This document provides an overview of industrial automation and modern connectivity. It discusses how connecting factory equipment to other networks allows data transfer and optimization of production processes. Three case studies are presented: an automotive story demonstrating automated data collection and reporting; a candy production story showing standardized recipe management across global plants; and an integrator story using remote desktop support. Basic security recommendations are provided, such as backing up software, network isolation, and using recommended practices guides.
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. Agenda
1. Modern Connectivity Overview
2. Three Modern Connectivity Stories
a. Automotive Story
b. Candy Story
c. Integrator Story
3. Security – Quick Tips
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. 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
14. Modern Connectivity – Why?
3: Convenience
Remote Support
Plant floor visibility at your desk
15. Modern Connectivity – Why?
4: Standardize and Control the System Inputs
Recipe Management
RECIPE
Benefits:
• Consistency and Quality
• Reduce Product Change Over Time
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
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
Example
22. 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)
23. 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
24. 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
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
Jammed Stamping
Press
DAILY FAULT COUNTS
Fault: Count:
Transfer Fault 9
Press Jam Fault 132
Low Air Pressure Fault 7
E-Stop Fault 5
26. 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.
27. Continuous Improvement - Solving Mysteries
Simple Mysteries:
• Problem -> Cause
• Paper data collection by operators
Complicated Mysteries?
29. Continuous Improvement - Solving Mysteries
Challenging Mystery: Inconsistent Production
Cause?:
• Particular Part
• Particular Fault
• No obvious pattern
30. 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
31. Continuous Improvement – Solving Mysteries
Improve Inconsistent Data Collection?
Through Automation!:
• Automated Data Collection
• Automated Reporting
32. 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
33. Continuous Improvement - Solving Mysteries
Challenging Mystery: Inconsistent Production
What was the cause?
Unmasking the culprit
34. 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.
39. 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)
41. Technical Details
Report Expert
Built in basic reports.
View Vabielew baby lWe beyb WBreobw Bsreor wser
Full Power of MS SQL Server
SMT APd Svearnvceerd/Complex Reports
42. Automotive Story Recap!
• Why? - Optimize Production
• How? – FactoryTalk Metrics and
Advanced Customizations
• Automated Emailed Reports
• Visibility!
50. A Better Way!
• Single Website
• Uniform Recipe Management System
• Keep Existing Control Hardware and Software
51. 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?
52. Technical Details - Overview
Intranet
Website
USA Plant 1
USA Plant 3
India Plant
Custom
Service
60. 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
61. 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
62. Technical Details
OPC Server:
• Standard: Support for 100s of
Industrial Platforms
• 1996
• OPC: “OLE for Process Control”
• OPC: “Open Platform for
Communications”
63. Candy Story Recap!
• Why?
• Standardize and Control
the System Inputs
• Convenience
• How? – Cost-Effective Custom System
• Flexible – Feed Multiple Platforms
84. 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
85. Resources
2. List of Vulnerabilities
https://ics-cert.us-cert.gov/ics-archive/
86. Recap!
Modern Connectivity and Industrial
Automation:
• Defined
• Why?
• Optimize Production
• Traceability
• Convenience
• Standardize and Control the
System Inputs
Factory
System
Internet
Intranet
Thank you all for coming to the IMTS show and coming to these presentations!
Introduce myself.
I work for a company called DMC.
Industrial Automation and Modern Connectivity
We are an engineering solutions company that focuses on software.
We’ve been around since 1996,
Growing! In addition to Chicago
Boston
Denver
We typically break the work we do into 4 areas.
We work in a lot of different fields, but more than 60%+ of our business is in Factory Automation and Integration.
PLCs, Servos and Motor Control, Robotics.
We also do a lot of custom software development for PCs, for the web, for databases.
Today I’m talking about Modern Connectivity so we really are talking about the intersections of these worlds.
Kettering University – formerly General Motors Institute.
It’s a Co-op school!
So I joined DMC as a Senior in College, basically as a co-op or an intern.
