Manufacturing Connectivity and Data Integration

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1 Manufacturing Connectivity and Data Integration Contents Advantages of Greater Connectivity... 3 Downside Risks of Heightened Connectivity... 4 Setting a Mobile Device Policy... 5 The Connected Enterprise in Action: Delivering Results... 5 The Roadmap to The Connected Enterprise... 6 Investment Rising for Analytics, Remote Monitoring & Mobility... 7

2 Manufacturing Connectivity and Data Integration Today s manufacturers can take advantage of a new era of connectivity promising greater productivity, improved utilization of assets, and better decisionmaking. Driving much of this change is the ability to smoothly mesh information technology with operations technology, enabling businesses to more fully leverage the value of their plant floor information. While many manufacturers, primarily the larger enterprises, have made substantial progress connecting plant floor data to the company network, the full benefits of The Connected Enterprise remain largely untapped. The reason is that integrating plant floor data with enterprise systems not to mention bringing Internet connectivity to production operations poses substantial challenges. Foremost among these are cost, the complexity of integrating technologies from different vendors, and security concerns. Despite these hurdles, bridging the gap between plant-level information and systems at the corporate level promises significant business value for those manufacturers willing to overcome them. Among the potential payoffs are faster time to market, lower total cost of ownership, improved asset utilization, and more effective enterprise risk management. Those are only a few of the benefits derived from a broad vision of enterprise information that connects the plant floor with enterprise systems in a seamless and secure fashion utilizing new technologies such as mobile devices, the cloud, and big data. But to reap the full advantages of The Connected Enterprise and the fast emerging Internet of things (IoT), manufacturers still have a ways to go. In a January, 2015 IndustryWeek survey of 581 manufacturing executives and managers, less than a third (28%) said their plant floor data was Internetenabled. Equally telling, of the larger companies with sales of $1 billion or more, just 8% said their company infrastructure was completely ready to benefit from the new Internet based technologies such as data mobility, cloud computing, and big data. 2

3 Manufacturing Connectivity and Data Integration Although larger industrial firms have made significant progress enabling business decision makers to fully access operational data to make more informed decisions, many midsize and smaller manufacturers have yet to achieve interoperability. In fact, the survey results tell a story of relative technological haves and have-nots : the larger companies with sales of $1 billion or more tend to have already achieved far greater connectivity with plant floor data internally and to the Web when compared to their midsize and smaller manufacturing brethren. Advantages of Greater Connectivity The benefits to industrial organizations of meshing production information with the company s business systems are many. Instead of having to return to headquarters from the field to firm up a shipping and delivery date of a customer order, a sales representative can use a mobile device to check on plant production schedules. Similarly, a supplier s real-time access to a manufacturer s just-in-time schedule helps ensure the smooth flow of parts essential to a lean manufacturing environment. Internet connectivity for plant floor equipment is viewed by manufacturers as being valuable for supply chain efficiency, as well as for driving six sigma efficiency improvements. Nearly half (45%) of companies responding to the IndustryWeek survey said Internet-enabled equipment is valuable for supply chain efficiency, while 40% indicated that such connectivity is valuable for enabling six sigma gains. In addition, half of all respondents said they found Internet-enabling of devices to be valuable for predictive maintenance. Similarly, 59% found it valuable for quality and inventory control and 56% for uptime. Corporate-wide visibility into production data typically pays off in better informed decision-making throughout the enterprise. Some of the benefits are smarter management of inventory, reduced consumption of energy, and gains in throughput. For example, a leading global cosmetics manufacturer installed Rockwell Automation FactoryTalk Metrics software to monitor, collect, and analyze production data at its Dallas plant. A new production line had been added, plagued by disappointing output and frequent line stoppages. To improve measurement of overall equipment efficiency (OEE) and gain greater control over the efficiency and quality of the new line, Lewisville, Texas-based Prime Controls installed FactoryTalk Metrics on a local server, connecting the program directly to the plant s network. After migrating the existing application to the FactoryTalk database, engineers analyzed the line in running mode. They found that the machine with the highest OEE rating was running at maximum level while other machines were either starved or blocked a condition that was not visible to the human eye. Engineers executed the necessary fixes to boost production while eliminating the faults in the process that had caused downtime. The FactoryTalk software was configured to calculate and visualize OEE for the monitored equipment. The result is that now when After migrating the existing application to the FactoryTalk database, engineers analyzed the line in running mode. They found that the machine with the highest OEE rating was running at maximum level while other machines were either starved or blocked a condition that was not visible to the human eye. 3

