Digital and Alcoa’s IT & Operational Technology Journey IT-OT...SCADA Nodes Historian Historian...
Transcript of Digital and Alcoa’s IT & Operational Technology Journey IT-OT...SCADA Nodes Historian Historian...
Digital and Alcoa’s IT & Operational Technology Journey
Peter Stamp
Chief Information Officer
June 2019
Alcoa Corporation – a proud 130 year history
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▪ Inventors of the original aluminium process
▪World's largest bauxite mining portfolio and alumina refining business
▪ 2018 sales revenue at $13.4B
▪ Award-winning sustainability leadership
Three segments across the aluminium value chain
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Geographically dispersed mines
with a premier low-cost position
Eight refineries on five continents
with access to growth markets in
Asia, Middle East and Latin
America
Global aluminum producer with a
proven ability to drive technology
advancements
BAUXITE ALUMINA ALUMINIUM
Global operations by business segment
Our values support our license to operate around the world
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Brazil:
Guinea:
Saudi Arabia:
Australia:
United States:
Norway:Iceland:
Spain:
Canada:
Suriname:
Bauxite Alumina Aluminum Transformation
Alcoa’s IT environment is standardized and integrated through global strategies and enterprise architecture
50M Emails/Month
7.4% 92.6%
1 IaaS Global Data Center
1 Regional Satellite
Multiple PaaS/SaaS/BPaaS
150K ERP
transactions daily
300+ Alcoans300+ Contractors with
Strategic Partners
1,100
VM/Servers1,500
Terabytes of
Storage
30 operating locations in 10
Countries around the Globe
17,000+ users of services
12,000 Laptops
&
Desktops
Global Network (MPLS/SD-WAN)
connecting Alcoans to the world
5,500 Managed Network Devices
Alcoa IT & Automation
Solutions
1 Global HCM instance
200+ SaaS Applications
800+ Business Applications
500K Skype &
Teams / Month
2,600
Mobile
Common Automation & Process Control Solutions (OT) are aligned with Manufacturing affinity†
Windows Servers Core Windows ServersWindows Clients Network Switches
SitesPLCsWindows Infra.SCADA NodesHistorianHistorian Tags
SitesOperator StationsAdvanced Control Apps/Inst.LCN NodesControllers (HPM/C300)Safety ControllersField I/OPLCsQUASAR Nodes*/UsersNetwork Switches/Aps/RoutHistorianHistorian Tags
Sites (Smelting/Casting)Sites (Rolling)SCADA NodesAPMSDG Nodes‡
AGVRobotsPLCsField I/ONetwork SwitchesHistorianHistorian Tags
Leveraged Manufacturing Infrastructure (LMI) – segregated from business domain and utilized in all manufacturing affinities
†Solutions share a common architectural framework, comply with cyber security standards, and leverage common manufacturing infrastructure, wherever possible
ALUMINUM SMELTING/CASTING/ROLLINGALUMINA REFININGBAUXITE MINING
Integrated “One Team” supports all levels of IT & Operational Technology / Automation Solutions
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IT & Automation Systems
Architectural Model Levels
Alcoa: Mining, Refining, Smelting, Casting, Rolling, Energy, Shared Services, Corporate
Sensors & Control Elements
Real-time Control & Robotics
Advanced Control
Mfg Operations Management
Business Planning, Logistics
IT & Operational Technology /
Automation Architecture
Aligning IT & OT realizes benefits on multiple dimensions
▪ Recognize and leverage the diversity of skills, experience & perspective – IT & Engineering
▪ All parties are aligned and work towards a Win-Win outcome to maximise business outcome
▪ Development of single integrated architectural framework for Levels 1-4 – “Sensor to
Boardroom“
▪ Adoption of common standards and accommodating unique technologies where required
People &
Organization
Architecture
& Solutions
Risk
Management
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▪ Visibility and management of cyber security risks for the entire system – CISO accountable
for all
▪ Maximises adoption of common cyber security standards and processes
▪ Utilise data across the entire organisation to maximise insight & decision making agility
▪ Facilitate automation of administrative and operational workflows and process
Value
Proactive Cyber Security
Cloud and Network Becomes Core
Digital strategy & solutions are enabled & optimized with IT/OT Integration
9Advance Knowledge and Talent
Bimodal ITAS and Efficiency Driven Organization
Integration Connects the Ecosystem
Mobility: Anything, Anytime and Anywhere
Transforming Alcoa
through Digitalization to Achieve
Agility, Efficiency and Value Creation
Advancing
Analytics &
Data Insight
Enable value from data &
improved decision making
Automate and
Optimize
Business
Processes
Modernize, right-size, simplified
Automated &
Intelligent
Manufacturing
& Operations
Automation, Analytics and
Security
Foster
Collaboration
and the
Connected
Worker
Internal andexternal digital
workplace
Digital
Optimization &
Transformation
Ideation
New types of innovation and
creativity
Bu
sin
ess
Driv
ers
&
Stra
teg
ies
Te
ch
no
log
y
Dri
ve
rs
World Economic Forum White Paper: Digital Transformation Initiative in Mining and Metals Industry, January 2017
Key Digital Transformation themes are emerging across Global Mining & Metals Industry
Automation, Robotics
and Operational
Hardware
Digitally-Enabled
Workforce
Integrated
Enterprise,
Platforms &
Ecosystems
NextGen Analytics &
Decision Support
Themes
The use of digitally-enabled hardware tools to
perform or improve activities traditionally carried
out manually or with human-controlled
machinery
Using connected mobility, virtual and
augmented reality to empower field, remote and
centralized workers in real time
Linking operations, information technology
layers and devices or systems that are currently
separate, within the value chain or the larger
