Cisco presentation in RAOTM 2012, HCMC Vietnam

© 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential Presentation_ID

Cisco Smart+Connected Manufacturing Operations Excellence Phan Thanh Son CTO, Cisco Vietnam

© 2009 Cisco Systems, Inc. All rights reserved. 1

© 2009 Cisco Systems, Inc. All rights reserved. Presentation_ID 2 Cisco Confidential

My IT, Communication, Industrial Convergence

Communications IT Industrial

1988 1989 1994


Achieving Operations Excellence for more Flexibility and Productivity

Make more informed business decisions using improved collaboration with real-time production visibility linked to business context

Enhance event response, with immediate collaboration for faster resolution to downtime and production issues

Improve productivity—quality, performance, cost—of production and people with unified communications and control infrastructure


Supplier

Retailer

Machine

Builder

Headquarters

Complex Manufacturing Environment Globalized Operations Need Efficiency, Agility

Raw

Materials/

Exploration

Distributor

Manufacturing

Plant

Power Plant

Supplier

Rising energy costs

Aging and remote workforce

Globally distributed operations

Customer support time zones

Flat world competition

Product proliferation

Asset optimization

Rapidly changing demand

Pain

Points


Manufacturing Operations Business Pressures and Priorities

0 10 20 30 40 50 60

Globalization

Profitability

Targets

Competitive

Advantage

Ensure Quality

Reduce Costs

All Others

0 10 20 30 40 50 60

Visibility for

Decision Making

Synchronize Plant

and Corporate

Objectives

Improve

Collaboration

Optimize Asset

Utilization

Reduce Production

Variability

All Others Best in Class

Top Business Priorities for Manufacturing Operations?

Top Strategic Actions to Achieve Business Objectives?

Source: Manufacturing Performance Management, Aberdeen Group, May 2009


“This is about a business change, to make our manufacturing facilities more flexible, more agile and more lean.”

Kirk Gutmann, Global Information Officer,

Manufacturing and Quality, General Motors Corporation


Operations Excellence

What If Production Issues Could Be Identified

and Collaboratively Resolved Immediately?


Industrial Automation 3.0: Converged Plant Architecture

Source: AMR, Industry Week, Cisco Analysis

Real-Time

Asset

Tracking &

Monitoring

Integrated

Business and

Plant Data

…Multi-Site

Collaborative

Tools and

Processes

Enhanced

Security and

Personnel

Tracking

IT and

Control

System

Flexibility

Mobile and

Remote

Workers

Sensor

Enabled

Manufacturing

Real Time

Restricted and

Isolated

Static Environment

“Solid State”

Traditional

Plant

Dynamic, Integrated

Mobile, Real-Time

Connected

Environment

“Liquid State”

Plant

of the Future


Challenges in Achieving Operations Excellence

Communication and collaboration across the value chain and down to the factory floor

Integrating innovation processes with operations

Converging plant floor automation with business networks and systems

Real-Time access to information and knowledge

Security

“Manufacturers must integrate product innovation with operations excellence to deliver complete customer value. An improper balance often leads to new products that are unprofitable to deliver or high-margin products that lack differentiation or strategic market impact.” Source: AMR Research


Manufacturing Excellence

Smart + Connected

Manufacturing

Collaboration Communication

Intellectual Property

Training Communications Availability

Safety Automation Energy

Delivery

Sales

Service

Satisfaction

Asset

Procurement

Visibility

Warehousing

Risk


What Is Smart+Connected Manufacturing?