4 operators are notified of an alarm, they can quickly understand the root cause of stoppage or inefficiency, and access the necessary data to identify actions needed to resolve the problem. Downside Risks of Heightened Connectivity Industrial enterprises seeking to tap the benefits of broader connectivity within the organization as well as with suppliers and customers must come to grips with the need to mitigate the potential risks, not to mention the cost of upgrading their existing devices, networks and infrastructure. In many instances, industrial control systems already incorporate both logical and mechanical provisions designed to enhance both safety and reliability. These systems typically include a mix of old and new components that have evolved over time. Thus, a common plant floor environment consists of a mix of old equipment and new systems, some of which may be readily compatible with today s newer technologies, and some less so. Often these heterogeneous control environments unavoidably result in greater exposure to a new set of cyber risks when opened up to greater connectivity and data accessibility. An infrastructure designed to mesh operational technology at the plant level and the information technology throughout the rest of the business works best when built upon open architectures using Ethernet and the standard internet protocol (TCP/IP) to enable interoperability with a variety of systems and applications. EtherNet/IP is the world s leading open industrial Ethernet network designed to connect across systems and subsystems and from the end customer s IT infrastructure to the instrumentation level. EtherNet/IP uses the same Ethernet and TCP/IP protocol suite that is used for , the Internet, and other commercial applications, providing the performance, resiliency, and security of traditional fieldbus solutions. Although this openness and increased interoperability affords considerable benefits, it also opens the enterprise to potential cyber threats from outside. In fact, larger industrial companies with sales of $1 billion or more tend to be more concerned about the security issues surrounding greater connectivity with the plant floor than manufacturers of all sizes, according to the IndustryWeek survey. Some 43% of large manufacturers cited security as a barrier to enabling machinery to have Internet connectivity, compared to 32% for manufacturers of all sizes. For this reason, industrial enterprises that embrace greater connectivity within and outside the organization must adopt a security strategy that covers both the plant and the broader enterprise. Security must be designed into all levels of the IT architecture, including devices on the plant floor, control systems, and the networks that comprise plant floor automation. Companies need to take a holistic view of industrial security, addressing people, process, and technology risk to maintain operational integrity and protect industrial assets. In most cases, this means following a defense-in-depth strategy that addresses both internal and external security threats. This is based on the premise that any single point of protection or individual firewall could, and probably will, be penetrated by the persistent attacker over time. The most effective defensive solution is to erect multiple layers of defense, including physical, electronic and procedural. Under this approach: Security is built into the infrastructure and becomes a set of layers within the overall network security; Attackers must first penetrate or circumvent each security layer undetected; and Any single point of penetration can be backstopped by different variables of capabilities provided by the other layers. The explosion of data contained at the plant level in production drives, servos, and programmable logic controllers (PLCs) warrants a high level of security to ensure that product and process information remains adequately protected. The commonly accepted notion that the PLC was the central point of information on the production floor has been eclipsed as a greater variety of more 4