ecosystem
Leveraging algorithms and AI to process data
from sources within and beyond the value chain
to provide real-time decision support and future
projections
Description
Smart Sensors
Initiatives
Autonomous Operations and Robotics
3D Printing
Connected Worker
Remote Operations Center
Asset Cyber Security
Integrated Sourcing, Data Exchange & Commerce Platforms
IT/OT Convergence
Advanced Analytics
Simulation and Modeling
Artificial Intelligence
C O N N E C T E D W O R K E R
A D VA N C I N G A N A LY T I C S
C O N N E C T E D B U S I N E S S
A U T O M AT I O N
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Focus on key Digital opportunity areas
“Automation & Smart
Manufacturing”
Process Control & Sensors Data Historian,
Calculations & Visualization
Manufacturing Execution
Systems (MES)
Modeling & Simulation
“Digital Twin”
Manufacturing Analytics & Intelligence
Automated Equipment
“Automation” of Operations consists of multiple components & disciplines
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Automated &
Intelligent
Manufacturing &
Operations
Automation, Analytics, & Security
QUASAR Automation program implemented in Alumina refining operations to achieve sustained, increased business value
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Process Control
Field Inst. Specialty Analyzers
DCS& SIS
Advanced Control
Manufacturing Operations Management
Historian & Data Model
Ops & Prod Mgmt.
Base & Visual Analytics
ERP Integration
Sustaining Support Services
Common Best Practice Solutions
Continuous Improvement
Local/Remote Systems Monitoring & Operations
Global Talent Leverage
• Realised incremental production increases and improved raw material conversion efficiencies
• Improved process stability & enabled operation closer to practical limits
• Managed process control equipment and systems obsolescence
• Achieved high level of process systems availability and compliance
• Leveraging the global manufacturing, technology and subject matter expert resources
Implementing Analytics Infrastructure to enable additional insights through Predictive Analytics
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ANALYTICS ENVIRONMENT & DATA LAKE
Provide a scalable, end to end analytics
solution capable of expanding with the
Advanced Analytics program.
The framework should enable efficient
analytic delivery at a low relative cost to
enhance the overall business case.
EQUIPMENT SURVIVAL MODEL
Significant
savings opportunity
in preventing
unplanned
equipment failures
Target State: An online Analytic predicts the likelihood of
Equipment surviving their campaign and provides insights
into the major causes for health deterioration.
We use our wireless infrastructure to fill data gap rapidly
Innovation cycle: use plant data, identify new opportunities, test ideas and implement
“Digital Twin” Plant-wide process models, rich data, advanced analytics & agility
We are continuously defining opportunities for improvement using Digital solutions
From installing wireless device on process to having process data : duration one dayPlantwide wireless mesh
SMART Manufacturing program has been implemented in Aluminum business to provide single source of truth
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• Well integrated, fine
granularity, long term
production data repository
• Increase collaboration
• Foundation for Advanced
Analytics & Reliability
Excellence
• Achieved significant
savings
Solution Results & benefitsChallenges• Aluminum market
• Improve competitiveness
• Enhance operational
excellence
• High retirement rates, loss
of SMEs
• Established the SMART
Manufacturing program
• OSIsoft Historian & Asset
Framework – 10M tags
• Deploy a robust, common &
globally deployed infrastructure
in all operating locations
• Mobilize key employees
SMART Manufacturing is the integration of data with process expertise to enable proactive and intelligent manufacturing decisions in dynamic environments
All equipment fails!
What it the best strategy for each individual component
Each equipment has specific failure modes!
Reliability Excellence (REX) and equipment example: motor/pump assembly
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Manual
Inspection
Manual Inspection or
Online sensor in PI
Online
sensor in PI
Historian
Improving REX outcomes by utilizing Predictive Analytics built on Smart Manufacturing with remote monitoring
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▪ Equipment condition PLC/Historian data and maintenance information from Oracle eAM is collected into the Analytics service
▪ Data is processed through algorithms to determine “normal” operations versus “upset” conditions
▪ Algorithms detect “possible issues” and users are notified
▪ Users act on issues and give feedback to analytics recommendations to improve models and results
▪ Analytics feedback integrated into Historian and becomes “a new measuring point” for asset health to monitor
Source: Graphics from Senseye
IDEATION & DESIGN THINKING
ENTERPRISE AGILITY
CHANGE MANAGEMENT
Digital Transformation is more than Technology
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▪Establishing business sponsorship is critical & takes time
▪Digitalization drives need for IT/OT alignment & integration
▪Hybrid cloud environments need to be well architected
▪ IT/OT integration provides visibility and enables leverage of data across the enterprise
▪Partner with key solution providers
▪ Identify high potential use cases and implement proof-of-concepts. Agile with quick wins or fail fast, then scale fast
▪Much more than technology – engaging people
Lessons learned along the way for IT/OT Integration and Digitalization (Optimization & Transformation)
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