Role of Standards in - Buffett Institute - Northwestern...

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

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Role of Standards in

Smart Manufacturing…

Alec McMillan

Rockwell Automation

Open Standards Enable Global Productivity

• “To drive global productivity and manage business risk, we

need real time access to the data on performance of

machines, lines, factories and the enterprise. The key enabler

is a fully connected enterprise built upon open standards

………for smart safe and sustainable manufacturing”

• Excerpt from Keith Nosbusch, Rockwell Automation President and CEO,

National Press Club Keynote Address – 9 September 2009

Supply Chain

Customer

• Customized Products

Factory

Multiple Product Transformations

Headquarters

• Cost, Productivity, Optimization

• Global Standards & Risk Mgmt.

• Intelligent Load Shedding based on process / equipment states

• Communications between the Utility and the Factory control system

• Optimize Energy

Consumption • Logically connect the Utility to the

Factory

• Constrained Utility

Distribution Center

Standards in all aspects of the supply chain…

Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

RoHS

Conflict minerals

Worker

certifications

Smart

Grid

standards

ISO 9000

ISO 14000

ISO 50001

Energy efficiency

Product standards

KPI’s

Social Accountability

standards

Environmental

Safety

EMC

Product

standards

Interoperability

Upgrade/Repair

Regulations

Product

Cataloging

Supply Chain

Integration

Some Relevant Factory Standards Activities

• IEC TC65 Digital Factory work group

• ISO TC 184 “Big Picture Project”

• IEC TC65/ISO TC184 JWG14 Energy Efficiency in Industrial Automation

• ISO TC184/SC5/WG10 Methodology to evaluate energy

efficiency of a manufacturing system

• IEC TC65 Sub Committees Safety , systems, control, communication

• IEC TC 17 Control components, sensors

• IEC TC22 Drives

• IEC TC44 Machine safety

• ISO TC184 Ad Hoc group on Mechatronics

• ISO TC184 Oil and Gas Industry Applications of Asset

Management Systems

• ISA Standards Batch control, Enterprise control, FDT, HMI

System Characteristics Safety

Environment

Integrated Functions

Other

Product

Product

Product to Product

Domain

Design Commissioning Operation Maintenance Disposal

System Specification

IEC Systems Approach

IEC Systems Approach

• System Specification – Concept Drawings

– Use Cases

• System Inventory

– Products, Processes, Personnel

– Listed with related standards , version and date

• System Mapping

– Maps inventory elements to the specification and concept drawings

• Roadmaps

– Showing current and planned evolution of the inventory over time

6 Copyright © 2011 Rockwell

Automation, Inc. All rights reserved.

Control System Framework

Customer Context

Automation System Design Context

7 (Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

Manufacturing

System

Design

Control

System

Design

Control

Program

Design

Manufacturing

System

Requirements

Multiple disciplines and tools required to support

the design and development of the automation

system

Information Exchange

Customer requirements -> Automation Solution

• How do we match our customer requirements with our automation

solutions?

– Complex decisions required to arrive at the automation solutions….

– What manufacturing system design systems are preferential for our customers?

– What is the customer domain requirements?

• Discrete, process, batch, logistics,

• Application sector in the domain?

– automotive, semiconductor, food, pharma, beverage, energy,

– Preferred automation framework?

– Driven by customer preference…end users

– Driven by 1st tier supplier preference…relationship to EPCs & System Integrators

– Driven by OEM preference…

(Confidential – For Internal Use Only)

Copyright © 2011 Rockwell


8

Generic Control System framework view for simple Pumping Application

Baseline (some examples)

• Project Management - (BOM, costing,schedule)

• Mechanical design (panel layout)

• Electrical design (wiring connections)

• Control application programming

– (PLC programming)

• Visualization (Human Machine Interface)

• Configuration tools (network management)

Productivity management

• Process management information (KPI’s)

• Energy monitoring information

• Condition monitoring information

• Simulation

• Optimization

• Software capability profiling -(manufacturing

software units - MSU) (Confidential – For Internal Use Only) Copyright © 2011 Rockwell Automation, Inc. All rights reserved.

9

HMI

VFD/ Servo

PLC

PB’s

Condition

Monitor

Sensors Actuators

Energy

Monitor

Simulation Optimization KPI’s

MSU

Pump

Control

Integrated Architecture provides a “framework” to meet the customer application integration requirements…

• Programming & Configuration

– RSLogix 5000

– RSLinx

• RSView Studio

• RS Energy Metrix

• FT-Vantage Point

(Confidential – For Internal Use Only)

Copyright © 2011 Rockwell


10

VFD/XM-120

Pump Control

Motor/Pump

services

SAP R/3

@ Ethernet Office-LAN Ethernet

Plant

Maintenance

Plant

Information

OPC-Server

Internet/

Intranet

LAN Fast Ethernet

MES-Clients BATCH

Service

Engineering

Station

Engineering

Toolset/ Product

Data

Programming

Device

Industrial Ethernet / Fast Ethernet

Device Bus

Fail-Safe

Device

Link-Modul

PLC

PLC

Fie

ldbu

s

Fie

ldbu

s

Fieldbus

Wireless

Communication

DCS

Security

Station

Zone 2

Zone 1

I/O

Module

Fie

ldbu

s Link-Modul

Device Bus

Y-Link

COx,

NOx, ...

