Accelerating Industrial Performance. Copyright 2014 Rockwell Automation, Inc. All Rights Reserved.

Transcription

1 Accelerating Industrial Performance

2 By billion new middle class consumers will add $8T to consumer spending Increased Demand on Industrial Production GLOBAL POPULATION TRENDS INCREASE DEMAND FOR Manufacturing Resources Infrastructure EMERGING MARKET CONSUMERISM 30% 100% More Water More Vehicles 80% More Steel 50% More Energy RESOURCE PRODUCTIVITY INVESTMENT $1T Annually Source: McKinsey 2

3 Government Initiatives Technologies Visions for fueling manufacturing leadership Innovations that redefine and create new value opportunities Smart Manufacturing Leadership Coalition Industrie 4.0 Made in China 2025 Manufacturing Usine du Futur Innovation 3.0 IoT Security CPS SMART MANUFACTURING ENABLED BY THE CONNECTED ENTERPRISE AVAILABLE Today and FOUNDATIONAL to Achieving These Visions Industry Consortiums Industry Standards Assemble and promote best practices Drive interoperability and commonality PUBLIC Copyright 2015 Rockwell Automation, Inc. All Rights Reserved.

4 THE CONNECTED ENTERPRISE Optimized for Rapid Value Creation Headquarters Smart Grid Customers Supply Chain Distribution Center 4

5 IT-OT CONVERGENCE Transactional information: orders, supply network, product design ERP FINANCIALS HR LOGISTICS QUALITY WAREHOUSE IT COMMON SECURE NETWORK INFRASTRUCTURE INDUSTRIAL THINGS Real-time data: alarms, events, states, energy, diagnostics, PLCS & SCANNERS MATERIAL & TRANSPORT OT MACHINES & TESTERS SHOP FLOOR PERSONNEL PRINTERS & LABEL SERVICES 5

6 Connected Enterprise The Industrial lot at work for Industrial Applications DATA & ANALYTICS SCALABLE COMPUTING & CLOUD MOBILITY Contextualizing and analyzing data Smart devices create more things to be analyzed Reliability, support, and disaster recovery Shift from CapEx to Flexible & Scalable OpEx Access to actionable information Workforce is Mobile during typical work day

7 Connected Enterprise Delivering Operational Excellence 90% ON TIME Top performers achieved better on-time performance to NEW PRODUCT INTRODUCTION LOWER Cycle & Change Over Times 18% 16% x2 INCREASE in annual financial improvements better than average Source: MESA Research Quality Improvement Fewer product defects Upstream supplier activities Flexible Operations Faster change over Performance increase Information Anywhere Contextualized data Smarter, more productive Protected Assets Safe & secure operations Protect Intellectual Properties Connecting People, Process & Technology

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9 The Connected Enterprise EXECUTION MODEL Assessment Secure, Upgrade Working Data Capital Analytics Optimize & Collaborate 9

10 Stage 1 ASSESSMENT 14% MANUFACTURERS in the US have completely INTEGRATED plant floor information to the enterprise 12% Have NO integration at all Source: 2013 Industry Week Study 71 % Perceive their control systems threat level as moderate to severe 24% Have NEVER performed a vulnerability assessment Source: Control Engineering 2014 Cyber Security report Increase VALUE and Reduce RISK

11 ASSESSMENT PROTECTION against security breaches VALIDATE network performance and reliability DATA MANAGEMENT reconcile disparate data sources FUTURE PROOF for expanded use & advancements in technology - CLOUD, MOBILITY, SECURITY First step in developing the BLUEPRINT to a CONNECTED ENTERPRISE

12 Stage 2 SECURE & UPGRADE 70% Of companies SUFFERED a security breach in the last year 28% Yet only strategic priority ranked SECURITY as a top five Source: 2014 Ponemon Institute survey Threats will continue to evolve is your architecture ready? 13% Of those that DO: ORGANIZATIONS that have implemented Smart Manufacturing 82% 49% experienced improved EFFICIENCY in their operations experienced fewer DEFECTS in their products Source: 2013 American Society for Quality (ASQ) Survey

13 SECURE & UPGRADE Automation and Networks SINGLE, UNIFIED network technology for both OT and IT PERFORMANCE INCREASE by replacing or isolating untrusted legacy systems REDUCE DOWNTIME leveraging the data from smarter devices & systems AUTHENTICATE, AUTHORIZE & ACCOUNT for who has access, and to what Better protect assets by SECURING the data flow all the way to the end points

14 Networking Design Considerations Reduce network Latency and Jitter, increase the Availability, Integrity and Confidentiality of data, and design and deploy a Scalable, Robust, Secure and Future-Ready network infrastructure.???? Single Industrial Network Technology Robust Physical Layer Segmentation / Structure Prioritization - Quality of Service (QoS) Redundant Path Topologies with Resiliency Protocols Time Synchronization PTP, CIP Sync, CIP Motion Multicast Management Convergence-ready Solutions Security Holistic Defense-in-Depth Scalable Secure Remote Access Wireless Wi-Fi 14

