A Modern Process Automation System Offers More than Process Control. Dick Hill Vice President ARC Advisory Group

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1 A Modern Process Automation System Offers More than Process Control Dick Hill Vice President ARC Advisory Group

2 Modern Business Requirements Dynamic Customer Requirements Requiring Agility More Distributed Operations Requiring Collaboration Shrinking Product Lifespan Increasing Global Competition Pressure to Lower Costs More Customer- Imposed Standards Lower Energy Costs Cyber Attack Defense Excessive IT Support Costs Aging Assets Aging Workforce in Manufacturing Plant and Personnel Safety Proliferation of Regulations Modern Business Pressures are Driving Manufacturers to become Real-time Enterprises and Achieve Operational Excellence 2

3 Modern Business Operations Automate Entire Supply Chain Headquarters Terminals Pipeline Pipeline Source Plant / Site Make Deliver Objective: Managing business processes and connecting systems and people, internally and externally, in a collaborative way 3

4 Many Installed DCSs are Not Designed for Modern Business Challenges A Collaborative Process Automation System (CPAS) strategy is needed. Plant Operations IT Modern Business Requirements Control Outdated Control System There are many lost opportunities to improve, if you are always just maintaining what you have. 4

5 CPAS is ARC s Definition of a Modern Process Automation System CPAS Guiding Principles Collaborative Environment Enables Operational Excellence Agility and Performance with Flawless Execution Highly Secure Control and Safety Common Infrastructure Provides Ease of Implementation and Lifecycle Management Enables Information Driven Manufacturing A Modern Process Automation System will Maximize Return on Assets 5

6 CPAS: Collaborative Environment Information-Driven Manufacturing Modern Process Automation Systems are Essential to putting Information in Context to the Current State of Operations. 6

7 How is CPAS Different than a DCS? Attribute From To Focus Technology Business Structure Hierarchical Flattened Cyber Security IT s Problem Secure by Design Data Multiple copies Single Version of Truth Integration Project-based & Standards-based & Common Customized MOM Separate System Integrated Applications Safety & Control Separate Integration Options Control & Electrical Engineering Design Separate Tied to Hardware & Software Integration Options Late-Binding for Hardware/Software Solution Services Supported by Users Serviced by Suppliers Technology is no longer a barrier 7

8 What does a CPAS Look Like? Automation-Specific Hardware Intelligent I/O & Field Devices & Sensors Visualization Application Servers Intelligent Networks Virtualization, Connectivity Safety and Security Application Software Analytics Automated Procedures Knowledge Workers A Collaborative approach is needed to integrate with Business! 8

9 CPAS Functional Model View of Operations From Technology focus To Business focus IT Control Functions that in the past were distributed across many applications and systems are now in just two systems: Business and Automation. 9

10 Modern Automation Projects Require A Revolutionary New Approach Execute a Lean Project with Design Independence Separate Physical design from Functional design Schedule Late Binding at the end of the project Automated Binding of Physical to Functional Physical I/O Counts, Locations Functional Hardware Design Source: Honeywell Instrument Index Late Binding I/O Assignment P&IDs, Narratives Final Shipment Cable Designs Marshalling Design System Configuration Control Configuration Alarm Studies, Set points Alarm Configuration Allow design to evolve Leverage Smart I/O System FAT Site Commission Allows the signal type, for each channel, to be configured Configuration Partial Shipment Final FAT Shipment Smart IO eliminates Marshalling Remove LERs, RIEs, cabinets, cables and complexity Functional HMI configuration Configuration developed in simulation on a Sketches, virtualized Procedures platform Tag name references only, no channel requirement required 10

11 CPAS Solutions View of Operations Solution Range Plant Performance Work Process Integration Software & Applications Systems Control Technology Technology Support & Service Process Knowledge * Human Empowerment * CPAS Goal Instruments Core Value Add Goal Capabilities Range CPAS enables services to be applied more consistently toward the overall business performance goal! 11

12 CPAS Architecture View Business Systems Communications To/From Process Visualization DMZ Wireless Field buses Process Control Firewall Common Information Infrastructure Safety Manufacturing Operations Management Virtual or Physical Servers Application Specific Appliances Logic & Motion Device buses Discrete Control 12

13 Will the Industrial IoT Change Plant Systems? XYZ Company Maintenance XYZ Company XYZ Company XYZ Company Engineering Purchasing Corporate Machine Mfr. Service Provider New IoT Analytics and Applications Enterprise Private Secure Connection to 3 rd Parties Plant Operations XYZ Company Smart Machine IoT Smart Module Local IoT Compute and Communicate module Physical asset with sensors, actuators Yes! Emerging Option: Connect Assets Using New Technologies 13

14 Thank You. For more information, contact the author at or visit our web pages at 14

15 Challenge: Improve Business Performance Effectiveness Unscheduled Shutdowns Asset Life Utilization Variable Costs Fixed Costs Improve Business Performance Collaborative Environment Information Barriers Empower Workers To achieve performance improvements, there needs Synchronization between Business Systems and Operations Systems. 15

16 Characterizable / Configurable I/O Characterizable within a *Family of Types * Families: AI, AO, DI, DO, etc Plugs into any slot, in any rack, for any field device type 16

17 How does it fit into a Functional Hierarchy? ISA-95 Hierarchies Provides a Model Level 4 Business Planning & Logistics Plant Production Planning & Scheduling engineering design, purchasing, customer order handling, etc. Enterprise Site Level 3 Manufacturing Operations Management Production, maintenance, quality testing, inventory and material flow management, etc. Process Cell Production Unit Area Production Line Storage Zone Level 2, 1 Unit Work Cell Storage Module Batch Control Level 0 Continuous Control Discrete Control Lower Level resources in batch operations Lower Level resources in continuous operations Lower Level resources in discrete operations Lower Level resources in material handling operations Modern Process Automation System needs to incorporate these Real-Time functions! 17

18 How Does a Modern Process Automation System Fit in? CPAS Guiding Principles ARC s Collaborative Process Automation System defines a Modern Process Automation Systems 18

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