Life Cycle Management Sesam

Transcription

1 Life Cycle Management Sesam Henrik Pedersen Life Cycle Management Hvorfor er Life Cycle Management en god ide? Hvad inkluderer Life Cycle management teknik, procedurer og organisering Hvorledes opnås viden om systemernes reelle tilstand for at vurdere om der skal ske en opgradering? Hvorledes inkluderer Life Cycle management forskellige opgraderingstyper? 1

2 Engineering for a healthier world The idea is quite simple: We cannot claim to save lives or cure diseases, but we place all our engineering and consulting capabilities behind the companies that do. And by serving our customers, we play our part. Who we are We are the leading consulting and engineering company in the complex field of pharma and biotech. We count close to 1,700 professionals with project experience and knowledge related to pharma and biotech. More than 200 have hands-on development or production experience. We executed 2,667 projects in Our project execution and our staff embody 10,000 years of experience within pharma and biotech 4 2

3 Our services 5 Automation and IT Automation & IT are key to obtaining competitive advantages by achieving faster, more efficient delivery at lower costs without compromising flexibility and quality. 6 3

4 Global reach - local knowledge 7 Globally +300 Automation & IT employees are ready at your service Hvorfor er Life Cycle Management en god ide? 8 The man who achieves makes many mistakes, but he never makes the biggest mistake of all - doing nothing 4

5 In the good old days life was beautiful We bought a system, put it in a corner office and locked the door. We let it run for 20 or 25 years without much needed maintenance or expenses. Our production setup was consistent so we rarely had to adjust our system. 9 We did have a few modest wishes 1. Much cheaper hardware, DKR for an operator station??? 2. Increased automation level and paperless production to save cost. 3. Implementation of global standards to help us tie our islands of automation together 4. Open (to the internet) systems that could help us integrate our global supply chain 10 5

6 The PC and the Windows OS technology seemed ideal to solve our problems It allowed us to buy cheap COTS hardware instead of the pricey Unix/VMS stations It eased interfacing between computers and applications to support our vision of paperless production. It gave us OPC and other standards to allow us communicate across different systems and platforms. It interconnected our global process control networks via the Internet 11 but 12 6

7 Proactive Life Cycle Management OK so the world of information technology is changing! We cannot anymore buy a system and set the egg-timer for 25 years. What now? 13 Life Cycle Management - why What s the business case in Life Cycle Management? 7

8 Automation systems expected lifespan* Average age of installed process automation systems in company Expected operable lifecycle of a new automation system 11,1 1,8 7,1 1-5years 6-10years 24, years 12, ,3 13,4 1-5years 6-10years 11-15years 16-20years 21-30years 21-30years 55,6 >30years 33,6 32, years >40years Average 13,75years Average 16,64years Are suppliers published obsolescence date the date a system is considered obsolete Systems installed beyond suppliers obsolescence date yes no 87,8 12,2 yes no 15 *) Source: ARC advisory group The cost of downtime The Great North East Blackout 1) FirstEnergy "failed to assess and understand the inadequacies of FE s system, particularly with respect to voltage instability and the vulnerability of the Cleveland- Akron area. 2) FirstEnergy "did not recognize or understand the deteriorating condition of its system"... A bug existed in General Electric's Unix-based XA/21 control system. This stalled control room alarm system for over an hour. System operators were unaware of the malfunction; the failure deprived them of both audio and visual alerts for important changes in system state. After the alarm system failure, unprocessed events queued up and the primary server failed within 30 minutes. Then all applications (including the stalled alarm system) were automatically transferred to the backup server, which itself failed. The server failures slowed the screen refresh rate of the operators' computer consoles from 1 3 seconds to 59 seconds per screen. The lack of alarms led operators to dismiss a call from American Electric Power about the tripping and reclosure of a 345 kv shared line in northeast Ohio. Technical support informed control room personnel of the alarm system failure at 15:42. 8

9 The cost of downtime Lost Revenue Lost Production time including startup costs Product scrapping and waste Repair costs Replanning efficiency loss Non compliance, Stress - people Stress - Machinery Accidents Penalties Goodwill / Brand damage Hvad inkluderer lifecycle management? 18 9

10 Asset Life Cycle Management - definitions Asset Lifecycle Management is a balanced and active management of assets over the lifecycle, coupled with business objectives. Managing IT equipment and product life-cycles is an important function of IT department staff. As a goal, equipment life-cycle management should reduce failures and data-loss because computer equipment is replaced before it fails, and it should reduce the total cost of equipment management over its lifetime Commision Design Operate Retire Maintain Repair Modify Upgrade Replace The Life Cycle Management business process context The Life Cycle Management business process should be closely integrated and embedded within the company s master planning and annual cycle of work. If a yearly assessment is chosen, It should be timed to feed into the budgeting process. 10