15 Converged Plantwide Ethernet (CPwE) Reference Architectures Enterprise Internet Wide Area Network (WAN) Physical or Virtualized Servers ERP, Active Directory (AD), AAA Radius Call Manager External DMZ/ Firewall Enterprise Zone Levels 4 and 5 Physical or Virtualized Servers Patch Management Remote Gateway Services Application Mirror AV Server Physical or Virtualized Servers FactoryTalk Application Servers & Services Platform Network Services e.g. DNS, AD, DHCP, AAA Remote Access Server (RAS) Call Manager Storage Array Link for Failover Detection Firewall (Active) Catalyst 6500/4500 Firewall (Standby) Cisco ASA 5500 Industrial Demilitarized Zone (IDMZ) Plant Firewall Inter-zone traffic segmentation ACLs, IPS and IDS VPN Services Portal and Terminal Server proxy Industrial Zone Level 3 Site Operations Remote Access Server Catalyst 3750 StackWise Switch Stack Industrial Zone Cell/Area Zones Levels 0 2 Phone Rockwell Automation Stratix 8000 Layer 2 Access Switch HMI Safety I/O Safety Controller Controller Camera Instrumentation Cell/Area Zone #1 Redundant Star Topology Flex Links Resiliency MCC I/O Soft Starter Cell/Area Zone #2 Ring Topology Resilient Ethernet Protocol (REP) Servo Drive Cell/Area Zone #3 Bus/Star Topology Robot Copyright 2014 Rockwell Automation, Inc. 9 All Rights Reserved.

16 Stage 3 WORKING DATA CAPITAL BIG DATA 2Exabytes Manufacturing generates more BIG DATA than any other sector. 24% Average annual IMPROVEMENT in Total Cost per Unit for Top performers better than average 11% Source: MESA Research Data is there, Are you using it to gain a COMPETITIVE ADVANTAGE? Transform DATA into INFORMATION

17 WORKING DATA CAPITAL DELIVER actionable information in real time to all levels of the business SHARE data securely across global operations OUT PERFORM competitors by optimizing your entire process UNLEASH THE VALUE of the stranded data from devices in and around operations

18 Stage 4 ANALYTICS: OPERATIONAL BENEFITS 80% OEE Top performers achieved overall equipment efficiency 10% Source: MESA Research higher Increase in annual Financial Improvements 14% (5X BETTER than average) 60% 30% Lack the necessary equipment connectivity to capture the data Have NO integration at all Source: 2013 Industry Week Study Transforming INFORMATION into KNOWLEDGE

19 ANALYTICS: OPERATIONAL BENEFIT REALIZATION UNDERSTAND process performance in real time RESPOND quickly to changes in the process INCREASE uptime and reduce waste Improve PRODUCTION EFFICIENCY and PRODUCT QUALITY

20 Stage 5 OPTIMIZE & COLLABORATE Anticipate activities throughout the ENTERPRISE and through the SUPPLY & DEMAND chain LOWER Customer Rejects & Returns INCREASE Supplier Incoming Quality (& Higher 1 st Pass Yields) KNOWLEDGE & EXPERIENCE will shrink significantly over the next years 5 Leverage centrally located DOMAIN EXPERTS across operations, sharing best practices and enlisting the knowledge base of an entire supply chain Transforming KNOWLEDGE into POWER

21 OPTOMIZE & COLLABORATE IMPROVE inventory by managing your supply chain - right parts, right time, right place CONTROL BUDGET by knowing the cost of goods produced - material, labor & energy REMOTE ACCESS to PEOPLE, ASSETS and DATA in real time - securely, anytime & anywhere INNOVATION that creates ACTIONABLE INSIGHT

22 Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

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24 The Connected Enterprise Implementation & Transformation 387, 000 SKUS 20 PLANTS 200 PARTS AVG ORDER 20 YEARS AVG PRODUCT LIFE PRODUCT TYPES Stock + Configure to Order Engineered to Order Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

25 ISSUES DISCOVERED Custom applications Numerous functional experts Independent ERP systems Model replication cost prohibitive Autonomous P&L centers No single system to run plants

26 The Connected Enterprise Rockwell Automation Transformation LOWER COST PLANT BEHAVIOR FASTER TIME TO MARKET SUPPLY CHAIN / LEAD TIMES ENTERPRISE RISK CUSTOMER SERVICE Inventory 120 days to 82 days Delivery Mid-80s to 96% Time to Want 82% to 98% CapEx 30% per year in capital avoidance Lead Times Reduced 50% Quality 50% reduction in PPM Productivity 4% to 5% per year

27 THE CONNECTED ENTERPRISE delivers transformational value in productivity and global competitiveness $ Faster Time to Market Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management

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