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

PUBLIC INFORMATION

Bausch & Lomb Leverages PlantPAx to ‘See Better,

Live Better” on Journey to The Connected Enterprise

Joseph Blasiak

Manager – US Engineering

Bausch & Lomb

Steve Schneebeli

Manager – Director of Engineering / IT

Malisko Engineering

AGENDA • Introduction

• Project Goals

• Selecting a PlantPAx® Solution

• System Overview

• Results

• Lessons Learned and Recommendations

• Next Steps

• Questions

INTRODUCING BAUSCH + LOMB AND

MALISKO ENGINEERING, INC.

WHO IS BAUSCH + LOMB? • Founded in 1853 in Rochester, NY

• Three Core Business Units:

• Vision Care: Contact Lenses and Eye-Care products

• Pharmaceuticals: Rx and OTC Medicines for various Eye Diseases and Irritations

• Surgical: Medical Devices, Instruments

• Global company with key US Manufacturing sites:

• Rochester, NY

• Clearwater and Tampa, FL

• St. Louis, MO

• Greenville, SC

• Acquired by Valeant Pharmaceuticals Aug. 2013 (VRX)

WHO IS BAUSCH + LOMB?

WHO IS BAUSCH + LOMB?

WHO IS BAUSCH + LOMB?

B+L LENS CARE SOLUTIONS FACILITY – GREENVILLE, SC • Aseptic Lens Care Solutions Manufacturing Facility

• Pharmacy, Compounding, Mixing, Filling, Packaging and

Palletizing

• Plant and Process Utilities

• Warehouse / DC off-site

• Originally built early 1980’s

• Volume growth of approx. 9.5% per year

• Products: Biotrue, Renu, PeroxiClear, Sensitive Eyes….

• ~ 25 Package formats and ~8 Package sizes

• 2012 Master Plan – identified DCS replacement for Risk

Mitigation – controls Process Utilities and Bulk

Manufacturing

WHO IS MALISKO ENGINEERING? • Experts in manufacturing automation and validation

• Founded in 1994

• Headquartered in St. Louis, Missouri USA

• Regional Offices in Denver, Colorado USA and

Eau Claire, Wisconsin USA

• Rockwell Automation® Solution Partner for Control, Process,

and Information Systems.

• CSIA Certified Member

Historic Laclede’s Landing

St. Louis, MO

Malisko Western Regional Office

Denver, CO

Phoenix Park Area

Eau Claire, WI

MALISKO’S PAST PRESENTATIONS

PROJECT GOALS

PROJECT GOALS

• Legacy DCS Migration / Risk Mitigation

– Main goal of new Process Control System (PCS) was to provide functionality similar to the existing DCS system

– Two Fisher Porter System Six DCS systems - Utilities and Mixing

– System cut-over done on a tank-by-tank, system-by-system basis – not ‘rip and replace’

• Provide an interface in the new PCS for future plant-level MES system

– Production Schedule Interface

– Electronic Batch Records

• Expose process (continuous) and batch data outside of the process network

– Existing DCS was an ‘island of automation’ – No direct ties to the corporate network

– All existing reports and historian data had to be printed out

– No visibility of the process outside of the DCS network

CHOOSING A PLANTPAX SOLUTION

“TRADITIONAL” DCS VS. PLANTPAX

Criteria Traditional DCS

Local Support Single Local Solutions

Provider

Local Eco-System consisting of dozens of local

Integrators and Solution Partners

Scalability Hardware + Additional

License required for additional I/O

No additional licensing required

Topology Dedicated Servers.

Software and Hardware Upgrades Expensive

Virtualization Fully Supported – Decoupling Hardware from Software

BASIS OF DESIGN PHASE

• Basis of Design (BOD) was performed to provide enough technical and financial detail to

determine the best course toward implementation.

• BOD deliverables included:

– Proposed System Architecture and Bill of Material with options for redundancy

– Preliminary Design Drawings, including preliminary CAD drawings for Network, I/O and Power Distribution

– Detailed Analysis against current URS

– Initial design engineering (FRS 30% – 50% complete, initial DDS draft)

– Technical options or considerations (i.e. Simulation System, FactoryTalk® AssetCentre)

– Preliminary schedule

– Validation Strategy

– Cost Estimate

SYSTEM OVERVIEW

DOCUMENT EXISTING SYSTEM FUNCTIONALITY

• No formal Functional Requirement Specification (FRS) or Detailed Design Specification (DDS)

existed for the Fisher Porter DCS.

• Malisko Engineers generated the FRS and DDS using DCS code exports and interviews with

B&L production and engineering groups.

• S-88 Modeling - Define Control Modules, Equipment Modules, Phases and Units.

• Optimized Existing Sterilization Procedure. DCS had multiple phases. PCS has a single

Sterilization phase with multiple steps.

• Several review meetings with key B&L production and engineering resources to finalize

system design.

PLAN FOR STAGED CUT-OVER

• Production scheduling eliminated the idea of ‘rip and replace’

• Malisko had to devise a plan to stage cut over of tanks and Utilities systems

• IFM modules were placed over the DCS termination boards, prior to tank cutover. This

allowed for a tank-by-tank cutover when a tank came available, thus minimizing the downtime

occurred by the tank.

• Tank cutover time – 2.5 days.

STAGED CUTOVER I/O PANEL PICTURES

PLANTPAX SYSTEM CHARACTERIZATION Characterization verifies that the system

provides the required performance.