5 Manufacturing Connectivity and Data Integration powerful devices make up the automation environment in today s manufacturing facilities. Through The Connected Enterprise, much of this plant floor data today is accessible via smartphones and other devices in effect, enabling this information to move in and out of the machine zone as use and demand requires. Despite these benefits to be obtained from making production data available over the Web to employees, customers, and suppliers, many manufacturers remain hesitant when it comes to Internet-enabling plant-level information. While the biggest concern over Internet enabling production machinery is cost 50% of enterprises with sales of $1 billion or more said this was the chief barrier to Internetenabling plant floor devices a close second was concern over security (43%). Setting a Mobile Device Policy Security issues also loom large as industrial firms grapple with the need to deploy IoT strategies. Despite the fact that just about every consumer owns or uses a smartphone, the use of these devices by employees to access production information remains relatively limited. Only one out of four manufacturers responding to the IndustryWeek survey have made plant floor data available on their employees mobile devices, and they have done so only for upper level managers or other select employees. Just 5% of manufacturers have made plant floor data available to all employees via mobile devices. A majority (51%) of large manufacturers report security concerns over external mobile devices. Many companies have dealt with this issue by establishing a clear policy for employees governing their access to company data corporate and plant-based using both company-issued smartphones as well as employee-owned mobile devices. Security concerns also are impacting manufacturers plans to leverage the cloud for data storage. While 21% of large enterprises report storing plant floor data in a private cloud, just 5% are using a public cloud for data storage. Overall, 16% of manufacturers are storing plant floor information on a private cloud, but only 3% are doing so using public clouds. The Connected Enterprise in Action: Delivering Results One of the most powerful benefits of The Connected Enterprise is the ability to visualize the performance of operations and take quick action to stem production problems either before they occur or early in their development. Industrial plants typically require different perspectives based on the operator s role or the supervisory level of the viewer. For instance, various groups such as engineering, maintenance, and operations all need visualization into operations that is tailored to meet the needs of their roles in the plant. FactoryTalk VantagePoint EMI software from Rockwell Automation offers dashboards, trending presentations, analysis, and reporting capability. It draws data from disparate sources and brings it all together into a single format called the Unified Production Model. One of the most powerful benefits of The Connected Enterprise is the ability to visualize the performance of operations and take quick action to stem production problems either before they occur or early in their development. 5

6 One company using the Unified Production Model (UPM) is Cybertrol Engineering, which used the UPM when setting up a process for a pipeline company that wanted enterprise-wide visibility. The pipeline company operates 150 pumping stations using Allen-Bradley ControlLogix PLCs at each station. The UPM was used to historically represent a massive amount of data from each remote station so that engineers could use the data for decision-making. The flexible, off-the-shelf solution enabled pipeline operators to check the discharge pressure for each pumping station using the UPM. The company found the UPM very effective as a tool for troubleshooting and analyzing various conditions. Another company that needed better visibility into operations is Hillshire Brands, which ships 150 million pounds of Jimmy Dean breakfast sausage annually. The company needed to control and maintain an exact amount of product in each package. After evaluating the entire production process, the company considered various solutions, finally settling on three dashboards to monitor production. The result was the company is able to collect key actionable data, spot trends, and make better decisions. Being able to standardize its plant infrastructure using Rockwell Automation integrated architecture with all Allen-Bradley controls has enabled King s Hawaiian Bakery s 150,000-square-foot Atlanta plant to deliver a high quality product while minimizing the learning curve for new employees due to a very user-friendly human machine interface (HMI). Plant workers use Rockwell Automation FactoryTalk VantagePoint to see production history as well as trends in production as they occur. If a piece of equipment is starting to fail, operators can identify the problem in advance and take corrective action. In another case, a Canadian water/wastewater operation with six treatment plants wanted to upgrade operations management by implementing a manufacturing intelligence strategy. The goals were to both reduce risk of downtime and optimize operations. The company s systems integrator, Grantek, provided a solution based on Rockwell Automation FactoryTalk VantagePoint software. The application provides visibility into production, putting all the company s historical production data into context through a Web-based reporting tool that gives users a comprehensive picture of factors contributing to operational performance. Because the FactoryTalk VantagePoint user experience is very intuitive, company operators can now access role appropriate information with a simple click-through on the Web-based system. While operators at one of the water/wastewater plants need specific production information to make fast decisions, a manager often is best served with a higher-level dashboard display that enables an assessment of the entire system with a quick glance. The result was that the water/wastewater operation s information gathering and reporting process was reduced from a four-day ordeal for two to four people to about half an hour for a single employee. The company estimates annual savings of 720 hours generating compliance and ad hoc reports. The Roadmap to The Connected Enterprise As connectivity becomes more ubiquitous and the Internet of Things becomes a reality for industry, manufacturers and industrial operators will adopt these new technologies in order to thrive in the new fully connected world. Achieving this level of connectivity requires forging a smooth bond between information technology and operations technology. Clearly, much work lies ahead for today s manufacturing enterprises. Only 5% of companies responding to the IndustryWeek survey say they are currently engaged in smart manufacturing initiatives defined as the integration of network-based data and information that provides realtime understanding and decision making. Nonetheless, manufacturers are intrigued by the promise of smart manufacturing, with 48% of companies either very interested or somewhat interested. Ensuring the readiness of the organization s IT infrastructure to benefit from IoT strategies is an essential first step to tapping the benefits of these new technologies. But few industrial organizations are fully ready to take advantage of the IoT promise in their operations. In the IndustryWeek survey of manufacturers, about half (47%) said their infrastructure was completely ready or somewhat ready to benefit from IoT strategies, while an equal number (47%) indicated that their infrastructure was not ready. Those asserting the greatest readiness (58%) not surprisingly were the large ($1 billion or more in sales) industrial companies. Toward this goal of infrastructure readiness, Rockwell Automation has developed The Connected Enterprise Execution Model: in effect, a roadmap for industrial companies seeking to bring their equipment and systems into the modern information-enabled world. Some key milestones on this journey include: Assess the organization s existing IT/OT network; 6

