Process Automation Technologies - Protecting The Plant V0.1 · 2013. 6. 15. · Automation Network Device Network Shop Floor Network Manufacturing Network “The outside world”

Copyright EnteGreat, Inc. 2006March 2006

Protecting The PlantManufacturing IT Best Practices

Mark KovacsEnteGreat, Inc.

2Copyright EnteGreat, Inc. 2006

Introduction

Today, plants face a wide assortment of problems concerning networks, data, systems infrastructure, applications, and support that are unique to manufacturing and not adequately addressed by corporate generated solutions.

The goal of this presentation is to provide a holistic view of both the problems and potential solutions using manufacturing industry best practices and emerging standards.

EnteGreat is a manufacturing consulting and systems integration company, serving primarily Fortune 500 manufacturing companies across North America. Rather than offering just technical solutions, the EnteGreat team is focused on helping clients implement supply chain and manufacturing IT systems that deliver measurable business outcomes from the project conception stage to world-wide rollout. We help our clients develop and implement continuous improvement initiatives for both manufacturing and supply chain operations that are facilitated by information systems solutions.


Agenda

• Overview – Trends In Manufacturing– The Culture Clash– Risks to Corporate & Manufacturing

• Using Standards– ISA-S95, What Is It?– Using ISA-S95 for Conceptual Systems Architecture– Using ISA-S95 for Mapping Systems to Manufacturing Business Functions– Using ISA-S95 for Data and Systems Segregation / Protection

• An Integrated Shop-Floor Scenario – An Overview of an Integrated Shop Floor Scenario– Shop-Floor System Descriptions & Criticality

• Where Worlds Collide• Summation


OverviewTrends in Manufacturing

• Increase Efficiencies– Supply chain influence on plant reliability (supply chain plans for delivery and

fulfillment require plant performance)– More emphasis on process efficiencies (e.g. Lean Manufacturing, etc).– Increase in automation and integration at plants as a means to increase

productivity and efficiencies.– Direction from Corporate to integrate manufacturing with the ERP.– Reduction in slack throughout entire supply chain creates intense dependency

on reliability (i.e. schedule reliability, performance reliability, quality reliability, etc.) which makes service level agreements for plant infrastructure and communications mission critical.

• Increases in Automation– Seen as a means to improve product consistency, costs, efficiencies, etc.– New equipment offers better integration potential using emerging industry

standards.– Such integrated equipment requires a reliable infrastructure for integration.

• Achieving and sustaining regulatory compliance • Industry Standards mature through real-world experience.• “Do more with less”…


OverviewThe Culture Clash

Corporate– IT: dedicated staff to specific

technical areas.– “Ledger” based systems, one

ERP, multitude of vertical applications that use business standard technologies.

– Direction to extend corporate solutions to the shop-floor.

– Access & Security defined as what a user can/can’t do with applications/systems.

Manufacturing– IT: Limited resources, jack-of-

all trades; broad experience.– Mixture of Batch &Time series

systems across disparate & specialized systems.

– Ability to integrate existing systems & equipment challenges ability to meet corporate standards.

– Access & Security defined as what is critical to human safety.

IT can provide tremendous value, but an understanding of what is critical to manufacturing must first be achieved. Manufacturing without IT may not gain the same level of efficiencies, security & maintainability as IT.


OverviewRisks to Corporate & Manufacturing

Some examples…– Security (i.e. viruses, intrusion, espionage, etc)

• Has become “old-hat” for IT. While Mfg leverages these standards for “business” systems, the increase in automation and integration of shop-floor equipment provide a set of potential security gaps with unique requirements.

• A dedicated Corporate IT Security staff responsible for “everything”, but lack visibility/exposure to manufacturing needs & the shop-floor.

– Drilling down to the Plant• Corporate IT lacks manufacturing experience, yet must leverage corporate

solutions to the plant for driving efficiencies and lowering costs.– Sensitivity for the Requirements & Technologies

• While a 10 second delay for posting to the ERP may not be an issue, it could spell disaster for manufacturing (i.e. lost product, safety issues, etc).

