DAU meeting Rockwool International A/S Hedehusene. Life Cycle Management

Transcription

1 DAU meeting Rockwool International A/S Hedehusene Life Cycle Management

2 Introduction Henrik Bo Christiansen Account Technology Strategist Microsoft Denmark Career: Siemens/Siemens Nixdorf Consultant/Project Manager Microsoft Denmark Consulting Services Interprise Consulting A/S Owner Consulting Manager Trifork Consulting Manager Microsoft Denmark Account Technology Strategist Henrik Pedersen Partner Automation IT consulting NNE Pharmaplan A/S Career: SattControl A/S Automation Engineer Project Manager Alfa Laval Automation Engineering Manager ABB Engineering Manager Vice President NNE Pharmaplan Partner Consulting 2

3 The perspective of the Automation end-user 3

4 According to a recent report by ARC, the global value of installed automation systems in process manufacturing facilities that have reached the end of their lifecycle is estimated at $65 billion. Setting the Scene On average, the investment in automation during the first half of the life cycle (justify, apply, and install) is only 40% of the total life-cycle investment. The remaining 60% is devoted to the second half of the life cycle Rapidly changing technologies make the previous practiceinstalling a control system and "letting it run" untouched for 15 or 20 years-impractical today The estimated average impact of unscheduled downtime is between 2-5% of total production value 4

5 In the good old days life was beautiful We bought a system, put it in a basement and locked the door. Let it run for 20 or 25 years without much needed maintenance or expenses. Our production line ran fixed and stable so we rarely had to reprogram our system. 5

6 We had a few modest wishes 1. Much cheaper hardware, DKR for an operator station??? 2. Increased automation and paperless production to save cost. 3. Implementation of global standards to help us tie our islands of automation together even if we had chosen to invest in multiple system brands! 4. Open (internet) systems that could help us integrating our global supply chain 6

7 The PC and the Microsoft Windows technology platform seemed as 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 7

8 but Why can t these Microsoft guys solve one problem without creating 2 new challenges? 8

9 Hacking Crime Development From Cool... To...Cool Cash 9

10 Industrial Automation security challenge High number of security threats (Viruses, worms, intrusions,...) also in automation environments. Stuxnet. Long term availability of industrial automation solutions (lifecycle) availability of patches. More connectivity between manufacturing and business networks process insights. Ongoing management of users, devices, configurations, patches. Increasing knowledge required for IT security and administration. Industry specific: Often a requirement to keep production going even when system is compromized. 10

11 Is this a Microsoft specific problem? Microsoft acknowledges high responsibility as a result of the broad installed base. This clearly is a software industry problem. Secunia 2010 Half Year Report: The overall conclusion: the software industry at large still proves unable to produce software with substantially less vulnerabilities 3rd party program vulnerabilities still perceive the operating system and Microsoft products to bethe primary attack vector, largely ignoring 3rd party programs In the two years from 2007 to 2009, the number of vulnerabilities affecting a typical enduser PC almost doubled from 220 to 420, and based on the data ofthe first six months of 2010, the number is expected to almost double again in 2010 to 760. A typical end-user PC with 50 programs installed had 3.5 times more vulnerabilities in the 24 3rd party programs installed than in the 26 Microsoft programs installed.it is expected that this ratio will increase to 4.4 in

12 Microsoft support policy

13 Proactive Life Cycle Management 13

14 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? 14

15 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 21-30years >30years 55,6 12,9 33, ,3 13,4 32,8 1-5years 6-10years 11-15years 16-20years 21-30years 31-40years >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

16 Proactive Life Cycle Management Evolution 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. Revamp: Significant functional change of system or exchange of system components. Migration: Update of system from one software platform to another or between two very dissimilar versions. Often also includes considerable functional changes. Strategy Plan 4-8years Migration Plan Strategy Plan 4-8years Migration Plan Start operation System upgrade System upgrade System migration System revamp System upgrade Decommission 16