Accelerate time to market for new products

Create a consistent, differentiated customer experience

Adapt your supply chain to changing markets

Improved operations efficiency

Benefits

Continuous Innovation

Customer Intimacy

Supply Chain Agility


Solutions Portfolio

Definition “Intelligent, timely information and collaboration in

context for superior business results”


Portfolio of Solutions to Enable Converged Plant Architecture

SAFE for

Process Control

Ethernet to

the Factory

Integrated plant and business networks

Secure visibility and remote access

Control system flexibility

Protect critical control system assets

Secure visibility and remote access

Integrated sensor and WLAN networks

Improved productivity through mobility

Enable new applications

Visibility into material and asset status

Accurately locate people and assets

Secure

Wireless Plant

Context Aware

Solution

Intelligent video monitoring and security

Access experts in real-time

Collaborate with design teams and suppliers

Improve productivity and issue response time

Enable effective mobile communications

Collaborate and share information, video, and voice to solve issues on the plant floor

Extend remote SME across the globe

Share knowledge and best practices

Video-Enabled

Collaborative

Production Management

Unified

Communications

Industrial Wireless

Video Surveillance Plant VoWLAN


Stand-Alone Networks, Information Silos, Single Purpose, Proprietary

Go From

Robotics

Human MachineInterface

PC-BasedControllers

Motors, Drives, and Actuators

Programmable Logic Controllers

Off ice Applications, Internetworking, Data Servers, and Storage

Back-Off ice Mainframes and Servers

Sensors and Other Input/Output Devices

Corporate Network

Control NetworkGateway

Control Network

Device-Level Network

Ethernet

Architecture for Manufacturing Communications and Controls Network Architecture for Manufacturing Convergence


Integrated Platform, Standard Architecture Enabling Real-Time Visibility and Collaboration

…To

Robotics

Human Machine Interface

PC-BasedControllers

Industrial Video

Programmable Logic

Controllers

Off ice Applications, Internetworking, Data Servers, and Storage

Back-Off ice Mainframes and Servers

Sensors and Other

Input/Output Devices

Corporate Network




Reduced Manufacturing

Downtime

Standard Global

Architecture

Remote Support for

Faster MTTR


Ethernet to the Factory “How-it-Works” Example

Visibility into

production

performance issue

at one plant

1 Log into automation

system with secure

remote access

capability

2 Check network

status through

FactoryTalk

integration

3 Access automation

system and devices

to identify and

resolve issue

4

Business

Value

Improves visibility into production systems for faster issue identification

Reduced travel time and cost

Faster response and resolution to issues reduces downtime

Prevents security incidents and unauthorized access


Improve Operations Efficiency Connecting a World Wide Manufacturing Operation

Standardize

operating model

globally

All devices in the

plant are connected

to the central

system, including

robots and PLCs

Network is a key part

of the infrastructure to

build and deliver

vehicles

Business

Value

Single system to see what’s going on in all the plants

Reinvent how GM makes cars and trucks

Get access to the right people at the right time to fix issues quickly

Reduced network downtime 95%

Moved from chaos and firefighting to innovation


SAFE for Process Control

Disparate Networks, Limited Visibility, Control Network Security Issues

Go From

Limited real-time information visibility

Multiple networks

Downtime and productivity issues due to security incidents

Poor asset utilization and performance



Secure Connectivity Between Plant and Business Systems, Visibility Into Production Systems

…To

Secure connectivity between plant and business systems

Real-time information visibility

Secure architecture

Remote access



Improved Asset

Utilization

Quicker Response to Production

Issues

Better Plant Performance

with Real-time Visibility

Reduced Downtime


Eliminating Wires and Cables Increase reliability

Reduce installation cost

Remote Device Monitoring Troubleshooting/maintenance

Instrumenting existing machinery

Tracking Assets RFID

Real-Time location services

Enabling Portability and Mobility Mobile HMI (People)

AGVs (Equipment)

Communications (VoWLAN)

Video Surveillance Security and process monitoring

Guest Access

Drivers for Manufacturing Wireless Applications More Points of Visibility and Control


Secure Wireless Plant Secure Wireless Network for Sensors and Advanced Solutions

Expensive Sensor Deployments, Multiple Isolated Networks, Limited Worker Mobility and Asset Tracking

Go From



Integrated Wireless Sensor and Information Network, Plant Wide Mobility and Access

…To



Increased Visibility

Improved Asset

Utilization

Efficient Deployment of

Plant Wide Wireless

Applications (Location, etc.)

