IT/OT Integration (Integrated Production Management System)

Transcription

1 IT/OT Integration (Integrated Production Management System) Marcel Kelder Sales Manager Advanced Solutions May 26,

2 Topics What we observe Different worlds IT/OT integration Cyber Security Infrastructure Services Summary 2

3 What we observe 3

4 Supply Chain Program Suppliers Feedstock Production Inventory Transport Customers Supply Planning Annual Delivery Program Sales and Operations Plan Tactical Planning 90 Days Planning Production and Distribution Plan Production Scheduling Weekly Schedule Production and Logistic Schedule 4

5 Information KPI Dashboard Production & Logistics Kaizen Maintenance Production Planning Yield Accounting Production Scheduling Production Tracking Distribution Scheduling Optimization RAM Analysis PQCDS Root-cause Analysis Operation Management Information Production Loss Analysis LIMS RTOS PAS SCS AMS Asset Performance Plant Historian LIMS: Laboratory Information Management System RTOS: Real-Time Optimization System PAS: Production Accounting System SCS: Supply Chain Scheduling System AMS: Asset Maintenance System RAM: Reliability, Availability, Maintainability PQCDS: Production, Quality, Cost, Delivery, Safety 5

6 Our Observation - POOR INTEGRATION LEAD TO SILORIZATION MANY HAVE INVESTED IN ADVANCED SOLUTIONS TO IMPROVE OPERATIONAL EFFICIENCY, BUT POOR INTEGRATION LEAD TO SILORIZATION Planning and Scheduling; Operational Management; Asset Management, Vibration Monitoring, AMADAS, etc.; Alarm Management, Operator Training Simulator MANAGEMENT CONCERNS AND CONTINUOUS IMPROVEMENT Close the Gaps between Planned and Actual in Real-time EFFICIENCY HUMAN RELIABILITY Trained Competency versus Actual Competency Asset Reliability UNPLANNED OUTAGE SAFETY HSE, Asset, Personnel, Incidents, Near miss reporting 6

7 Different worlds 7

8 The different domains Internet Level 4 Level 3 Enterprise Resource Planning system (Office domain) Level 3.5 Demilitarized Zone (DMZ) Systems to integrate level 2 and 4 (MES) IT OT Level 2 Supervisory, control and safety systems (PCD) OT Level 1 Sensing and manipulating equipment (e.g. instrumentation and valves) PCD = Process Control Domain MES = Manufacturing Execution System 8

9 So many stakeholders Share holders Senior Management Trade Planning HSE Finance HR Readiness Business Communication and integration Operation Maintenance Training Marine / Port Engineering Readiness Operations Contractor / Vendor 9

10 Change management Legal Terms and Conditions Human Resources Roles and training Quality New procedures IT New Technology Integration Management Recources and budget Sales and Marketing Operations Third Part Supplier Services 10

11 Prerequisites for Change HIGH SKILLS adequate LEADERSHIP MOTIVATION adequate HIGH adequate HIGH 11

12 IT/OT Integration 12

13 Business Excellence Operational performance Business performance 13

14 Key Pillars for Operational & Business Performance Business Performance Supply Chain Management Operations Management Asset Management Production Management Minimize disruption to supply chain and ensure committed delivery. Ensure safe operation and regulatory compliance - License to operate. Maximize asset deployment and avoid unplanned downtime by ensuring equipment is healthy and operating in the optimum mode. Clear alignment of business and production objectives. Minimize operating cost and improve yield. Operational Performance 14

15 Typical Yokogawa Logical Diagram Phase ISA Level 4 Business Planning & Logistics ERP Sales, Marketing and Planning L4 Middleware Enterprise Data Historian Document Management IT Security L3 Middleware ISA Level 3 Production Operation Management Supply Chain Scheduling Production Accounting (Mass balancing) Laboratory Information Management Terminal Management for Tank, Ship, Train and Truck Procedure Management Shift Handover and Work Instructions Incident Management Management of Change Permit To Work CMMS Inspection/Integrity Management Analyser Maintenance System Performance Dashboard Energy Real-Time Optimizer Alarm Management Modular Procedure Automation Data Historian System ISA Level 2 Manufacturing Control Movement Control Functional Safety Monitoring and Overide Advisor CONTROL & SAFETY SYSTEM (DCS & SIS) Device Maintenance APC OTS Blending Control Analyser system 15

16 Integration levels Value added lies in integrating the various applications into one environment Application A Application B Application C Business Information Application Technology People Security Framework 16

17 From zero to chaos What is the single truth No budget No budget 17

18 Focus integration Production - Safety & Security - Availability - Efficiency - Reliability Information - Enabling - Interfacing - Aligning Business - Profitability - Sustainability Implementation by Contractor IT department Business consultant Focus L3 Integration Low Medium Medium Scope uncertainly Relatively low High Relatively high Interdependency Moderate High Very High 18