I’m part of our Senior Management
Overview – frame the discussion
Stories – what they did, and why.
TECHNICAL DETAILS!
Security – hot issue!
Before we get started, we need to define what we are talking about.
Look at traditional factory line:
Interface connected to the PLC which controls the entire system.
And that’s it.
Island – not connected to anything else.
What are we connecting to?
Why add modern connectivity to our factory system?
We want to make sure it makes sense. Nothing is free and there are always costs.
Reason 1!
Optimize your production
If I tweak the temperature or tweak the recipe, what happens?
Traceability – knowing where your product came from.
“I hope to introduce some new ideas or some new ways of looking at old ideas to help you get the most out of Modern Connectivity.”
A good friend of mine works for the automotive industry. He’s an engineer at a supplier.
Every Monday morning he has a continuous improvement meeting. He’s responsible for his set of machines that produce automotive parts and making sure they are running at optimal performance.
Every Monday morning he has a continuous improvement meeting. He’s responsible for his set of machines that produce automotive parts and making sure they are running at optimal performance.
For some quick examples.
This is a machine where parts travel along a conveyor,
Some stamping and inspections are done.
Now the press station over here takes a lot longer (bottleneck) so there are more of them.
The transfer station puts each part into one of the available presses.
A lot of transfer faults at the press.
They noticed that every time they ran part A27
they had a high number of transfer faults.
This part had the smallest diameter.
They redesigned the end effector of the part transfer station to better handle these smaller parts.
A large number of faults at station 4.
Caused by 2 parts getting stacked on top of each other.
Watched the system, noticed that station 3 was running fast and allowing 2
Fixed the problem by adding better part queuing.
Okay – so those were easy mysteries.
On this machine their Production was all over the place.
On this machine their Production was all over the place from day to day.
Nothing correlated.
No obvious pattern.
The real problem is they didn’t trust their data. It was recorded by hand by operators via paper.
Consistency
Quality
Every day the engineers and shift supervisors get emails of machine performance broken down by dozens of different factors:
Production Data By machine, by Part
Fault Data
Downtime Data
So after sifting through all the data, what was the cause of the issue?
When an operator switches from producing one part to another, the equipment needs to be adjusted as well.
Tracks along the conveyor adjusted for the diameter.
The Presses need to be adjusted for the new part.
Getting to each press is difficult – there is limited space for the operator and adjusting each one is a tight fit.
The operator was disabling certain presses rather than go through the effort of setting them up for the next part during change over.
The presses are the bottleneck so this caused a large drop in productivity.
Consistent Automated Data Collection and Reporting
Correlating was straightforward
This was a good investment.
Better armed for future mysteries.
Allen Bradley PLCs
Rockwell Automation Solution: FactoryTalk Metrics!
Automated data collection and reporting.
Base functionality can be easy to set up (preconfigured options, tools, wizards).
Customizable – Fully utilize it!
Broad overview – pulling data from multiple PLCs using FactoryTalk Transaction Manager
Storing data in a database
Viewing the data through reports
PLC 1:
Tags or Variables that tell the current state of the machine.
Basic Tags
Create a tag that keeps track of anything that might be relevant.
Closer look at the Windows Server and FactoryTalk Metrics
Getting data from the system!
Report Expert – you can browse to it. These are the simple preconfigured reports I mentioned before.
But for this system, they wanted detailed analysis of the data.
SQL Server Reporting Services.
SQL Queries.
Email configuration is simple.
Optimize – not just to fix this problem but to give them the data they need for future continuous improvement
Visibility – getting the information to the key people.
When it comes to candy, you can get a lot of variety by just slight tweaks to the ingredients. For example, for chewable candy, you add sugar, water, and gum or gelatin. If you vary the amount of moisture or gelatin you can get anything from a soft chewy gummy bear to a jujube – it’s almost more of a hard candy that you suck on.
The other component is the coloring and the flavoring.
As a result, you can create a wide variety of products and flavors from a single system by varying the recipe.