– Business Continuance / Disaster Recovery• Again, “old-hat” for IT but manufacturing presents unique technical

challenges (e.g. process historian’s real-time data sensitivities).

There are both common and unique risks to the corporate and manufacturing worlds. Recognizing the difference between the common and unique as well as developing appropriate responses could result in significant gains.


Agenda






Using StandardsISA-S95, What Is It?

• Committees started in 1996.• To separate business

processes from manufacturing processes.

• Provide clear delineation of responsibilities and functions.

• Provide a clear description of exchanged information using industry standards

• Provide common framework for integration from vendors.

Source: ISA dS95.01 Enterprise/Control System Integration

Business Planning & LogisticsPlant Production Scheduling,Operational Management, etc

Level 4

ManufacturingOperations & Control

Dispatching Production, Detailed ProductionScheduling, Reliability Assurance, ...

Level 3

Levels2,1,0 Batch

ControlSystems

ContinuousControlSystems

DiscreteControlSystems

For this presentation, we will only look at the smallest fraction of what ISA-S95 can offer for manufacturing.

See: www.isa.org


Using StandardsUsing ISA-S95 for Conceptual Systems Architecture

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Enterprise Systems:Centralized

• COTS• Variety of bus. functions •Central Mgmt• Corporate IT• Transactional data

Plant Systems:• Central or Plant• Mfg Specific• Local Mgmt• Corporate & Mfg IT• Mix of Batch and Transactional data

Shop Floor Systems:• Area-Level• Mfg/Equip Specific• Local Mgmt / Engr.• Mfg IT & Engr.• Time series, real-time & event data


Using StandardsUsing ISA-S95 for Mapping Systems to Manufacturing Business Functions

Use ISA-S95 as a framework to map standard manufacturing functions to systems. Note that S95’s QA is weak for Life Sciences…


Using StandardsUsing ISA-S95 for Data and Systems Segregation / Protection

• Special requirements exist for the lower networks:

– Specific timing requirements.– Data communicated in increments of

milliseconds.– Delay in transmissions can cause

loss of data, quality & potential safety issues.

– Servers must be “as reliable as needed”.

– Special environmental conditions impact selection of computer hardware (e.g. NEMA4X, C2D2).

– Systems and Networks must always “be On” while the plant runs.

Level 4 – Business Systems

Level 3 – Manufacturing Systems

Level 2 – Shop Floor Systems

Level 1 – Devices

LIMS MES Facilities /Equip.

Building Mgmt

Data Historian

Batch Engine

I/O Devices Sensors

HMI PLC / SLC

Automation Network

Device Network

Shop Floor Network

Manufacturing Network

“The outside world”

OPCSCADA

ERP PLM HR Quality

For demonstration purposes, we’ll use a simplistic model that aligns systems to the appropriate S95 Levels.


Agenda






Shop-Floor System Descriptions & CriticalityAccess Controls

• Utilize “Virtual” networks to segregate data and systems.

• Restrict cross communication at lowest granularity.

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• Manufacturing Network– Only Mfg Systems can talk to

the Shop-Floor Network– All Mfg Servers can talk to the

Business.• Shop Floor Network

– All Shop Floor can talk to MES.– Need Monitoring, SNMP, SMTP,

etc. to pass thru to business.– Only Shop Floor talks to

Automation Network• Automation Network

– Monitoring tools, alerts, etc. need to pass to people (via server in Mfg VLAN).

– Only talk to the Shop-Floor and Device networks


Shop-Floor System Descriptions & CriticalityMES Servers

Overview– Could be centralized or distributed.– Critical to keeping the plant running

(i.e. executing work orders).– Need for near-real-time information

to manage supply chains from Enterprise level (requires continually increasing depth of plant data)

Reliability - Critical– Outages could stop the plant .– Potential for major disruption in the

overall supply chain (plan for delivery, fulfillment, capabilities, etc).