Enhanced Worker

Productivity


Context Aware Manufacturing

Lack of Information, Lost WIP Assets, Unresponsive Supply Chain, Regulatory Challenges

Go From

High Scrap Rate Lost Inventory

Safety Challenges Labor

Inefficiencies


Context Aware Manufacturing

Holistic View of Assets, WIP, Inventory and People with Interactive Real-Time Responsiveness

…To

Over Cisco

Unified Wi-Fi

Network

Status

In-Use

Condition

Location

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Context Aware Manufacturing Use Case

“AeroScout eliminated the manual scanning

process and removed human error.” says Matt

Miesner, Six Sigma Blackbelt at Viracon, “We went

from between several hours to several minutes to

find a carrier, down to less than a minute.”

* Matt Miesner is a Six Sigma Blackbelt at Viracon


1

MES system provides

next Job

Context Aware Manufacturing “How-it-works” Supply Chain (WIP) Example

2

System provides rack

number and lot location

is displayed on map

3

Visual blinking indication

on tag speeds up

detection

Business

Value

Reduces several minutes per each operation, over hundreds of process steps over previous manual operator search process

Significant improvement in production throughput over manual system


Business

Value

Improve Operations Efficiency Cisco Context Aware Solution

Improved productivity due to ability to quickly locate parts and tools

Enhance parts traceability and reduce cycle time to solve in-service issues

Reduced production delays and government fines

1700 critical parts,

plus tools and

machines in the

factory have RFID

tags and can be

located instantly

Because each

component has a

unique tag, items

can be better

identified to resolve

service issues

Advanced wireless

technology from Cisco

used to overcome

dead spots in the

building

Source: Cisco® Customer Business Transformation Group


Industrial Wireless Video Surveillance

Limited Plant Wide Security Visibility, Disparate Security Networks, Expensive Deployments

Go From

New security and compliance requirements

Difficult remote equipment and process monitoring

Expensive, disparate video systems

No plant wide visibility



Integrated Video Surveillance Systems, Efficient Deployment, Improved Security

…To

Industrial video surveillance

Efficient deployment on Cisco wireless architecture



Improved Plant Safety and Security

Open Architecture for Efficient Deployment

Integrate Into Plant

Applications

Industrial Grade

Security and Monitoring


UC for Manufacturing

Provides Collaboration Across the Value Chain

for Improved Shop Floor Communications

Real-Time Emergency Contacting

MES Interfacing; Equipment

Downtime Alerts to Phone

Production Performance Tracking

ERP Interfacing; Inventory/Supply

Chain Alerts to Phone


Plant Voice over Wireless

Multiple Communication Devices and Networks, Limited Access and Communication on the Plant Floor

Go From

Limited communications outside of control rooms

Separate networks for “walkie talkies”

Multiple devices and missed communications

Limited access to applications and data


Plant Voice Over Wireless

Real-Time Collaboration Across the Plant, Mobile Application Access, Integrated Networks

…To

Effective communication across the plant

Single device for desk and mobile communication

Access to data and applications on IP phone or other mobile device

Support for Cisco and partner devices


Plant Voice Over Wireless

Reduce unplanned stoppage

times by up to 50%

Improved communication

for issue notification

and resolution

Efficient deployment

on Cisco Unified

Wireless Network

Eliminate silos of

communication


Increasing Productivity and Cost Savings on the Plant Floor Using UC

Metals and Mining

Major Use Case

1 Smelter operator needs

to check process data to make adjustments

2 Pulls up critical

production data on PDA

Calls operator in another location to discuss change using soft-phone on PDA

3 Makes process change

accurately and rapidly via PDA

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

Business

Value

Source: Cisco® Customer Business Transformation Group


UC Can Help Reduce the Response Time in Crises Case Example: Responding to Equipment Failure in the Refinery

