

• Out-of-the-box integration enables simple and fast bulk

deployment of the Library of Process Objects, and Machine

Builder Library

BUILD APPLICATIONS

• Library Designer is integrated into Studio 5000 Logix Designer®

• Flexible library authoring – structuring reusable content the way

you want it

• Allows the librarian to manage dependencies between library

objects, easily share and manage common objects

DESIGN LIBRARY OBJECTS

• Configure the library object instance

• No programming needed

• Export to Excel for bulk configuration

Leverage

Rockwell

Automation

libraries for

easy project

creation,

or create your

own

Easily add, edit, project

content by library object


Improve time to market to meet customer delivery commitments

20

DEVELOP:Modular Programming

Modular Programming for Machine builders

Complies to Standards ISA88 -Originally was Batch control and becoming de-facto standards

for all Machine and Equipment Control,

Foundation of Modular programming / FOMP Bring discipline amongst the team and allows best programming

practices

Overall provides common technology framework

Allows code re-usability to reduce development time for new machine /

feature

Optimized e-CAM design tools for smooth machine operation

Certified validated Safety functions with ready to deploy and re-usable code

Two Hand Control

Crank Shaft Position Monitor

Main Valve Control


DELIVER:Simplified Integration

2

• EtherNet/IP backbone• No data remapping• Skid/ Machine Application is untouched• Common security• Single HMI look and feel for on-machine and main

control room HMI• RAPID interface for line integration.• Reduced commissioning time

EtherNet/IP


DELIVER: Remote AccessMaximize Uptime| Increase Efficiency| Secure Authentication

Be PROACTIVE,

not Reactive!


Continuum to “Value beyond Costs”

23


Key Takeaways

• High availability information

– Preferred parts status provision indicating high volume and high availability

– Essential products identified to meet the most common requirements

• Design and integration enablers

– Provision of essential part information to design with confidence

– Scalable solutions, pre-configured profiles, wizards, faceplates and tools

• RA OEM team resources

– Collaboration to assess, educate, design, validate and assist

– Industry and design, applications knowledge and experience

• Local supply partner

– Front line team, dedicated to your localized needs

– Flexible commercial, staging, inventory and technical people and programs

• Full life cycle support

– Helping users upfront, at the OEM site and beyond into the field

– Flexible services offered to meet OEM and End User requirements

raotm 2018- tm05 design productivity tools...design productivity •oem collaboration w/gotcs &...

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