17 Project Initiation Mobilization Risk Opportunity Analysis Production Requirement Mapping Specification System Vendor Selection System Development Test Replacement System Replacement Test Production System Handover Support Why do you need a Life Cycle strategy for your automation MES systems? By working with a strategic Life Cycle Strategy for Automation and Production IT systems a proactive Evolution 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 Even if system migration is urgently needed making a migration strategy helps scan multiple options and assess business needs to find the best possible Migration Plan (and make a virtue of necessity) good and robust execution of the migration 17

18 When to migrate When you cant buy spares on ebay anymore Our data showed some occurring failures that weren t impacting control, but indicated that reliability in the future might become a problem Obsolescence does not happen on a specific date, but rather is a gradual process that starts with a vendor discontinuing support. At some point, spares become too expensive or too hard to find, obsolescence becomes inevitable and migration must occur Our project was undertaken in conjunction with a plant expansion. The existing control system is still supported, but we did not want to install obsolete technology on new process units. 18

19 When to migrate Risk is a function of time and can often be mitigated. Opportunities (business case) are most likely emerging from changes in the business environment, the business needs, new or improved products, new technology available etc. A migration decision can be triggered by risk, by new opportunities or by a combination of the two. 19

20 Risk Mitigation Operational risk in an Automation/IT system is a function of time. By careful planning the operational risk can be kept at an acceptable level, while protecting existing investments and minimizing Life Cycle Cost. Planned Mitigation Of risk 20 Unmitigated risk scenario Mitigated risk scenario

21 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 5-8% of a plant s assets Don t let Automation/IT be a roadblock to capture new business opportunities. Use it as enabler!! 21

22 Migration Plan - Sorting out priorities There are many tradeoffs - Get the priorities sorted out! Migration Priority Map Downtime 5 You can talk about generic tradeoffs but project by project assessment is needed! Investment Environment If you don t know your priorities you can t find the optimal solution. Operating Cost 1 0 Quality Risk Time 22

23 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 23

24 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 riskcost down. Our current system was designed for our needs in 1989 not 2009! 24

25 Proactive Life Cycle Management OK so proactive life cycle management will help us stay in control But why does it have to be so screaming expensive to migrate automation systems? We need cheaper and better managed solutions! 25

26 What s Up? Future Development and Services - Biztalk -Cloud Microsoft Management Tool - NEW 26

27 Updating Migration Savings Cloud Service Patch Update ERP Application PCS, SCADA OS PLC OLD OLD OLD OLD? DELTA NEW NEW NEW NEW BAM * SSRS SQL D * Business Activity Monitoring

28 Managing security in modern Windows based Automation System environment Windows Embedded Device Manager 2011 New product based on Microsoft System Center Configuration Manager. Thin Client Windows XP Embedded Windows Embedded Standard 2009 Windows Embedded Standard 7 Point Of Service Windows XP Embedded Windows Embedded for Point of Service Windows Embedded POSReady 2009 Digital Signage Windows Embedded Standard 2009 Windows Embedded Standard 7 Use the differential VHD to always boot from a secure image Ask your vendor to use Windows Server Core to reduce the number of required patches by approx. 59% 28

29 How to benefit from Cloud Computing in securing Automation Systems Microsoft Intune Manage and secure PCs using Windows cloud services and Windows 7. IT staff can remotely perform a number of essential management tasks including Microsoft updates, malwareprotection, and inventory management so IT and end-users can remain productive from virtually anywhere. Windows Azure and SQL Azure Web services Biztalk competence Patch management Updates CloudGUARD 29

30 Further Info Learn more about Microsoft Products SecureGUARD: Microsoft Embedded: Embedded Device Management: Windows Intune Developing Secure Code: Secure Development Lifecycle (SDL) on MSDN: Secunia half year report. Industrial Automation ISA 99 Website Example Siemens Security Framework PCS7 and WinCC 30

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