19 Pain and Owners Level 3: Vision of a Solution Level 2: Admitted Pain Companies willing to discuss problems, difficulties, or dissatisfaction with the existing situation. Business owner: Often the person at the end of the pain chain and has direct influence on the process. Budget owner: The person who is able to make budget available for the investment Level 1: Latent Pain Companies who are not looking and not actively trying to solve a problem are in latent pain. 19

20 Chaos versus managed Physical firewall Physical firewall L3 Switch L3 Switch Hyper Converged Hyper Converged Many boxes many brands Multiple policies for infrastructure and security Many point to point interfaces Excel is our best friend Significant human intervention No single truth Brands and boxes managed One policy for infrastructure and security Few interfaces preferable via middleware Excel is not an solution Almost no human intervention One single truth 20

21 Cyber Security 21

22 Causes of intrusions No proper procedure in place for Cyber security in the Operational Technology (OT) Domain. No ownership for Cyber security in the OT Domain. Company information not well protected. User profiles not well defined. Hardware not proper hardened (e.g. switch of USB ports) Computers and servers don t have to latest patches. No updated anti virus software. No proper monitoring of hardware, software and applications.

23 User and Information streams Level 4 Office Network Users Data Level 3.5 DMZ Network Level 3 Process Information Network Level 2 Process Control Network The way information is exchanged between the different layers significantly determines the Cyber Security Infrastructure 23

24 Security Precausions Physical Security Application Systems Network Security Host Based Security Integration Application Based Security Disaster Recovery Users Services

25 Plant Security Program Plant Security Program Level Plant Alert Plant Remote Plant Secure Plant Baseline Assessment Awareness Cyber Security Training Plant Security Master plan design Plant Security Policy and Procedures Plant Security Design Service Plant Security Implementation Service Plant Security Capability Training Package Remote Monitoring - 24/7 Live Monitoring - Patching and update service - Asset Management and logging - Third party remote access Incident Management - Incident Response - Maturity Reporting 25

26 Change management assessment Legal Terms and Conditions Human Resources Roles and training Quality New procedures IT New Technology Cyber Security Management Recources and budget Service Incidents Operations Managed Services Third Part Supplier Managed Services 26

27 Infrastructure Yokogawa Plant Security Emerson Yokogawa Plant Security Vendors Secure Centre Secure Site WSUS Anti virus Host Honeywell Emerson WSUS WSUS Honeywell OPL Anti virus Anti virus WSUS Host Anti virus Remote access Remote access Yokogawa Yokogawa Others Others Others WSUS Host Anti virus 27

28 Secured Remote Solutions FY 14 Achievements ARC Forum (9 th 12 th Feb in Orlando) Press Release (Japanese/English) User Presentation & Panel Discussions

29 Managed Services delivered by Yokogawa Requirement Asset Inventory O.S. Security patching Anti-Virus Management & Updates Remote Access Yokogawa Managed Service Automated asset discovery and asset inventory Automated distribution of validated Microsoft updates Automated distribution of validated signature updates Unified secured remote access, with 2 factor authentication Log file collection Security majority reporting Proactive system monitoring 24x7x365 supported Incident response Automated log file collection to central log server Automated report of the status of the applied security measures CPU, Memory load, Disk usage, system and software failures Helpdesk and managed services Global security incident response team 29

30 Incident response center Glance overview to support Help Desk Operation & SLA with below information: - SecureCentre and SecureSite Locations - SecureCentre/Sites Monitoring - Call Handling Status - Ticketing/Incident Monitoring - Compliance Status/Report L2 Help Desk in Romania L3 Help Desk in Amersfoort

31 Infrastructure 31

32 Virtual Machines Virtualization is a proven software technology that is rapidly transforming the IT landscape and fundamentally changing the way that people compute, such as an operating system, a server, a storage device or network resources. Application Operation System Application Operation System Application Operation System Hardware Virtual Machine Monitoring Hardware CPU Memory NC Disk Traditional server with operating software CPU Memory NC Disk Server with two virtual machine operating software 32

33 Middleware setup Presentation Layer Business Process Middleware Service Bus Application Application Application Application 33

34 Storage Storage Area Network (SAN) Block level data Primary media: Optical fiber Reliability Performance Access Network Area Storage (NAS) File level data Primary media: Ethernet Remote Access File Sharing Scalable 34

35 Hyperconverged Systems Optimize performance and efficiency - simplify deployment of servers, storage, and networking for business applications Centralized management of compute, storage and virtual machines 10GbE networking for application and storage performance High availability 35

36 Summary Integrated Production Management System IPMS is critical for the operational and business performance of the plant Assign a business owner and budget owner for the IPMS Write a IPMS master plan at an early stage of the project IPMS budget is often forgotten with consequences Deployment of the IPMS afterwards happens rarely IPMS is the responsibility of the operator and not the EPC Delivery time IPMS is often under estimated (12 18 months) The IPMS provides the single truth which is a completive benefit 36

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