SYSTEM ARCHITECTURE • Three Physical Servers with eight virtualized images

– FactoryTalk® View Servers (Primary and Secondary)

– ACP Thinmanager Remote Desktop Services (RDS) Servers (Primary and Secondary)

– FactoryTalk® Batch Servers (Primary and Warm Backup)

– FactoryTalk® Historian

– Microsoft SQL Server

– Seven FactoryTalk® View SE Thin Clients

• Two Engineering Workstations

• Cisco Stackwise Switches between Data Center and DCS I/O Room

• Device-level Ethernet Ring – Utilized for all I/O Chassis

• Separate network cards for connection to B&L business network for domain authentication. – Controlled by access rules on B&L corporate switches

• VPN Connection into system for Remote Support

PLANTPAX PROCESS OBJECTS

• V3.0 PlantPAx process objects

• “Out of the Box” PlantPAx AOIs

• “Enhanced” PlantPAx Global Objects (Valves, Pumps, etc)

HMI SCREEN SAMPLE (EXISTING DCS)

• 19” 4:3 Monitors

• 1024 x 768 resolution

• Ability to move main process screens

utilizing Windows pop-up functionality

HMI SCREEN LAYOUT (PLANTPAX)

• 24” 16:9 Monitors

• 1920 x 1080 resolution

• Ability to move main

process screens

utilizing Windows

pop-up functionality

FACTORYTALK BATCH

• Primary and Warm Backup Servers

• 30 Unit License – 19 units used

• 33 Phases across two processors

• Validated default recipes

• Using ‘off the shelf’ Rockwell Batch Overview

screen for viewing and controlling batches

• Developed custom screen for starting orders read in

from future B&L MES system

REPORTING • Reporting done through SQL Server

Reporting Services allowing Web-based

access to reports

• Data taken from SQL tables and

FactoryTalk® Historian SE

Confidential

DATA HISTORIAN AND SQL SERVER • 1,000 tag FactoryTalk® Historian SE server with

redundant FactoryTalk® Live Data interface nodes

• Historian data gathered from both PCS

ControlLogix® processors and stand-alone skids

• Ability to import Historian data into Excel using

DataLink add-in

• SQL database used to store FactoryTalk® Batch

data, FactoryTalk® Alarms and Events, and

FactoryTalk® Diagnostics data utilized for reporting

• Future connectivity of SQL and FactoryTalk®

Historian to upcoming FactoryTalk® VantagePoint®

installation

BIOMETRICS FOR USER AUTHENTICATION

• DigitalPersona U.are.U 4500 Readers

• Utilizes U.are.U Software Development Kit

• VB .Net application used to detect and log-in users into FactoryTalk View SE

• Users can enroll up to two fingerprints

• Challenge of getting reader to work with ACP Thinmanger Thin Clients

VB.Net App Interprets data

from Reader and sends FT Login

Credentials

Fingerprint Read from Reader

FT User is Logged into

System

RESULTS

IMMEDIATE RESULTS

• Robust, redundant system including servers, PLCs, application software, and networking (I/O

Ring and Server to Client utilizing Stackwise switches)

• Local Rockwell support and readily available replacement parts

• Remote access for troubleshooting support if needed

• Built on a standardized set of process objects (PlantPAx)

• Easier for maintenance and engineering to learn and troubleshoot the system

LONG TERM BENEFITS • PCS system provides the framework to get data exposed to the corporate level

• Roll-out of VantagePoint to display and analyze data on the desktop (process users or engineers)

• Provide standardized programming environment following site standards

• S-88 model utilizing Phase Manager opens up options for further automation of the Mixing

System

• Ability to interface with future B+L MES system to pass production orders down to the batching

system, and feed critical production data for Electronic Batch Records

LESSONS LEARNED AND

RECOMMENDATIONS

LESSONS LEARNED AND RECOMMENDATIONS

• DCS replacements require planning and communications if not ‘rip and replace’

• At the mercy of Production, so scheduling needs to be flexible

• During initial design, factor-in framework for new enhancements, even if replacing with

similar functionality.

• While laying your framework for the Connected Enterprise, have early and often

conversations with plant IT groups. Make them part of the design process.

• Spend time with operators on the existing system. Don’t just ‘reverse engineer’ the old DCS

code.

B&L LESSONS LEARNED AND RECOMMENDATIONS

• Create a comprehensive URS – approved by key stakeholders; incorporate inputs from SME’s

• Include and fund a BOD phase if appropriate

• Follow a formal vendor selection process; evaluate proposals against critical criteria

• Align vendor capabilities with business needs

• Create and follow a detailed Project Plan in partnership with your vendor(s)

• Include SME’s in Design Reviews

• Understand Change Order process

• Include Contingency Plans

NEXT STEPS

• Work towards bringing other isolated systems into the new Process Control Network

• Determine data to be collected via Historian (continuous) and SQL (events)

• Roll-out ‘Data to the Desktop’ initiative. Utilize VantagePoint and Historian DataLink.

• Look for ways to automate existing manual processes

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

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

PUBLIC INFORMATION

Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Contact Information Steve Schneebeli

Malisko Engineering Inc.

Director of Engineering / IT – St. Louis, MO

sschneebeli@malisko.com

Joe Blasiak, P.E.

Bausch & Lomb, Rochester, NY

Engineering Manager – US Automation

Joseph.Blasiak@bausch.com