The candy industry isn’t immune to the pressures of globalization and competition. They have to always be innovating, coming up with new flavors, new ideas, new recipes.
The global engineering group for one of our clients was responsible for implementing a new recipe all around the world, a soda flavoring cross over.
These plants are all over the world, they were all built in different eras, using different PLC hardware.
So for each location around the world they had to either fly out a team or find some local integrators.
There has got to be a better way.
Windows Server
Intranet Website: Login to Update or Change a Recipe
Database: Where the Recipe Data is Stored
Custom Service (Application): Updates the recipe variables on the PLCs
Technical Details of the website
There are a lot of other Content Management Systems out there – Joomla!, Drupal to name a few.
We at DMC are Microsoft Gold Certified Partners, we love Microsoft’s tools – DNN is built on Microsoft’s stack so it makes sense.
Out of the box!
Third Party Examples:
Database editing tool.
Graphing/Charting Tool.
Reporting tool.
I can get a DNN installation up and running in 1 – 2 hours.
Base functionality of DNN on both the ASP.NET and SQL Server side.
We built an top of that using ASP.NET and SQL Server for the recipe management system.
Next let’s look at how the active recipe gets updated on a PLC.
Well first let’s look at how the system used to work before the upgrade.
There is a PLC with all these Tags or registers that tell the system how to make that recipe.
The operator selects the recipe from the interface and all of these variables get updated.
Now on the new system…
The active recipe is still selected from the interface.
The Custom Service running on the server reads the active recipe and then updates all the tags with the appropriate values for that recipe.
We wrote the Custom Service to pull in recipe data from the database.
But how do we communicate to all of these different PLC platforms?
We write to the PLCs using an OPC Server.
OPC Foundation
Why?
How? Built from Off-the-shelf and scratch components.
CMS and OPC servers and the custom software that links them all together.
They didn’t have to revamp their control systems.
As integrators at DMC we have to travel a lot. My coworker Jimmy had a rough first year.
Over his first year, he was in the office for a total of 43 days.
Jimmy was finishing up a long trip, onsite commissioning for a new line at a chemical plant.
It felt like he was so close to being done.
Jimmy was testing the I/O and of course everything was wrong.
He commanded Pump 1 to go Forward and Pump 5 went in reverse.
He commanded Valve 3 to close and Valve 6 opened.
It was a complex system with hundreds of I/O points. Typically you would look to activate each I/O bit one at a time and see what happens.
But of course the control panel is a hundred feet away from these pumps.
Typical 1 person at the controls, another at the system, signaling back and forth.
With a lot of the system left to test, what he thought would be days was looking like it would be weeks.
Jimmy gets a simple but powerful idea. He employs a connectivity idea that we use in the office all the time, that’s been used in IT for years.
Bring the controls right next to the pumps.
How do you do this?
Your interface is running on Windows, in this case iconics.
Use Remote Desktop Protocol to bring your interface onto your Windows, Android, or iOS device.
Using this tool Jimmy shaved a lot of time off and got to go home.
The client uses a tablet now as a remote interface to control the pumps when they have to go outside to connect the tankers.
This can be done on any interface software that runs on Windows.
No “One Size Fits All” Plan
A lot of variation in cost and complexity depending on what you are protecting and what you are protecting against.
Security is Challenging.
If you do nothing else for security, do this.
Production down time is typically the biggest concern.
In my experience, this is not done very often.
Stuxnet,
Target Breach (Credit Cards),
J.P. Morgan and some other banks breach from Russia? ->
in all of those cases damage could have been prevented or mitigated if these practices had been in place.
Known vulnerabilities
Automotive Story about Automating Data Collection and Reporting
Purpose: Optimize Production
Candy Story about a Global Recipe Management System that Communicates with Different Platforms
Purpose: Standardizing the System Inputs
Integrator Story about a simple trick to create a mobile interface for your system
Purpose: Convenience
Security Tips and Tricks and some great resources that the Dept of Homeland Security has to offer.
I hope today you leave with some new ideas or new ways of looking at old ideas.