US Refining

Major

Improved employee safety

Faster incident response and resolution

Higher refinery uptime and production

Business

Value

1 Equipment failure

in the refinery that can cause production loss and safety issues

2 Partner extension to

MeetingPlace to quickly initiate a blast dial for emergency personnel with up to 3 pre-populated phone numbers per individuals

3 Enter the meeting

through touch-screen on IP phone

5 Conduct meeting

with ‘show and tell’ of equipment set-up and action plan

4 Meeting Room

appears on your PC bringing together all key participants in minutes


Video Enable Collaborative Production Management

Limited Visibility and Collaboration with Plant Floor, Inefficient Resolution of Production Issues

Go From

Globally distributed operations

Limited remote access and collaboration across global production sites and suppliers

Slow, expensive issue resolution



Real-Time Collaboration Using Voice, Video, and Web Conferencing Across Global Plants, Enterprise, and Suppliers …To

Streaming mobile voice and video from the plant floor

Share video across company and with partners using WebEx

Find experts using TelePresence

Integrated with Unified Communications & Cisco WLAN for efficient interoperability



Quickly Resolve Issues to Reduce

Downtime

Improve Productivity and Reduce

Costs Due to

Reduced Travel

Capture and Share Videos

for Best Practice and Knowledge

Sharing

Extend SME Across the

Globe


Enabling Faster and More Effective Response to Plant Floor Issues

*TP/WebEx integration and multi-conferencing need testing and validation

Plant Floor

Remote Expert Resources/ Central Technical Support

Internal Experts

External Suppliers

Issue Connect with central support

Onsite Expert and/or CUPC audio/video

call

Share via TelePresence*

and WebEx

IM and WebEx with Supplier

Need to connect with Supplier

Externally

Publish on Portal Show and Share

Engage Camera

Alert Employee

Onsite

Need to Find An Expert Internally


TelePresence for Manufacturing

Accurate planning can be

hampered by inefficient

communications

Use TelePresence for

more efficient, effective

communication and

collaboration

Improved business agility,

reduced supply chain

costs and improved

forecast accuracy

TelePresence Value

Distributed participants

Short timeframe to act

Collaborative decision has high business impact

Complex information to share

Multicultural participants


Converged Plant Architecture Plant Floor Safely and Securely Connected with the Enterprise

Integrated key expertise through voice, video and access to applications improving operational efficiency

Increased information on plant process and assets by extending sensor network and adding location determination

Reduced cost by relying on standard network

ERP, etc.

Plant Floor

Plant IT Network

Manufacturing Router

Distribution Routers

IT Servers

Core Routers

Enterprise Automation and Control Applications

Automation and Control Devices

Plant Wi-Fi Network

Sensor Mesh Network

Remote

Access Switches

Ethernet

Industrial Switch Cell/Area Wireless Sensor

Network

SiSiSiSi

SiSiSiSi

Teleworkers/ Customers

and Partners

Wi-Fi Mesh and Location Receivers

Wi-Fi Voice

Industrial Video

Location Chokepoint

Location Tags

Plant DMZ

Wireless Controller

Location Engine

Security and Network Administration

Terminal Server

Video

Voice

Wireless, Video and Voice Servers

Wide Area

Network

Internet


Managers, Engineers


Converged Plant Architecture Plant Floor Safely and Securely Connected with the Enterprise

Integrated key expertise through voice, video and access to applications improving operational efficiency

Increased information on plant process and assets by extending sensor network and adding location determination

Reduced cost by relying on standard network

ERP, etc.

