Working with the Mainstay team, the Cisco IOT Manufacturing Marketing team combined research from manufacturing trade associations, management consulting research and an internal benchmarking project to create an Executive Briefing Presentation that would educate CxOs on the opportunities IOT can provide. This content was also repurposed to create a manufacturing IOT whitepaper to provide an asset to entice prospective customers to consider Cisco’s IOT offerings.

1. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 1
Discrete MFG IoT Factory of the Future
August 28, 2013

2. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 2

3. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 3
* “The Truth About Robotics White Paper,” Seegrid Corporation, Fall 2013
** “US Manufacturing Nears the Tpping Point: Which Industries, Why and How Much, BSG April 2013
*** “Manufacturing Moneyball: using big data and business intelligence to spur operational excellence”, Forbes 11,2011
**** From slide #77b – check sourrce
Robot
Advancements,
Additive
Printing
NPI
Convergence
Manufacturing
Onshoring
Plant
Flexibility
Manufacturing
Big Data
Converged
Plant Networks
Robot
Advancements,
Additive
Printing
Plant
Flexibility
Manufacturing
Onshoring
NPI
Convergence
Manufacturing
Big Data
Converged
Plant Networks
U.S. Competitive Drivers
Source: “The next big thing in Manufacturing? On-Shoring”,
Logistics Viewpoints; Michael Rackley, April 2013
Input
Costs
Natural Gas
75% Cheaper
Wage
Gap
Asian Wages
Increasing
15–20%/year
Productivity
U.S.
Productivity
Runs 3–3.5%
Higher
Supply Chain
Simplicity
Domestic
Production
Reduces
8 Weeks
of Inventory
Profit

4. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 4
Sensors Everywhere | Machine-to-Machine | Pervasive Intelligence | Automation
RobotsPersonal
Devices
Sensors Security
Devices
Real Time
Analytics
Ruggedized
Wireless AP
Industrial
Routers & Switches
Industrial
Security
Hardened Mobile M2M
Gateway
Access Points Designed
to Mobilize your Factory
Network Solutions That
Reduce Factory TCO &
Downtime
User & Control Level
Factory Security
Industrial Plug-n-Play
OT/IT Connectivity

5. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 5
Before
 $3B process/discreet Industrial Co
had neglected its US plants
 Heterogeneous PLC/Network
w/miles of blue hose & long
outages
 Quality issues (operator errors)
from paper-based work orders
 Plant security vulnerabilities were
a board level concern
Solution
 Standardized on converged Cisco
and Rockwell network and PLCs
– VLANs ( physical segregation)
– Managed switches
– Cisco Firewalls
US Plant
Average OEE
2011 2012
50%
Improvement
Results
US Plant Ave Line
Mean Time to Fix
2011 2012
Hours/Days
to <30 Mins
After
 Quality Increase:
– Production and order
integration via SAP and PLC
integration
– Electronic Customer orders on
HMI
 Reduced Safety Downtime: Cut
machine vs. whole line (keeping
boilers warm etc…)
 Reduced Electrical Downtime:
Instantly locate problem vs.
searching hours or days (i.e.
grounds)
 Now investing in US plants:
Viewed as strategic investment

6. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 6
Automation Robots Flexibility Wireless

7. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 7

8. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 8
Physically Segmented Network Converged Plant Network
Air Gapped Plant Security Plant & Controls Level Security
Resource Constraints Resource Mobility/Productivity
Trapped & Siloed Data Real-time, Big Data
Mfg Operational Silo Mfg linked w/SC, R&D, Sales
Plant in Isolation Virtualized Production
Factory Today Factory of the Future
• TCO savings
• Downtime reduction
• Production flexibility
• Risk Mitigation
• IP theft
• OT to IT damage
• Plant downtime
• Plant OEE increase
• Plant cost reduction
(energy, inventories,
maintenance)
• Operator productivity
• Flexible manufacturing
• OEE – Fast Response

9. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 9
• Industrial Plug-n-Play OT/IT
Connectivity creates access to
the universe of factory data
• User & Control Level Factory
Security to ensure protection
from IP theft and malicious
attacks
• Wireless Access Points
that mobilize access to data,
adding productivity to the
factory workforce
• Network solutions that
reduce factory IT TCO while
simplifying the integration of
the factory to the corporate
systems
Resiliency
Flexible
Production
Visual
Factory
Visibility Manageability SpeedAutomation
New
Services
Open
Port
Remote
Access
MalwareProximalPhysical
Mobile
Control Room
Remote
Access
Wireless
Machines
Mobile Task
Management
Guest Worker
Access
Virtualized
Production
Real-time
Supply Chain
Energy
Management
Traceability
ERP/MES/P
LC
Integration
Predictive
Maintenance
Collaboration
in Factory
Apps

10. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 10
Gbps Link for
Failover
Detection
Firewa
ll
(Activ
e)
Firewall
(Standb
y)
Layer
3
Route
r
Layer 3
Switch
Stack
Layer 2 Switch
Driv
e
Controlle
r
Controlle
r
Driv
eHMI
Controlle
r
Driv
e
HM
I
Distributed
I/O Distributed
I/O
Level 0–2
H
MI
Cell/Area #1
(Redundant Star Topology)
Cell/Area #2
(Ring Topology)
Cell/Area #3
(Bus/Star Topology)
Cell/Area Zone
Manufacturing Zone
Level 3
Demilitarized Zone (DMZ)
Demilitarized Zone (DMZ)
Enterprise Zone
Levels 4 and 5
Windows 2003 Servers
• Remote desktop connection
• VPN
FactoryTalk Application Servers
• View
• Historian
• AssetCentre
• Transaction Manager
FactoryTalk Services
Platform
• Directory
• Security
Data Servers
Flexibly Meeting
Demand Shifts
Enterprise
Ethernet
Proprie
tary
Ethern
et
To next
machine
I/O FieldbusMotion Net
Safety Net
STAR
FIBER
RING
DAISY
CHAIN
TRUNK/DROP
Multiple segmented plant networks
(up to 6!)
• Excessive cabling
• Data integration complexity
• Data routing limitations (not real-time)
• Multiple data directories
• Multiple topology rules, protocols,
configs
Increased Line
Uptime
Reduced Network
IT TCO by 18%
“I need a flat network so I can
save money and get big data
from machines without having
to reprogram every PLC.”
With Cisco Reliably Converge
Network with managed switches
that offer:
- Quality of Service (QOS)
- VLAN vs. physical segments
- Storm control
- IGMP, NAT, DHCP, POE, etc.
- Configuration Smart Ports
- MAC ID Port Security
- IEEE 802.1x Security
- Rockwell/Cisco validated design

11. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 11
Resiliency
Flexible
Production
SpeedAutomation
Visual
Factory
Video
Collaboration
1
• High speed
• Lower
latency
and jitter
• QOS
Automation
2
• Flexibly shift
sequencing and
inputs vs. hard
coding
• Change
production recipes
from managers
office at click
of a button
• Enable new
product
innovation
Flexible
Production
4
• Provide next-
generation,
omni-channel
customer experience
seamlessly across all
channels
• Develop fully
interactive, secure,
and automated
banking tech
Visual
FactoryVisibility ManageabilityManageabilityVisibility
“We reduced line
downtime from
hours to minutes”
Plant Engineer
3
• Greater visibility and
manageability (“we’re
flying blind today”)
• In operator tools for
quick response
• Granular control over
shut-downs
• Resiliency and faster
recovery (REP)
Resiliency
6
• Mobility
• Visualization
• Machine monitoring
• Physical security
New
Services
5
• Ethernet speeds
new line set up
(e.g., ebugging 10
stations with 12
robots takes 2 days
vs. 1–2 weeks)
• Collaborate between
plant and R&D to
speed NPI and ECNs
Speed

12. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 12
Harley-Davidson’s smart factory uses Cisco’s
industrial Ethernet, wireless networks, and integrated
video/digital signage to produce multiple models on
same assembly floor while improving worker training Stakeholders view/make decisions
based on what’s happening on
factory floor
New processes enable centralized
location-driven “ubiquitous display”
Digital media content creates
world-class “visual factory”
Video monitors relay real-time
visual information to key
stakeholders
People Machine People

13. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 13
Use Case 1: Converged Plantwide Ethernet TCO Comparison
Fieldbus /
Profibus (Serial)
Ethernet
(Unconverged)
Ethernet
(Converged)
Example Automation Cell Components
Each Robot: 1 controller interface (1 port) 1,000$ 1,100$ 10$
Profibus IP Interface Card
1 IO interface (8 ports) 2,000 2,400 2,400
Coper wiring IO to sensors/cameras/actuators 400 360 360
1 safety IO (8 ports?) 1,000 - -
6 Tecnology modules (drives, timers, etc…) 3,000 1,500 1,500
Stratix managed switch 400 600
Cables modules to switch (with no DLR) 750 1,350 1,350
With Resiliance
ETAPs
Cables from switch to PLC 150 135 135
PLC IO cards 2,100 2,200 1,100
Cost per Robot 10,400$ 9,445$ 7,455$
Number of Robots 8 8 8
Total Cost of Robots for Example Cell: 83,200$ 75,560$ 59,640$
Each End Affector: 1 control IO -$ -$ -$
1 diagnostic IO 2,000 2,400 2,400
1 safety IO - - -
Cables from robot to PLC - - -
PLC IO cards - - -
Cost per End Affector 2,000$ 2,400$ 2,400$
Number of End Affectors 8 8 8
Total Cost of End Affectors for Example Cell: 16,000$ 19,200$ 19,200$
Machine conveyers, sensors, etc.. (assume using DLR topology to reduce wiring & IO cards)
Ports in machine 50 50 50
Cable ringing devices, IO, PLC, Switch 2,500$ 2,250$ 2,250$
Copper cable from devices to IO 1250 1250 1250
# of ETAPs at device level 0 0 0
# of IO blocks 8 8 8
Switch (assume IP67 switch) 1000 2000
Interface cards 3100 2200 1650
Box, connectors, enclosures (assume IP67 switch)
IO blocks cost 3200 3520 3520
Total Cost of machine (non-Robot) for example cell 10,050$ 9,220$ 8,670$
Control/supervisor level switching
# of switch ports needed
Switch -$ 1,000$ 1,800$
Switch ETAP 250 250
Cabling to Aggregation Level Switches 2500 2500 2500
Extra switch/hub to reach aggregation switch 250 250 250
Total Cost of Control/supervisor level switching for cell 2,750$ 4,000$ 4,800$
Transition to IT
Aggregation level switching and security from cells with Robots
Aggregation level switches (e.g., 3750s) 192,500$ 192,500$ 192,500$
Firewalls (2 at plant level 3) 20000 20000 20000
Security policy and identity managers 40000 40000 40000
Cabling to MES/Historian systems 1000 1000 1000
Total Cost of Aggregation level switching and security for cell 1,014$ 1,014$ 1,014$
Total Network Related Hardware Cost for Example Cell 113,014$ 108,994$ 93,324$
Managed
-3%
Auto Converged Platform TCO Analysis
• Resiliency
• Management
• Big Data
• Low Cost
WEAK
WEAK
WEAK
WEAK
WEAK
WEAK
MEDIUM
WEAK
STRONG
STRONG
MEDIUM
WEAK
STRONG
STRONG
STRONG
STRONG
Plus better performance with converged network
(1 IO per PLC with vLANs)
EQUIPMENTCOSTS(inmillions)
Profibus
(Serial)
25
20
15
10
5
0 Ethernet
(Unconverged,
Unmanaged)
Ethernet
(Unconverged,
Managed)
Ethernet
(Converged)
$22.6 $21.8 $22.3
$18.7
Example of Auto plant with 200 robotics cells – Lower Cost

14. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 14
Reduce HW cost (3 switches to 1)
Shrink cabinets
Reduce wiring
Reduce design cost
Reduce points of failure and
unmanaged switch ports (E-tap)

15. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 15
 Removable SD card stores config for quick,
plug & play replacement by anyone
 Install and configure in Logix
Product
Installation and
Replacement
Diagnosis and
Troubleshooting
Management
 Resiliency protocols (REP <50 msec
recovery) avoiding application time out
downtime
 Rapid debug and troubleshooting with
managed switches
- CIP in switches enables network visibility
and mgmt in Rockwell apps
- Predefined Logix tags
Help
Alarms
Configuration
Status
Trending
 Coming: Integration w/ Rockwell Asset Center.
See and recover from undesired config changes
- Manage switch configs in same tool as other
machines and& devices on line
- See changes, see histories, back-up

16. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 16
• New class of industrial focused security solutions
- Identity and Policy
• Centrally managed
• Enforced at switch and AP level
- Coming: In-line protection of critical
machines via deep packet inspection of
application traffic
• Today’s control’s environments have “soft middles”
• Increasing trend of disrupting critical infra controls
- Stuxnet: Siemens Controls (via USB)
- Shamoon: Schneider (Telnet) client
- Others: Flame, Duqu ,etc.
• Today’s solutions not geared to protect against
threats like APTs

17. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 17
2012 Industry Cyber Attacks
(Percent of Total Attacks)
Source: Internet Security Threat Report – 2013;
Symantec Corporation, April 2013
PERCENTAGE OF TOTAL ATTACKS
0% 10% 20% 30%
Energy
Government
Sevices
Finance
Manufacturing
• #1 attacked
industry —
24% of total
• 2x increase
against critical
infrastructure
• 32% increase
for MFG in last
6 months
Intrusion Protection
Detection & Response
Remote Access
Firewall & VPN
Content Security
SPAM/ Web Filtering
Endpoint Security
Host IPS/AV Solutions
Network-
Attached
Device
Nexus® 7000
Switch
802.1X
Protected
Resources
IP Phones
Supplicant
Cisco®
Catalyst®
Switch
Users,
Endpoints
Campus
Network
Guest User
ISE
• Growing business risk
• Stolen IP (e.g., car design)
• Downed production
(RasGas)
• OT attack spread to IT
(Aramco 30,000 PCs)
• Defense in depth with:
• ISE Policy
• Switch enforcement
• Central management of ACLs
• Strong security across IT & OT

18. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 18
Manufacturing
Device,
Managed Asset
Security
Camera G/W
Agentless Asset
MAC: F5 AB 8B
65 00 D4
Francois Didier
Corporate
Headquarters—
Remote Access
6:00 PM
Group:
Manuf
Group:
Facility
Group:
Guest
Time and Date
Posture
Location
Device Type
Access Type
Broad Access
Limited Access
Guest/Internet
Quarantine
Deny Access
Track Activity for
Compliance

19. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 19
Key Characteristics:
 Ruggedized, DIN-Rail platform
 FW, VPN, Application whitelisting, and
DPI for Industrial Protocols
 Ease of use — zero-touch deployment
 By-pass (bump in the wire) and reliability
 Security Information & Event Management
(SIEM) integration (e.g., Prism and SIO)
 Policy Management integration

20. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 20
• Have to walk down line to see machine status
• Manual, paper-based warehouse processes
• Security concerns with wireless guest access
• Plant downtime from line set up changes taking longer
due to needing to rewire
• Empower plant workers with mobile controls access
• Automate warehouse processes with mobility
• Drive integrated wireline and wireless security
• Wireless machines for next gen manufacturing flexibility

21. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 21
Maximizing Workforce Productivity
(Mfg Labor Output vs. Compensation)
• Manufacturing labor productivity continues to grow to
an all time high as compensation hits a record level
• Manufacturers must continue to find ways to increase
the productivity of these resources as they hit limits
under legacy factory processes
*Bureau of Labor Statistics, “Economic News Release - 3/2012; Appendix Table 4. Durable MFG sector:
Productivity, hourly compensation, and unit labor costs
80
85
90
95
100
105
110
115
120
1 2 3 4 5 6 7 8 9 10
Converged Plant Wireless Impact
Improved
Uptime
Productivity:
Save 10%-40%
Mobile Voice
Cost Savings
Labor output
per hour
Labor
compensation
Managers are confined to control room;
engineers need to make trips to/from
office for equipment/communications
Today’s
Plant
There is a free flow of people and
resources across all areas of the plant
Converged
Plant

22. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 22
Source: Cisco® Customer Business Transformation Group
Metals and Mining
Major Use Case
1
• Smelter operator needs to check
process data to make adjustments
• Makes process change accurately
and rapidly via mobile device
32
• Pulls up critical production data on
hardened PDA
• Calls operator in another location to
discuss change using soft-phone on PDA
Source: Cisco® Customer Business Transformation Group
Business Value
• Eliminated three to four wasted hours walking to control room per shift per operator
• >80% faster operator decision making
• 50% reduction of physical control rooms

23. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 23
• Operator able to see virtual
HMI on iPad without having
to walk down the line
• Can locate trouble spot with
more granularity saving
potentially hours in searching
(e.g., “which of 50 grounds”)
Event
Occurs:
ALARM
Control
Room
Mobility
NOC
HQ
R&D
Contractor
SME

24. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 24
Source: Motorola

25. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 25
Cell / Area Zone Level 0 – 2
Drive
HMI
Cisco IE Cell/Area #
(Ring Topology)
Controller
Discrete M. Wireline Access Configs
Introduced w. CISS Rel.1.5
Cell/Area #1
(Redundant Star Topology)
Drive
Controller
HMI Distributed
I/O
Controller
Drive
HMI
Distributed
I/O
Cell/Area #
(Linear Topology)
Drive
HMI
STRATIX Cell/Area #
(Ring Topology)
Layer 2
Access Switch
with
Resilient Ethernet
Protocol
Controller
Discrete Mfg. Wireline Access Hardened WiFi Factory
& Wireless sensors Ntwk.
Enterprise Zone Level 4 - 5
Manufacturing Zone Level 3
Manufacturing Di-Militarized Zone
Catalyst 3750-X
Catalyst
4500/6500
Enterprise / Campus Core
Patch Management
Terminal Services
Data Share
Application Server
AV Server
ASA 55xx-X
(Active)
ASA 55xx-X
(Standby)
Real–Time Control
Fast Convergence
Traffic Segmentation and Management
Ease of Use
Site Operations and Control
Multi-Service Networks
Network and Security Management
Routing
Application and Data share
Access Control
Threat Protection
Enterprise/IT Integration
Collaboration
Wireless
Application Optimization
• Wide Area Network (WAN)
• Physical or Virtualized Servers
• ERP, Email
• Active Directory (AD), AAA – Radius
• Call Manager, etc.
Plant Firewalls:
• Inter-zone traffic segmentation
• ACLs, IPS and IDS
• VPN Services
• Portal and Terminal Server proxy
Web DNS FTP
Catalyst
Switch Internet
Layer 2
Access Switch
with
Resilient Ethernet
Protocol
Cisco
5500 WLC
Cisco
WLC
Anchor
Cisco
WLC
SiSi SiSi
Future Release
Future
Release
Future Release
Discrete M. Wireless
Access Opt. & Adv. Security
Asset Management
HMI Server
Manufacturing Execution
Historian
Cisco Prime
Network Services
Remote Access Server
ISE 34xx
Catalyst
2960-X
Catalyst
2960-X
Catalyst
2960-X
Catalyst
2960-X
IE2000

26. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 26
• Real time visibility into machine level performance
(“what is happening in the plants now”)
• Enable move to build to order versus build to stock
production models (real time flexibility, ATP)
• Automated and Proactive Maintenance can impact
factory profitability by as much as 30%
• Only 19% of manufacturers state they have an effective link
between plant and business KPIs*
• Only 4% of factories in the machine tool industry monitor
their equipment*
• High machine unplanned downtime and maintenance cost
from “blind” fixed schedule maintenance
*IDC Manufacturing Insights 2012; N=83

27. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 27
Converged Plant Operations Impact
Reduced
Energy
Use
Today’s Plant Converged Plant
Reduced
Maintenance
Cycles
Order to
Production
10% DSOs
NPI Cycle
Time
20-50%
Source: IDC Manufacturing Insights 2012. N=81
Make to order
Make to stock
Engineering to order
Assembly to order/Build to order
100%
90%
80%
70%
60%
50%
40%
30%
20%
10%
0%
21%
39%
29%
11%
9%
34%
35%
22%
Today 5 Years
JourneytowardMake-to-Individual

28. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 28
Alarm alerts operator of peak
load utility penalties threshold
Checks MES real time prod
vs. plan & energy threshold
Reduces variable speed drive
to avoid peak
Operator checks co-gen capacity
Raises output to avoid peak load
Real-time gap visibility –
adjusts supply chain,
MRP, and factory build
plan to shift prod to
plant with capacity w/o
impacting ATP or
inventory
Leverage Cisco
collaboration tools to
quickly decide and act
cross silo
Business Value
Plant Productivity: Reduce energy costs (typical first year -— 20% with new
Software/Devices/Ethernet NW)
Challenge
Real time operator decision making tools across multiple variables, applications, and sites in a
complex supply chain (many factors to simultaneously consider)

29. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 29
Challenge
• Manual sales processes delayed order to prod
response and was prone to manual errors
• Orders are passed to inside sales person creating
transcription issues, dirty orders, and 4-day delay in order
processing time
• Lack of visibility to order details at customer site
• No access to configurator, order promise, status of existing
orders all limit ability to close business
Solution
• Fully integrated process from Opportunity to
ATP to Order to Plant Floor Production
• SFDC integrated with Oracle EBS, configurator and plant
floor visibility via plant floor Andon screen
• Eliminates order entry errors, reduces order processing
time, electronic order is immediately confirmed with ATP
engine and visible at plant floor
Sales:
Remotely track orders
from opportunity to
configuration to ATP to
order status
Inside Sales:
Eliminates manual order
entry - focus on new
business creation
Factory:
Real-time order
visibility; reduce dirty
orders; electronic
orders
Management:
Real-time reporting
of sales, order and
production performance
Results
• $3M in annual sales
increase
• DSO reduction of 2%
• 75% reduction in Order
Entry Cycle Time
• Reduced dirty orders
reduced
• Improved NetPromoter
Scores
• 6 FTE inside sales
productivity gain

30. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 30
Device
Network PLC
MES/S
cada
Historian DMZ ERP
Data
Velocity:
Data
Quality:
Data
Security:
Real Time (<1 second roundtrip) Push every 2 to 9 Hours
Nightl
y?
Today
up/down data
flow not real
time:
??
Auto-
configuring of
tags and
profiles
Open,
unmanaged
ports. USB
ports ???
No network
visibility or
resiliency
(reducing
data quality)
PLC
backplane
limits real
time pass
through
(“every 9
hours”)
Vulnerabilitie
s to man in
middle, USB,
PC, HMI
client attacks
Segmented
physical
networks
required hard
coded
mappings
Segmented
physical
networks
required hard
coded
mappings
Vulnerabilitie
s to man in
middle, USB,
PC, HMI
client attacks
Segmented
physical
networks limit
data
availability
and quality
Batch
updates to
send
upstream
every 20 to
30 minutes??
??
Segmented
physical
networks limit
data
availability
and quality
No security or
block all but
limited data
feeds
No security or
block all but
limited data
feeds
No security or
block all but
limited data
feeds
Not real time
Poor data
quality from
plant & lack
of device
taxonomy
Devic
e Network PLC
MES/
Scada
Historia
n DMZ ERP
Data
Velocity:
Data
Quality:
Data
Security:
Real Time (<1 second
roundtrip)
X seconds?
X
secon
ds?
X
secon
ds?
Today
up/down
data flow
not real
time:
??
Auto-
configurin
g of tags
and
profiles
Still need
integrated
controls
security
Full
visibility
and
resiliency
protocols
VLAN 1
stop
routing by
passes
any
bottleneck
s??
Still need
integrated
controls
security
Converge
d Plant
NWs
Less hard
coded
integration
s than
with
segmente
d NWs
Less
integration
than with
segmente
d physical
networks
Batch
updates
to send
upstream
every 20
to 30
minutes??
??
Less
integration
s than
with
segmente
d physical
NWs
Policy,
identity,
easier
central
managem
ent
Policy,
identity,
easier
central
managem
ent
Policy,
identity,
easier
central
managem
ent
Memory
resident
real time
processin
g
Large SI
integration
and data
clean up
work still
needed
• Batch applications can delay MFG visibility for hours
• Segmented physical networks require mappings and
hard-coded integrations
• Significant security risk (e.g., man in the middle,
DMZ vulnerabilities)
• Limited visibility to data flow/availability
• Converged network simplifies data path
• Integrated management provides real time
data flow visibility
• Single, unified architecture creates near real-time
visibility to MFG performance
• Joint architecture addresses security risks and
removes barriers

31. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 31
 Integrates different sources of real
time data all the way to sensors in
the end machine
 Used by both machine manufacturer
and operator
 See source of problems real time to:
– Lower costs (e.g., dispatch technicians
with spare parts needed)
– Get more efficiency (e.g., reduce “hard”
downtime)
SAP is a leader in big data and real time analytics with HANA
Cisco is working with SAP to enable better quality and quantity of data to allow faster reaction and better decisions
SAP Windpower Video

32. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 32

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Unmanaged,
Unconverged
Ethernet
Converged
Plantwide
Network
Multi-Service
Platform
Step 1
Step 2
Step 3
Starting
Point:
- Fieldbus
- Proprietary
- Serial
• Real time
distributed
control
• Resiliency
• Richer sensor
data
• Converge
separate
physical
networks with
managed
switches
• OT Ethernet Upgrade — line
equipment moves to Ethernet to
reduce TCO and add flexibility
• Converge OT/IT Networks to further
reduce plant TCO, unlock big data
• Factory of the Future — virtualized
production, real-time IT/OT
monitor/management
• Manufacturing Strategy
• Business Case
• Proof of Concepts / Showcases
• Plant Architecture Design
• Implementation
• Controls security
• Control Room
Mobility
• Video &
Collaboration
• Remote Monitoring
& Control
• CLOUD, FOG
• Software Defined
Plant Networking

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Lifecycle
Services
Industry-Leading
Partners
Business Risks
Reduced
Faster Deployment,
Better ROI
Q. Top barriers to implement your factory of
the future strategy
Source: IDC Manufacturing Insights 2012. N=81
PERCENTAGE OF COMPANIES
Processes not
consistent across
multiple sites
Low maturity/lack of
production technology
Change management
Finding skilled people
No factory of future
strategy
Difficulty
in demonstrating
ROI / Cost
74%
73%
73%
71%
61%
58%

35. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 35
Best of Both Worlds to Change the Industry
Best of Cisco
 Cisco IOS™
 Catalyst™ switch architecture and feature set
 CLI and Device Manager
 Secure integration with enterprise network
Best of Rockwell Automation
 Common Industrial Protocol (CIP) interface to Rockwell Automation Integrated
Architecture™
 RSLogix 5000™ for configuration via Add-on Profile (AOP)
 Predefined logic tags for diagnostics
 FactoryTalk™ view faceplates
Best for the Plant Floor
 Compact flash for “zero-config” replacement
 Industrial environmental ratings
 Default configurations for Industrial Automation
 Easy to maintain
A Unique Product in the
Market…
…Integrating the
Enterprise and
Manufacturing
Environments

36. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 36
Discovery Workshop
with OT and IT
• Business challenges
• Best practice
sharing
• Use case
brainstorming and
prioritization
• Run POCs in a
Showcase
manufacturing facility
to prove the value and
technology
• Document future state
architecture (e.g., 3 to 5
years out), gaps with today,
change management, and
phased plan to get there
• Quantification of top
value opportunities
for senior
management (TCO,
OEE, and overall
benefit models)
POC Design
TCO or OEE Opportunity
Quantification
End State Architecture
Assessment