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Industrial Automation and Modern Connectivity

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In an age when manufacturing is overrun with information, getting the right information to the right person at the right time is crucial. A new era of mobile devices has helped deliver the promise of greater productivity. With it comes the challenge of network security, achieving both is possible, as we’ll demonstrate.

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Industrial Automation and Modern Connectivity

  1. 1. Industrial Automation and Modern Connectivity
  2. 2. DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world 70+ employees & growing
  3. 3. Areas of Expertise
  4. 4. Presenter Info Matt Puskala Project Director, Sr. Management Technical: Factory Automation, PC, Web, and Database Applications B.S. in Electrical Engineering Kettering University (GMI) Joined DMC in 1999 Student co-op
  5. 5. Agenda 1. Modern Connectivity Overview 2. Three Modern Connectivity Stories a. Automotive Story b. Candy Story c. Integrator Story 3. Security – Quick Tips
  6. 6. Modern Connectivity: Definition Define “Modern Connectivity” in the context of Industrial Automation.
  7. 7. Modern Connectivity: Definition Traditional Automation Line Interface PLC Factory Equipment
  8. 8. Modern Connectivity: Definition Any time you are connecting the factory line to other networks to allow data transfer (input or output). • Internet • Intranet/Subnet
  9. 9. Modern Connectivity: Definition Any time you are connecting the factory line to other networks to allow data transfer (input or output). Connections To: • Servers and Databases • Enterprise Systems (MES, ERP) • Internet/Remote Access
  10. 10. Modern Connectivity – Why? Pros ? Cons Cost Complexity Security
  11. 11. Modern Connectivity – Why? 1: Optimize Production Identification of productivity loss. When? Tomorrow? Immediately?
  12. 12. Modern Connectivity – Why? 1: Optimize Production Improve your process. Data mining.
  13. 13. Modern Connectivity – Why? 2: Traceability FDA Regulations Recalls
  14. 14. Modern Connectivity – Why? 3: Convenience Remote Support Plant floor visibility at your desk
  15. 15. Modern Connectivity – Why? 4: Standardize and Control the System Inputs Recipe Management RECIPE Benefits: • Consistency and Quality • Reduce Product Change Over Time
  16. 16. Modern Connectivity  Definition?  Why?  Goal? Factory System Internet Intranet
  17. 17. Modern Connectivity - Goal Introduce new ideas or new ways of looking at old ideas to help you get the most out of Modern Connectivity with your Industrial Systems. Factory System Internet Intranet
  18. 18. Continuous Improvement
  19. 19. Continuous Improvement Solving Mysteries!! 1. Identify a big problem. 2. Find the Cause. 3. Find a Solution.
  20. 20. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Example
  21. 21. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Transfer Faults Transfer Faults (dropped parts)
  22. 22. Continuous Improvement - Solving Mysteries Mystery: Transfer Faults (Dropped Parts) Part A27: Smallest Diameter SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 273 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
  23. 23. Continuous Improvement - Solving Mysteries Mystery: Transfer Faults (Dropped Parts) Simple Solution: Improve the part transfer! SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
  24. 24. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Jammed Station 4 Jammed Stamping Press DAILY FAULT COUNTS Fault: Count: Transfer Fault 9 Press Jam Fault 132 Low Air Pressure Fault 7 E-Stop Fault 5
  25. 25. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Jammed Station 4 DAILY FAULT COUNTS Fault: Count: Transfer Fault 9 Press Jam Fault 0 Low Air Pressure Fault 7 E-Stop Fault 5 Add better part queuing.
  26. 26. Continuous Improvement - Solving Mysteries Simple Mysteries: • Problem -> Cause • Paper data collection by operators Complicated Mysteries?
  27. 27. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production
  28. 28. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production Cause?: • Particular Part • Particular Fault • No obvious pattern
  29. 29. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production Real Problem?: Inconsistent Data Tracking SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
  30. 30. Continuous Improvement – Solving Mysteries Improve Inconsistent Data Collection? Through Automation!: • Automated Data Collection • Automated Reporting
  31. 31. Continuous Improvement - Solving Mysteries Daily Emails of Reports to Engineers and Shift Supervisors SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
  32. 32. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production What was the cause? Unmasking the culprit
  33. 33. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Inconsistent Production Part Change Over Disabling presses. Reduction in throughput.
  34. 34. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production
  35. 35. Continuous Improvement - Solving Mysteries Automated Data Collection and Reporting • Consistent Quality Data • Visibility Technical Details?