Plant Floor

Plant IT Network

Manufacturing Router

Distribution Routers

IT Servers

Core Routers

Enterprise Automation and Control Applications

Automation and Control Devices

Plant Wi-Fi Network

Sensor Mesh Network

Remote

Access Switches

Ethernet

Industrial Switch Cell/Area Wireless Sensor

Network

SiSiSiSi

SiSiSiSi

Teleworkers/ Customers

and Partners

Wi-Fi Mesh and Location Receivers

Wi-Fi Voice

Industrial Video

Location Chokepoint

Location Tags

Plant DMZ

Wireless Controller

Location Engine

Security and Network Administration

Terminal Server

Video

Voice


Wide Area

Network

Internet


Managers, Engineers

Safe and Secure Plant Integration

Tightly manage access to plant systems

Control flow of traffic and data between key zones

1

1

Extend Visibility into Plant Processes

Improve operational efficiency with more information by cheaply deploying additional sensors and devices

Reduce loss and search time with location context of mobile assets and product

Improve Operational Response

Key experts respond to issues with access to plant applications and access to voice and video

Mobile technicians stay in touch and have access to key data

3

3

Reduce Support Costs

Rely on IT for support on standard networks

Reduce the number of technologies supported

Improve Support and Decision Making

Enterprise-based users access up to date operational status

Enterprise applications integrate real-time with plant floor applications

2

2


Roadmap to Operations Excellence Secure Wireless

Plant

Locate and track valuable assets and resources

Context-Aware

Solutions

Efficiently expand plant-

monitoring capabilities

SAFE for

Process Control

Industrial Wireless

Video Surveillance

Boost efficiency and security of manufacturing

assets

WebEx

Communicate in real-time,

regardless of location

Achieve real-time visibility

and integration with business

systems

Protect and secure

production assets

Integrate data, voice, video, and sensor networks

Deploy rapidly and cost-

effectively in harsh

locations

Optimize the movement of material and

people

Improve efficiency and

mobility of communications

Secure Wireless

Plant

Ethernet to the

Factory

Industrial Wireless

Video Surveillance

Location-Based

Services Plant VoWLAN


Smart+Connected Manufacturing Operations Excellence Benefits

48

Create flexibility to react to changes in demand and market needs

Improve efficiency, reduce cost and decrease idle time

Identify and respond collaboratively to process exceptions in ERP workflow

Business Results

Provide real-time communications to factory floor personnel

Manage operational risk and improve compliance



Additional Material Cisco and Rockwell Automation Alliance

Website http://www.ab.com/networks/architectures.html

Design Guides CPwE DIG 2.0

Education Series

Whitepapers • Securing Manufacturing Computer and

Controller Assets

• Production Software within Manufacturing Reference Architectures

• Achieving Secure Remote Access to Plant Floor Applications and Data

http://www.ab.com/networks/architectures.html

http://literature.rockwellautomation.com/idc/groups/literature/documents/td/enet-td001_-en-p.pdf




http://literature.rockwellautomation.com/idc/groups/literature/documents/wp/enet-wp005_-en-e.pdf










Cisco & Rockwell http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html

http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html





Reference materials


Cisco Vietnam Opened office in Vietnam since 1999

60 people in HCMC and Hanoi offices: Hanoi office is moving to VN tallest building by end of July 2012 HCMC office: 9th floor Saigon Trade Center, 37 Ton Duc Thang, HCMC

Web site: http://www.cisco.com/VN/

Toll free: 1800 585807, [email protected]

Distributors: Ingram, FPT Distribution

Partners and resellers: more than 300

Segments: Service Provider, Public Sector, Enterprise, Mid-market, SMB and Consumer

IT: 45 Mbps HCMC-Singapore, 20 Mbps Hanoi-Singapore, TP, VC, etc.

Cisco & Rockwell: http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html

http://www.cisco.com/VN/

mailto:[email protected]







Connected Manufacturing Book http://www.cisco.com/web/about/ac79/docs/wp/ctd/ConnectedManufacturingFINAL.pdf

http://www.cisco.com/web/about/ac79/docs/wp/ctd/ConnectedManufacturingFINAL.pdf




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Cisco presentation in RAOTM 2012, HCMC Vietnam

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Transcript of Cisco presentation in RAOTM 2012, HCMC Vietnam