Batch-Server

PLC DCS

Product

Data

Server

Diagnostic

Station

Wireless

Communication

Motor Drive Sensor

Controller

Valve Analytics

Sensor Valve

Sensor

Drive

Converter Converter Switch

Security

Station

Diagnostic Station

Product

Data

Server DCS

Station

Security

Motor

Starter

SAP R/3

@ Ethernet Office-LAN Ethernet

Plant

Maintenance

Plant

Information

OPC-Server

Internet/

Intranet

LAN Fast Ethernet

MES-Clients BATCH

Service

Engineering

Station

Engineering

Toolset/ Product

Data

Programming

Device

Industrial Ethernet / Fast Ethernet

Device Bus

Fail-Safe

Device

Link-Modul

PLC

PLC

Fie

ldbu

s

Fie

ldbu

s

Fieldbus

Wireless

Communication

DCS

Security

Station

Zone 2

Zone 1

I/O

Module

Fie

ldbu

s Link-Modul

Device Bus

Y-Link

COx,

NOx, ...

Batch-Server

PLC DCS

Product

Data

Server

Diagnostic

Station

Wireless

Communication

Motor Drive Sensor

Controller

Valve Analytics

Sensor Valve

Sensor

Drive

Converter Converter Switch

Security

Station

Diagnostic Station

Product

Data

Server DCS

Station

Security

Work in IEC 22G Work in IEC 17B

Work in IEC 3D/

IEC 22G/65/17 B

Motor

Starter

Together

IEC 65A

/ISA S88

Together with

TC 65/ ISA

S99 Together

with IS0

184 SC 5

Common

horizontal

Work with

IEC TC 77

IEC TC 66

IEC TC 57

Together with IEC

65E/ISA S95

A Digital Factory may be described electronically

All Devices, Functions, Communications must be included (called

automation assets)

All static and dynamic Relationships between the automation assets

– must be covered including the timely behavior

It must be possible to describe the Processes (System Functions)

based on the automation assets

Data Repository

Contains the electronic

Description of all

Assets in Digital

Factory

Automation Assets

Program/

Software

Digital Factory

System Functions/

Process Engineering Configuration Operation Security Maintenance

Length of the Sensor Cell

Diameter of the Sensor Cell

Sensor Cell Material

Weight of the Sensor

Dimension of the Housing (length, wide, high)

Material of the Housing

Vibration Protection

Local Display

Local Operator Panel

Threshold Level

Event Signalling

Linearisation Curve

Compensating Function

Time Stamp Function

Self Calibration

Fail Safe Mode

Measuring Time

Cycle Time

Filter Time

Communication Intervall

etc.

Functions

(Software)

Functions

(Software)

Function

(Software)

Ortsinformationen Ortsinformationen Location

e - business e - business e - business

Performance

Construction

(Mechanic, Electric)

Konstruktion

(Mechanik, Elektrik)

Construction

(Mechanical & Electrical Equipment)

ISO 8000 Quality Data

Data that meets requirements

Data that is Portable

ISO

22745 ISO 8000

Portable data

Quality data is portable data; it is independent of the software application

and accessible by any application

Data

de-dup

app

Data quality

analysis

app

Data

validation

app

ISO Data Standards are the Antidote to Application “Lock-in”

User

Application

Operating system

Hardware

• The software we will be using tomorrow will be different from what we are using today

and • we will need access to our data …. Over a long time period

and • data that cannot be separated from licensed software is may also

be considered licensed data.

Then:

The Need for Portable Data

Our data should be “portable”; independent of any licensed

software application.

ISO 8000 quality data is portable data!

eOTD (ECCMA Open Technical Dictionary): a registry of terminology from many sources where each concept is assigned a unique and permanent public domain identifier and where concept identifiers may be mapped to each other and ranked according to their use (ISO 22745).

eOTD® public domain

Concept Identifier

ECCMA Open Technical Dictionary (eOTD)®

TerminologyTerms Definitions Images Symbols

Semantic Encoding

Rockwell Automation has one of the first ISO 8000 compliant

multilingual industrial product catalogs

Leading the way

Class ID: 0161-1#01-1070992#1

Property ID Concept ID

0161-1#02-090875#1 0161-1#07-283802#1

0161-1#02-091253#1 0161-1#07-288789#1

0161-1#02-090986#1 0161-1#07-328695#1

0161-1#02-060215#1 0161-1#07-286471#1

0161-1#02-091119#1 0161-1#07-289000#1

0161-1#02-091183#1 0161-1#07-283065#1

0161-1#02-091118#1 0161-1#07-280777#1

Class Name: Contactor

Property Term Value

Product Type lighting contactor

Special Features mechanically held

Coil Voltage 208-240V AC

Frequency 50/60 Hz

Enclosure Rating NEMA 4/4X

Mounting Facility surface mounting

Enclosure Material stainless steel

Technical Description

Marketing Description

Mechanically Held Lighting Contactor

Lighting Contactor,Mechanically Held,208-240V AC,50/60

Hz,NEMA 4/4X,Surface Mounting,Stainless Steel

Leading the way

Rendering guide

Better and better descriptions

Easier to find

Easier to integrate

Easier to order

Role of Standards in - Buffett Institute - Northwestern...

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