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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
PUBLIC INFORMATION
Reliability SolutionsDriving Asset Optimization and Greater Plant Productivity
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Why Are We Here…
What's your Healthy and Balanced approach for Success!
Using modern technology with proven techniques… Reliability
Solutions leverage same Health & Performance Balanced approach
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Asset Reliability ServicesGreater Plant Productivity = Asset Performance + Reducing Risks
3
Understanding the
Asset Baselines
Operational
Continuous
Improvement
Diagnostic
Reliability Data
Intelligence
Reliability
Professional and
Program Mgmt. Asset Tracking and
Repair Management
Storeroom
Management/
Operations
Stores and
Plant Floor
Assessment
Critical Spares/
Support Analysis
Equipment
Reliability
Analysis
KPI / Metric
Driven
Performance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Diagnostic Reliability ServiceUsing an Asset Intelligence System Enabled by The Connected Enterprise
Diagnostic Reliability ‘DR’ Service provides our clients
improved risk mitigation and control system compliance
on their most critical production assets
Asset Knowledge
Risk Reduction
Asset Performance
DRS Value Proposition
Maximizing RoA - Uptime - Compliance
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 5
Diagnostic Reliability Service implemented on 6 site locations (~500
devices per site)• Online monitoring and auditing
• Ongoing equipment health trending within dashboards
• Proactive maintenance activities driven by analysis
• Asset Management improvement plan roadmap to drive operational and
maintenance efficienciesRESULTS
• Accurate Management of Control Assets• Accuracy and completeness of control asset records
• Spares inventory correctly supports installed base
• Sustainability of enterprise system data records
• Verify asset lifecycle management
• Multiple sites within a region with many layers of
devices & systems
• Regulated & Compliance requirements
CHALLENGES SOLUTION
Large Producer & Refiner of OilReal Results: Diagnostic Reliability Service
• Implement Rockwell Automation Diagnostic
Reliability Service
• Including Network Assessment
• System Implementation to IT requirements
• User Training with specific dashboard design
• Ongoing Service contract
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Closing Comments
DRS Asset Intelligence Walk Through
DRS Use Cases
Asset Reliability Services
Industry – State of the Union
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Industry Challenges for the Next Decade
• Pressure on Efficiency and Reliability
• Shrinking Expertise in Workforce
• Aging Assets
• New Assets Increasing in Complexity
• Increasing Regulatory Pressures
Manufacturers spend 40% of their time on reactive
maintenance vs. their 12% ideal (Maintenance Technology)
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Industry Opportunity - Evolution
8
Asset intelligence possible from The Connected Enterprise
enables better decisions across your maintenance and production
systems creating substantial plant productivity!
How am I managing my most critical assets?
Am I leveraging smart device information to drive predictive maintenance decisions?
Are my networked devices running within known control limits and healthy?
How am I tracking asset data?
Will replacement parts meet required specifications?
How much downtime is caused by parts issues?
Do I have governing policies to manage asset change and alternative configurations?
How can I culturally evolve my maintenance program to be more predictive?
Accelerating High Performance Operations by Empowering PEOPLE to make SMARTER, more INFORMED decisions
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Closing Comments
Asset Intelligence by DRS
Scenarios- Use Cases
Asset Reliability Services
Industry – State of the Union
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
The Reliability Story of ‘Smokey the Bear’
“Variable Frequency drive on the Cereal Mill caused major downtime… Again!”
Customer has a major downtime event on a critical mill – drive must get powered up ASAP to get production moving
Maintenance to the rescue – all parties fire fighting
Asset Management Professional frantically trying to expedite parts –on the HOT seat
All options are on the table with multiple solutions being put into action
Maintenance device swapping, re-commissioning
Stores/ AMP calling suppliers and expediting parts
Operations rescheduling/ diverting production, shift adjustments
Time clicks on.. more People and Parts to resolve.. more issues.. finally running
Are you ready for change? Are all your heroes fire fighters?