7 Secure and upgrade network and controls; Define and organize working data capital (WDC); Leverage the newfound IT/OT capabilities with analytics; and Utilize predictive capabilities to optimize operations and improve collaboration with suppliers and responsiveness to customers. Based on extensive experience with the five stages of The Connected Enterprise Execution Model, Rockwell Automation works with manufacturers and industrial organizations that are in advanced positions, as well as those at the beginning of their IT/OT intelligence journey. Industrial companies continue to further mesh operational data with business systems, as well as to make production information available to employees, suppliers, and customers over the Internet. Leveraging this higher level of manufacturing connectivity and data integration offers significant gains in productivity, efficiency and cost savings, while delivering far greater visibility into operations to the rest of the enterprise. At the same time, manufacturers must become more fully educated and aware of the need to adopt an enterprise-wide security strategy for securely connecting plant floor automation with the rest of the business. l Allen-Bradley, ControlLogix, Factory Talk and Factory Talk VantagePoint are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of the ODVA. Trademarks not belonging to Rockwell Automation are property of their respective companies. Investment Rising for Analytics, Remote Monitoring & Mobility In an effort to assess the degree of connectivity of plant automation as well as manufacturers interest in pursuing IoT strategies, Rockwell Automation worked with IndustryWeek magazine to survey the manufacturing community on these issues. Survey participants represent a broad crosssection of U.S. industrial firms, with all industries and manufacturing sectors represented, with the largest groups being automotive, industrial machinery, and aerospace & defense. All sizes of companies were represented, including about one third (31%) with sales of $1 billion or more, one fourth (24%) with sales of $100 million to $1 billion, and the remainder (45%) with sales under $100 million. Respondents were predominantly executive (25%) or managerial (45%), with about one-third working in operations/production, and another 22% in general management. In the January, 2015 survey of 581 executives, managers, and other employees at industrial companies, the larger enterprises had achieved a greater level of connectivity between the plant floor and their corporate-wide business systems. Almost half (48%) of larger firms had achieved plant to enterprise data integration compared to just 28% of the smaller companies. When asked about plans to invest in IoT technologies for plant floor operations, a majority of respondents said their companies are currently invested in, or plan to invest in data analytics (67%), remote monitoring (65%), and mobility (54%) over the next five years. Similarly, nearly half said their companies are either currently investing in, or plan to invest in cloud computing (48%) and big data (45%) over the next five years. Again, company size played a role in plans to invest in the new IoT strategies. For example, 78% of large manufacturing companies said they had current or future plans to invest in data analytics compared to 59% of small manufacturers. The disparity in spending plans was even greater for big data initiatives, with one out of three (32%) small firms planning to pursue this technology compared to three out of five (60%) of big firms. The technology expected to see the greatest growth in investment by manufacturers over the next three years is data analytics. Some 46% of manufacturers anticipate increasing their investment in analytics. Surprisingly, just 11% of respondents said their firms would increase spending on big data technologies during the same time. 45% 31% 24% sales of $1 billion or more sales of $100 million to $1 billion sales under $100 million Over the next five years, companies are currently invested in, or plan to invest in: data analytics - 67% remote monitoring - 65% mobility - 54% cloud computing - 48% big data - 45% Manufacturers with current or future plans to invest in data analytics: 78% 59% Large companies Small companies 7

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