  36. 36. Technical Details – FactoryTalk Metrics • Data Collection • Reporting • Preconfigured Reports and Wizards • Open System
  37. 37. Technical Details – FactoryTalk Metrics PLC 1 PLC 2 PLC 3 Reports
  38. 38. PLC 1 PLC 2 PLC 3 Reports Technical Details Part Number Fault Number Operator Good Part Rejected Part Rejection Cause Tags System State Part Created PLC 1 Running Faulted Setup (Change over) Test Mode Starved (Up Stream Problem) Blocked (Down Stream Problem)
  39. 39. Technical Details PLC 1 PLC 2 PLC 3
  40. 40. Technical Details Report Expert  Built in basic reports.  View Vabielew baby lWe beyb WBreobw Bsreor wser  Full Power of MS SQL Server SMT APd Svearnvceerd/Complex Reports
  41. 41. Automotive Story Recap! • Why? - Optimize Production • How? – FactoryTalk Metrics and Advanced Customizations • Automated Emailed Reports • Visibility!
  42. 42. Recipes produce variety on a single machine Recipes
  43. 43. Innovate
  44. 44. New Crossover Recipe: Global Implementation
  45. 45. Global Platform Variety 1998: USA Plant 1 2007: China Plant 2012: USA Plant 3 2010: India Plant 2002: USA Plant 2 2000 2005 2010
  46. 46. New Crossover Recipe: Global Implementation
  47. 47. Cost of Implementation? 5 Months $100,000+ Ready for the next new product? Better way?!!
  48. 48. A Better Way! • Single Website • Uniform Recipe Management System • Keep Existing Control Hardware and Software
  49. 49. New System Update Recipe? 1. Log In To the Website 2. Select Plant 3. Select Production Line 4. Select Existing Recipe and Edit OR Create New Recipe Technical Details?
  50. 50. Technical Details - Overview Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
  51. 51. Technical Details Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
  52. 52. Technical Details: Intranet Website DNN: a Content Management System (CMS) Built on the Microsoft Stack: • ASP.NET • SQL Server Database
  53. 53. Why Content Management System? Proven Pre-existing Functionality: • Security • User Management • Hundreds of Third Party Tools
  54. 54. Why Content Management System? • Easy to Add Pages and Features • Up and Running Fast
  55. 55. Technical Details Intranet Website Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service DNN Tables Custom Recipe Tables Custom Functionality
  56. 56. Technical Details Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
  57. 57. Interface 1 5.3 15.2 3.1 .2 .3 Technical Details PLC Legacy System Select Recipe: 1 Tags Recipe Number Sugar (kg) Gelatine (kg) Water (L) Flavor 1 (kg) Flavor 2 (kg)
  58. 58. Technical Details Interface PLC Select Recipe: New System 1 Tags Recipe Number Sugar (kg) Gelatine (kg) Water (L) Flavor 1 (kg) Flavor 2 (kg) 1 Custom Service 5.3 15.2 3.1 .2 .3
  59. 59. Technical Details Custom Service 5.3 15.2 3.1 .2 .3 1 PLC DNN Tables Custom Recipe Tables OPC Server USA Plant 1 USA Plant 3 India Plant
  60. 60. Technical Details OPC Server: • Standard: Support for 100s of Industrial Platforms • 1996 • OPC: “OLE for Process Control” • OPC: “Open Platform for Communications”
  61. 61. Candy Story Recap! • Why? • Standardize and Control the System Inputs • Convenience • How? – Cost-Effective Custom System • Flexible – Feed Multiple Platforms
  62. 62. Onsite Commissioning - Chemical
  63. 63. Onsite Commissioning - Chemical I/O Issues Interface Pump 1 System REV FWD Pump 5 REV
  64. 64. Onsite Commissioning - Chemical I/O Issues: • Hundreds of I/O Points • Trial and Error Debugging
  65. 65. Onsite Commissioning - Chemical Slow 2 Person Job Controls Pumps 100’
  66. 66. Onsite Commissioning - Chemical Days? WEEKS?
  67. 67. Onsite Commissioning - Chemical Simple Idea!
  68. 68. Onsite Commissioning - Chemical Controls Controls Pumps
  69. 69. Technical Details Interface System:  Pumps  Valves  Feedback PLCs Mobile Interface
  70. 70. Onsite Commissioning - Chemical
  71. 71. Onsite Commissioning - Chemical
  72. 72. Integrator Story Recap • Why? – Convenience • Remote Desktop Protocol – Simple and Cost Effective!
  73. 73. Security Considerations Security is Complicated 1. Three Quick Recommendations 2. Some Resources
  74. 74. Recommendation #1: Back Up Control Software • Any time any change is made! • Archive or software repository is best.
  75. 75. Recommendation #2: Isolate from Outside • Use VPN for External Access • Be wary of WiFi • Remove internet access all together?
  76. 76. Recommendation #3: Isolate from Inside • Consider using internal Subnets and Firewalls
  77. 77. Resources 1. Recommended Practices https://ics-cert.us-cert. gov/Recommended-Practices
  78. 78. Resources Recommended Best Practices “Improving Industrial Control Systems Cybersecurity with Defense-in-Depth Strategies” https://ics-cert.us-cert. gov/sites/default/files/recom mended_practices/Defense_in_De pth_Oct09.pdf
  79. 79. Resources 2. List of Vulnerabilities https://ics-cert.us-cert.gov/ics-archive/
  80. 80. Recap! Modern Connectivity and Industrial Automation: • Defined • Why? • Optimize Production • Traceability • Convenience • Standardize and Control the System Inputs Factory System Internet Intranet
  81. 81. Recap! Stories: Factory System Internet Intranet
  82. 82. Recap! Security Factory System Internet Intranet
  83. 83. Thank You!

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