Lets explore same scenario with a balanced proactive strategy…
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Customer Use Case - Asset Knowledge
Maintenance
ERP/ Stores
Control System
Power Devices Asset Intelligence System
Central Support Expert gets email alert from Asset Intelligence System: Red-Alert: Area
‘Mill 2’: Device ‘VFD’: Off-Line, Fault…
Support Expert goes into the system; VFD and other related system components were
down – validates with maintenance event, does data analysis (before/ after) on device,
seeks out spares situation…
No direct match for the failed parts was in inventory, so as stores was calling
suppliers the he works with maintenance technician to locate other plant equipment
with same unit using the system. Good news - part found on blower…
Mill equipment was repaired and re-commissioned. System verified what unique
VFD units are installed and tracked asset service cycle.
How can we shrink ‘mean time to restore’
on critical Assets?
• Locate/ Identify status of troubled devices early
• Obtain proactive notice of device change/ history
• Track device service cycles
• Identify device/ system firmware
• Ensure critical/ spare parts are available
WHY… Greater OEE, Reliable Uptime, Lower MRO $
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Customer Use Case: Reducing Risk
Maintenance
Production
Control System
Power Devices Asset Intelligence System
Central Support Expert has been noticing lots of minor faults. In order to get down to the
root cause more data triggers will need to be set for greater analysis/ decisions… Evaluating the situation back to VFD fault/ failure, as a detective we are asking
ourselves why, when, how, what so proper corrective action options can be created…
During maintenance repair event, the support engineer quickly identified device
firmware/ configuration relative the system compatibility to ensure work quality …Mill leadership wanted to ensure chronic/ acute problems on critical assets are
tracked in plant dashboards to ensure fixes are validated and sustained.
How can we eliminate ‘bad actors’, while
mitigating risks throughout Life Cycle?
• Proactively track/ trend potential bad actors
• Mitigate at-risk legacy equipment
• Product safety/ service advisories impact
• Improve asset life cycle mgmt. processes
• Ensure safety-security of network device changes
WHY… Safety-Security, Reliable Uptime, Lower MRO $
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Customer Use Case: Performance
Maintenance
Production
Control System
Power Devices Asset Intelligence System
Central Support Expert desires to get relevant device alerts that align to maintenance
strategy, so starting with system processors he profiles/ defines key attributes to monitor… Support Expert uses his intelligence system to package information of status changes,
condition parameter limit breaches and event instances leveraging baseline dataset…
Seeking ways to improve production processes and uptime, data decisions around
how assets are performing by area/ system is key to prioritizing projects/ activities…Central Support Expert knows it’s a team effort to drive improvements continuously
so defining enterprise, facility, area scorecards or dashboards is ideal his culture.
How can we proactively sustain asset
health, while using actionable data to
improve mfg. productivity?
• Identify status of troubled devices early
• Trend device change with impact analysis
• Track device service cycles
• Device diagnostic information
• Intelligence dashboards/ Portal
WHY… Greater OEE, Reliable Uptime, Productivity!
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Agenda
Closing Comments
Asset Intelligence by DRS
Scenarios- Use Cases
Asset Reliability Services
Industry – State of the Union
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Diagnostic Reliability System
Data
Platform w/
User
Interface
Process Control Network (PCN)
PLC-5
SLCControlLogix®
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Addressing User Case Scenarios
What if I could simply…
Locate/ Identify status of troubled devices
Obtain proactive notice of device change/ history
Track device service cycles
Identify device/ system firmware
Determine product safety/ service advisories impact
Mitigate high-risk equipment risks
Perform a critical/ spare parts gap analysis
Verify migration plans to reduce legacy obsolescence
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Diagnostic Reliability ServiceUsing an Asset Intelligence System Enabled by The Connected Enterprise
Asset Knowledge• Complete installed asset records of networked
devices (live/ historic)• Device profiles with status/ fault identification• Critical spares inventory analysis
Risk Reduction• Lifecycle obsolescence status, prioritization
and mitigation plan validation• Security/ Safety safeguards – device
monitoring, detecting threats early, MOC validation, advisory impact analysis
• Asset support strategies, firmware/ version compatibility management
