Shared Infrastructure: What and Where is Collaboration Needed to Build the SM Platform?

Smart Manufacturing Forum Shared Infrastructure: What and Where is Collaboration Needed to Build the SM Platform? 10:45-11:45am panel discussion Moderator: John Bernaden, Vice Chair, Smart Manufacturing Leadership Coalition Panelists: John Dyck, Business Development Manager, Rockwell Software Jim Porter, DuPont (retired VP Global Engineering) Kevin Sullivan, Director, Industrial & Diversified Manufacturing Practice of the Cisco Internet Business Solutions Group Michael Yost, President, Manufacturing Enterprise Solutions Association Copyright 2011 Rockwell Automation, Inc. All rights reserved. 1

The Business Case and Big Benefits Plant-wide Industrial Automation and Process Control (IAPC) network convergence can drive a company s competitiveness by enabling strategic business decisions backed by real-time production data Provide better visibility into the plant floor to optimize supply chains Shorten lead times for bringing new product production up-to-speed Mitigate risks by improving production uptime and safety with a defense-in-depth approach for critical manufacturing assets. Lower totals costs through increased common or standard IT tools, technologies and training capabilities for engineers, operators and maintenance personnel Unleash a viral surge of often unexpected innovation and productivity tools for industrial applications and workflow process improvements via future access to a Smart Manufacturing platform and App Store Copyright 2011 Rockwell Automation, Inc. All rights reserved. 2

Plant-wide integration of all data In the first phase, Smart Manufacturers need to interconnect and better harmonize individual stages of manufacturing production to advance plant-wide efficiency. A typical manufacturing plant uses a myriad of information technology such as digital sensors, intelligent motors, computerized machines, robotics, programmable controls and other technology to manage each specific stage or operation of a manufacturing process. These complex manufacturing systems are increasingly generating millions of bits of data accessed by a growing array of devices. Typically today, each is an island of efficiency. Smart manufacturers will integrate these islands, enabling data sharing throughout the plant. An integrated IT Reference Architecture is the foundation for control and information solutions that enable operators to business managers instant access to plant data no matter where they are. Copyright 2011 Rockwell Automation, Inc. All rights reserved. 4

Plant-wide connectivity creates Big Data President Obama said the U.S. should develop a Smart Manufacturing infrastructure and approaches that let operators make real-time use of Big Data. from fully-instrumented plants in order to improve productivity, optimize supply chains, and improve energy, water and materials use. Copyright 2009 Rockwell Automation, Inc. All rights reserved. 5 5

Reference Architecture Considerations Integrated Plant-wide Industrial Network Challenges Industrial production characteristics Interconnectivity and interoperability Real-time communication, determinism, and performance Availability CyberSecurity Manageability Scalability Manufacturing partners, machine builders, and system integrators Open Architecture interface to Platform - at what level? Cell/line controllers, plant production center or enterprise systems Panel Discuss on Phase One Copyright 2011 Rockwell Automation, Inc. All rights reserved. 6

Phase 2: Manufacturing Intelligence Manufacturing Intelligence software meshes together factory-floor data for operations, reports, and passing data to other systems Copyright 2009 Rockwell Automation, Inc. All rights reserved. 7 7

SM Vision: Develop an Industrial App Store Performance Management Data & Modeling Workflow Phase 1 Phase 2 Management Dashboard Integrated Architecture Data Collection Manufacturer Manufacturing Data Warehouse Manufacturing Intelligence Software Local/Global Integrated Productivity Metric Dash Board Encrypted links Data Validation App Smart Manufacturing App Store Real-time Action & Risk Support App EPM App from Toolkit Linked Apps to Form Function Risk Scenarios App Reduced Order Model Scenarios App

Multiple levels of Manufacturing Intelligence Customer Demand Manufacturing Intelligence Automatic Machine Diagnostics & Maintenance Supply Chain Visibility Flexible Production Manufacturing Intelligence Manufacturing intelligence transforms data into actions & knowledge 9 (Confidential For Internal Use Only) Copyright 2010 Rockwell Automation, Inc. All rights reserved. 9

Manufacturing Intelligence Issues Open Architecture interface to Platform - at what level? Cell/line controllers, plant production center or enterprise systems Manufacturer driven vs. Technology vendor driven standards? What standards? ANSI, IEC, OPC, ODVA, others? Other Challenges / steps to achieving that vision: Lack of skilled workers ROI / Cost considerations for these major investments International organizations Is there a burning platform or an urgent threat? Lack of leadership by CEOs, government or a voice of Manufacturing Failed U.S. Manufacturing Enterprise Integration Act of 2002 Panel Discussion on Phase Two Copyright 2011 Rockwell Automation, Inc. All rights reserved. 10

Phase 3: Optimizing Manufacturing Intelligence High Performance Computing Data mining / informatics Advanced process models / simulation Secure Ethernet Gateway Internet 2.0 Model - predictive control Advanced Manufacturing Big Data Measurement / Sensing / Metrology High speed data collection Copyright 2011 Rockwell Automation, Inc. All rights reserved. 11

An Example: Industrial Energy Management Internal: Machine / process level energy sensing, measurement, analysis, optimization, control External: Enhanced T&D system load balancing with real-time info from major industrial users Transform factories from passive to active energy management Copyright 2009 Rockwell Automation, Inc. All rights reserved. 12