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

New Strategies to Monitor, Optimize and Support

Your Machines – Leveraging the Cloud


Opportunities for a Connected EnterpriseThe 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 OperationsSaaS* 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 NewInsights

Scale Up/DownElasticity

‘0’ InfrastructureTo Support

TrustworthyExchange of Info

Business ModelFlexibility

*Software as a Service


Cloud ComputingCloud 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 AssetsMoving from Traditional Software Deployment to Software as a Service

5

Site 1 Site 2 Site n

CloudGateway

LANWireless

CellSatellite

AutomationSystems

Asset PerformanceManagement

Performance ManagementEquipment and Process

Behavior and Optimization

Predictive AnalyticsEquipment and Process

CharacterizationModel Development

Predictive Maintenance


B

A

Supplier A

Machine Builder A

Support Org

Customer 1

Rockwell AutomationSupport

Utilities

CorporateHeadquarters

Machine Builder BMachine Builder C

Supplier B

Prod/ProcDesigners

Cloud

Gateway

Customer 2Customer 3

Data Sources

Quality Org

Simple, Secure Data & Equipment Access for ALL Sanctioned Stakeholders

C

WeatherForecast


M2C* Gateway: Secure Data TransferScalable 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 ManagementSimple, Secure Remote Monitoring Solutions

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 PlatformData 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 streamsEncrypted keys token

enabled

Transient token


Cloud Application PlatformData 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 HierarchyEmail 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 AnalyticsLive 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 AnalyticsAlarms, 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 ManufacturingCurrently in Prototype / Proof of Concept Status

16

Manufacturing

Intelligence

80%

Predictive

Analytics

250%

Machine Plant Floor

Predictive AnalyticsEquipment and Process

CharacterizationProcess Optimization

Predictive Maintenance

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

should be performed to avoid unplanned downtime


PowerFlex® 7000 Remote Monitoring ServiceWhat 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 ServiceVisualization Examples


New Business Model – Supplying ConsumablesInnovation 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 ManagementGlobal Manufacturing Re-invention

23

Global

Food & Beverage

Manufacturer


The Cash Machine of the Oil & Gas IndustryRemoving the Potential for Error

24

Trigg Technologies

L.A.C.T. Unit

Manufacturer


The Cash Machine of the Oil & Gas IndustryAsset Performance and Transactions

25


Remote Asset Performance ManagementLiquid Natural Gas Terminals

26

Supermajor O&G

Building & Managing

LNG Retail Stations


Product SerializationMinimize Counterfeiting and Diversions of Specific Foods & Medicines

27

Brand ProtectionGlobal Dairy

Company


vMonitor®

The Connected Oilfield

28

OptiLift - NFNaturalFlow

OptiLift - ESPElectricSubmersiblePump

OptiLift - PCPProgressiveCavityPump

OptiLift - RPCRod/SuckerPump

OptiLift - GLGas Lift

OptiLift -PLPlungerLift

OptiLift - WMWellMonitoring

Digital Oil Field


Remote Asset Performance ManagementSoftware as a Service Order Components

Application ConfigurationModel Development

Dashboard DevelopmentBusiness Rule Configuration

Workflows

Non-Recurring-Eng Costs Per Site/Asset*

Cloud Gateway HardwareCloud Gateway Software

APM Platform commissioningOptional

Wireless HardwareGPS Hardware

SaaS Subscription Fee**

All ‘Compute’ infrastructureAll ‘Data Storage’ infrastructure

Provisioning additional infrastructureAPM Platform (per Asset)

Support SLA

OptionalCellular data contract

Rockwell Automation application support

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


Other Cloud Related Sessions


We Care What You Think!

Please take a couple minutes to complete a quick session survey to tell us how we’re doing.

On the mobile app:

1. Locate session using Schedule or Agenda Builder.

2. Click the survey icon on the lower right corner of the

session detail.

3. Complete survey.

4. Click the Submit Form button.

Thank you!

3

1

2

4