Asset Performance• Device and system health diagnostics• Dynamic user interface with unified data model
provides good analytics• Simplified user tools
Diagnostic Reliability Value Proposition
Maximizing RoA - Uptime - Compliance
Our asset intelligence service is typically integrated
within our customer’s central decision support
center to drive continuous improvement outcomes:
Asset Lifecycle Management
Automation Controls Network Compliance
Asset Reliability and Performance Improvement
Maintenance efficiency towards uptime goals
Optimal storeroom critical spares management
“The Rockwell Automation Diagnostic and
Reliability Manager is like an EKG heart
monitor for process control equipment.”- Reliability Services Customer
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Solution Summary Part I
DR Solution provides a health monitoring system and engineering services to improve reliability of your critical
PLC infrastructure that includes PLC/PAC processors, I/O and comms, system networks and connected power
control field assets. DR Solution for your Central Decision Support Center will be packaged to perform the
following capabilities:
User interface with analytical triggers and central information HUB
Serve data in structured central database including all plants
Data agent/ collection schema (weekly, daily, near real time), while remaining non-intrusive
Configurable device profile/ criteria for rule triggers by system
Device data by type, record health dataset: state, health indicator, diagnostics
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Solution Summary Part II
19
System interface will serve pertinent information to users, empowering them with data analysis, reporting and
information dashboard screens sharing the health of PLC/PAC system devices. Our DR system will provide data
collection, processing and information management layers across your vast device infrastructure using safe and
secure methods; resulting in a unified data model that is centrally viewed and managed.
System engineers – both database and device specialists – will configure analytical triggers and device data
management rules by type, ensuring health data context is rich. Our DR engineering services will not only be
validating, testing and deploying system across selected facilities/ IT environments, but will be supporting/ training
users, periodic maintenance and fine-tuning management packs/ criteria over time with users as asset/ devices
change.
Program managers will be versed in your culture, policies and procedures to effectively execute the project well
within your program structure. Streamlining processes, while handling unique characteristics of each plant, is the
program manager’s role.
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Central Decision Center PLC Health Monitoring Requirements
20
In Scope:
DR system with following dataset
Identification attributes - general
Manufacturer
Device Name
Device Type
Serial Number
Firmware
Node/ IP
Status
Health attributes/ Diagnostic data by category
[PLC/ PAC processors]
Status description (online/ offline)
Fault state description (major/ minor)
Fault code on minor/ major if available
Battery status
Key switch position
Chassis rack/ slot location (processor/ IO/ Comms in racks)
CPU performance data (memory, connections, task scan time)
[PLC/ PAC in chassis I/O]
I/O model status
I/O channel status
I/O performance data
[PLC/ PAC communication cards]
Ethernet network performance data (ports, connections, link status,
media counters)
ControlNet performance data (node status, network parameters/
configuration, counters)
DeviceNet performance data (node, scanner status, configuration)
[PLC/PAC distributed/ non-chassis I/O]
Communication protocol
I/O model status
I/O channel status
I/O performance data
[VFD/ AC-DC Drives]
Parameter/ attribute data for diagnostics
Frequency (Output, Command)
Power (Current, Voltage, Power factor)
DC bus voltage
Speed feedback
IGBT temperature
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED 22
Explore the DRS interfaces
Database – Backend Information Portal – Frontend Data Diagnostics – Frontend
SQL Light switch Interface FTVantagePoint Interface FTViewSE Interface
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
30 23 22 22 15 10
24 24 14 19 21 10
33 3326 30 26
13
58 5835 41
1617
43 43
1637
24
10
43 43
36
47
32
21
49 49
40
43
36
26
0
50
100
150
200
250
300
Plant A Plant B Plant C Plant D Plant E Plant F
Dev
ice
Fau
lt C
ou
nt
Plant PCN Device Faults per date
9/30/2014 9/29/2014 9/28/2014 9/27/2014 9/26/2014 9/25/2014 9/24/2014
PCN Device Alerts
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.Rockwell Automation TechED 2015 @ROKTechED #ROKTechED
Why Are We Here…
Using modern technology with proven
techniques… Reliability Solutions leverage same
Health & Performance Balanced approach
Accelerating High Performance Operations by Empowering PEOPLE to make SMARTER, more INFORMED decisions
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