11 1 Project Initiation & Mobilization 2 Risk & Opportunity Analysis Production 3 Requirement Mapping & Specification 4 System & Vendor Selection 5 System Development & Test Replacement 6 System Replacement & Test Production 7 System Handover & Support Proactive Life Cycle Management Life Cycle Management Plan or Strategy plan: Long term overall plan for system evolution, depicting upgrades, component replacements and system migrations. Upgrade: 1:1 update of system from one software version to another very similar. Normally involves very limited system changes. Migration: Update of system from one software platform to another or between two very dissimilar versions. Often also includes considerable functional changes. Revamp: Significant functional change of system or exchange of system components. Strategy Plan 4-8years Strategy Plan 4-8years Migration Plan Migration Plan 21 Life Cycle Management planning By working with a strategic Life Cycle Strategy for Automation and Production IT systems a proactive Life Cycle Management Plan can be created to address possible automation/it pain points before they upset business performance. the right solutions in the right sequence and at the right point of time Preparing for a major migration, making a migration (project) plan helps scan multiple options and assess business needs to find the best possible Migration Plan good and robust execution of the migration 22 11

12 Hvorledes opnås viden om systemernes reelle tilstand for at vurdere om der skal ske en opgradering? 23 Two factors influence the Life Cycle strategy planning Risk Management Business Opportunities Capacity increase Capacity Utilization (flexibility) COGS reduction BUSINE$$ Case? customer service Quality Improve ments 12

13 Business opportunities Today s companies are continuously faced with new challenges and new opportunities. Knowing where you are and where you need to be in 5-10 years time is key to the delivery of continuous top of class performance. Automation/IT typically represents 2-8% of a plant s assets Don t let outdated Automation/IT solutions be a roadblock to capture new business opportunities. 25 Risk Management Risk is a function of time Use a structured tool to: Identify all risks Assess all risks (objective, data driven) Extrapolate all risks 13

14 Risk Management Mitigated risk-curve Spare part stocking 2010 Partial HW upgrade 2011 Major system upgrade 2013 Sample tool to assist migration considerations High Filling Line MES system EMI solution Business/Risk driven Business driven Level of IT integration Risk driven Utility system Business/Risk driven Pilot plant Robot cell control Low Flexibility & business dynamics High 28 14

15 Hvorledes inkluderer Life Cycle management forskellige opgraderings typer? 29 Working with the migration strategy Is this a Migration Strategy?? This can be a very important question! Answering this question sometimes takes up 80% of migration analysis? In many situations other considerations are even more important Ex. data-migration, fall-back options. Do we go with Siemens or ABB? 30 15

16 Types of migration Incremental Big Bang Keep risk low and downtime reasonable! Get it over with, save money! Focused (partial) Extensive (new platform) Only fix what needs fixing! Keep platform up-todate. Prevent budding and system degeneration Types of migration Forward engineering Reverse engineering I want you to design the system we really need. I need all the good stuff we put into the system for the last 15 years to be ported to the new system. Upgrade Revamp Don t mess with fancy add-ons. Do the basics and keep risk&cost down. Our current system was designed for our needs in 1989 not 2009! 16

17 Actively considered trade-offs scope time risk quality cost tradeoffs downtime cost cost risk cost The Pit Stop migration Strategy 1 Project Initiation & Mobilization 2 Production Replacement Production Risk & Opportunity Analysis 3 Requirement Mapping & Specification 4 System & Vendor Selection 5 7 System Development & Test 6 System Handover & Support System Replacement & Test 17

18 Selected Project Examples Client/Project Old system New system Special challenges & learning's PCS replacement in bulk facility PCS replacement in bulk facility SCADA upgrade in Fill Finish facility PCS replacement in bulk facility Procos Sattline Do not rely on old documentation which is not necessarily consistent with current system configuration & current validation approach AB2000 DeltaV Make sure that the process design is completed/tested in due time before programming the automation solution FIX32 ifix Use a risk based approach, it may reduce the time/cost by 50% SattLine System800xA Try to avoid hybrid solutions with a mix of different technologies not tested before PCS upgrade/enhanceme nt bulk facility Various AB PLC/SCADA systems Latest version of AB PLC s, Compact- Logix It might be necessary to decrease the level of automation in order to get the necessary flexibility in a multi purpose facility 18