Level 1 – Devices

Automation Network

Device Network

Shop Floor Network




LIMS Facilities /Equip.

Building Mgmt

Data Historian

Batch Engine

HMI

SCADA

PLCs

ERP PLM HR Quality

OPC

I/O Devices Sensors

PLC / SLC


Shop-Floor System Descriptions & CriticalityOPC Servers

Overview– Does not store data, but acts as a

translator and gateway for MES, Historian, etc.

– Processes real-time data.– MES accesses data only on an ‘as

needed’ basis, thus reducing network traffic and processing load on MES servers.

Reliability - Critical– Equipment visibility, may require

redundancy or high-availability if this is the main “source of record” for process data.



Level 1 – Devices

Automation Network

Device Network

Shop Floor Network





Building Mgmt

Data Historian

Batch Engine

HMI

SCADA

PLCs

Device Server

Equipment

ERP PLM HR Quality


Shop-Floor System Descriptions & CriticalityBatch Engines

Overview– Controls the execution of batch

processing for equipment independent of MES.

– Communicates batch level data to the Data Historian (e.g. Lot #).

– Communicates critical parameters and procedures with MES.

Reliability – Mixed to Critical– Equipment process control, may

require redundancy or high-availability.

– Criticality dependent on level of operation/phase management.



Level 1 – Devices

Automation Network

Device Network

Shop Floor Network





Building Mgmt

Data Historian

HMI

SCADA OPC

Device Server

Equipment

PLCs

ERP PLM HR Quality


Shop-Floor System Descriptions & CriticalityProcess Historians

Overview– Historian DB Server

• Accessible to applications (e.g. MES) for extracting data.

• Uses proprietary data storage…– Historian DA Server

• Needs to be accessible to the DB.• Needs to access the devices controlling

equipment.• May needs to access the OPC Server.

– Control Equipment (I/O Servers)• Collection of devices (HMI PCs)• Could be software that runs as a service

on the HMI, Server, or equipmentReliability – Mixed

– Mixture of needs...– Critical requirement for data collection

(Data Acquisition servers).– The “million dollar batch”



Level 1 – Devices

Automation Network

Device Network

Shop Floor Network





Building Mgmt

HMI

SCADA OPC

Device Server

Equipment

PLCs

Batch Engine

ERP PLM HR Quality


Agenda






Where worlds collide

• Some IT practices that negatively impact Manufacturing– Automated patch management to the MES or shop floor may stop

production (“but it’s a critical patch from Microsoft, it should work just fine”).

– Strict standards that do not take into account unique needs of manufacturing (e.g. real-time series, time sensitivity, etc).

– Driving efficiencies via centralization (e.g. attempting to run process historians over the WAN – “What’s a scan rate and why is it in milliseconds?”)

• Some Manufacturing practices that negatively impact IT– Access to HMIs and computers that control equipment is defined via

group or users shared Ids & passwords.– Use of home grown or non-supported applications as a “quick fix” (e.g.

“come on, how hard can it be to write VB code?”).– May not take advantage of existing IT best-practices (e.g. “I know I have

a back up my PLC code somewhere…” )

Some real-life examples of where IT and Manufacturing practices collide…


Summation

• Leverage industry standards to define the responsibility, functionality and integration points for manufacturing systems (e.g. ISA-S95).

• Leverage Manufacturing best practices and standards for common frameworks (e.g. B2MML, PackML, OPC, ISA-S88, etc, etc).

• Leverage IT best practices and technical expertise for common technologies, systems and support.

• Use cross-functional teams to fill the knowledge gaps.• Use such technology as HA servers where appropriate

for availability; reducing applications complexities; and need for highly skilled local support.


Questions?


Thank You

Mark Kovacs(205) 968-3050 ext. 312

[email protected]

Documents

Process Automation Technologies - Protecting The Plant V0.1 · 2013. 6. 15. · Automation Network Device Network Shop Floor Network Manufacturing Network “The outside world”