MSD Biotech Upstream Processing (USP) Oss Instrument Asset Management IIoT Cloud Analytics Out of the Box

Transcription

1 MSD Biotech Upstream Processing (USP) Oss Instrument Asset Management IIoT Cloud Analytics Out of the Box Jaap Westeneng Endress+Hauser

2 IIoT Cloud Analytics bij MSD in Oss De industrie wordt met het toepassen van IIoT oplossingen uitgedaagd om op een veilige manier informatie te ontsluiten naar de Cloud. Aan de hand van een concrete case bij MSD in Oss willen we laten zien hoe een IIoT Cloud Analytics toepassing is gerealiseerd voor het beheren, bewaken en borgen van hun productiemiddelen.

3 MSD, Netherlands De Geer Biotech Operations Manufacturing of active ingredients for medicines in a biotechnological way Moleneind MSD Netherlands Oss Human health Haarlem/Hoofddorp Human vaccines and human health Boxmeer Animal health Location Oss is largest international MSD facility. Pharmaceutical Operations Manufacturing, packaging and distribution of prescription medicines De Geer Biotech Operations Upstream Processing (USP)

4 Biotech Operations Location De Geer Manufacturing of active ingredients for medicines using livings cells and microorganisms. Registered medicines Pipeline products that are still being researched Around 400 people work at Biotech Operations Investments > 100 million euro ( ) State of the art facilities Innovative technologies

5 Timeline MSD location Oss 1947 The Van Zwanenberg family company is quoted on the stock exchange: NV Koninklijke Zwanenberg- Organon 2001 Start construction Schneider (Foxboro) Process Control System (PCS) in combination with digital fieldbus communication (PROFIBUS) 1923 Dr. Saal van Zwanenberg founds Organon 1971 Diosynth (active pharmaceutical ingredients) divested from Organon

6 Timeline MSD location Oss 2003 Construction complete Commissioning and startup by means of universal configuration software (CommuWin) and PROFIBUS network switchboard

7 MSD Simplified Network Architecture Schneider (Foxboro) Process Control System 1 29 Switchboard 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Universal Configuration Software (CommuWin)

8 Timeline MSD location Oss 2004 First commercial batch rec-insulin 2003 Construction complete Commissioning and startup by means of universal configuration software (CommuWin) and PROFIBUS network switchboard

9 Timeline MSD location Oss 2004 First commercial batch rec-insulin 2003 Construction complete Commissioning and startup by means of universal configuration software (CommuWin) and PROFIBUS network switchboard 2006 Implementation of FDT (Field Device Tool) based Device Configuration Management (DCM) system (FieldCare) while maintaining network switchboard

10 MSD Simplified Network Architecture Schneider (Foxboro) Process Control System 1 29 Switchboard 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Universal Device Configuration Management Software (CommuWin) (FieldCare)

11 Timeline MSD location Oss 2004 First commercial batch rec-insulin 2007 Schering-Plough acquires Organon, Intervet and Nobilon 2003 Construction complete Commissioning and startup by means of universal configuration software (CommuWin) and PROFIBUS network switchboard 2006 Implementation of FDT (Field Device Tool) based Device Configuration Management (DCM) system (FieldCare) while maintaining network switchboard

12 Timeline MSD location Oss 2012 Johnson Controls (JCI) takes over calibration activities from internal team 2009 Merger Schering-Plough and MSD 2014 PCS Upgrade project Schneider (Foxboro) PCS replaced by Siemens PCS 7 while maintaining PROFIBUS infrastructure

13 MSD Simplified Network Architecture Schneider Siemens (Foxboro) Process Process Control Control System System 1 29 Switchboard 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Device Configuration Management (FieldCare)

14 Timeline MSD location Oss 2012 Johnson Controls (JCI) takes over calibration activities from internal team 2015 Plant Asset Management project Smart Installed Base Analysis Cloud based Asset Information Management (AIM) and PROFIBUS gateways to enable NAMUR NE107 device monitoring 2009 Merger Schering-Plough and MSD 2014 PCS Upgrade project Schneider (Foxboro) PCS replaced by Siemens PCS 7 while maintaining PROFIBUS infrastructure

15 MSD Simplified Network Architecture Siemens Process Control System Common Equipment Record (CER) cer.endress.com Private Cloud Public Cloud Asset Information Management Portal) portal.endress.com 1 29 Intelligent Switchboard PROFIBUS Gateway 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Device Configuration Management (FieldCare) Asset Information Management (W@M Enterprise)

16 MSD Cloud based Asset Information Management All smart and non-smart assets are managed and maintained in Cloud application and synchronized with an Enterprise (on premise) application. Save time in searching the right information Avoid failures by right and up-to-date data Insure a good overview and traceability of the installed base Manage asset information over total life cycle Information automatically available for Endress+Hauser devices starting from production date (Product Status, Spare Parts, Manuals, Certificates, Reports, ) Information for 3 rd party devices can be added manually.

17 Timeline MSD location Oss 2017 Initial kick-off field trial IIoT Cloud Analytics Realization Cloud based Installed Base Analysis by means of out of the box IIoT Edge device 2016 Enterprise Asset Management (EAM) upgrade Infor Datastream D7i replaced by SAP PM (Plant Maintenance)

18 MSD Simplified Network Architecture Common Equipment Record (CER) cer.endress.com Private Cloud IIoT Cloud Analytics iiot.endress.com Public Cloud Asset Information Management Portal) portal.endress.com Siemens Process Control System 1 29 Intelligent PROFIBUS Gateway 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Device Configuration Management (FieldCare) Asset Information Management (W@M Enterprise)

19 MSD

20 MSD Value Drivers for IIoT From Reactive/Preventive towards Condition Based Maintenance. From Manual to Automatic Smart Asset Registration. Autonomous Life Cycle Management. Automatic Installed Base Analysis and Automatic Insights; standardization, criticality and migration. From Planned Calibrations to Self Calibrating and Monitoring (e.g. temperature)

21 Why IIoT Cloud Analytics? As-Is situation Current Cloud based Asset Information Management application Portal) is not able to cover 100% Asset Integrity. (Difference between installed and registered devices) No overall plant overview of all smart assets and their respective status. No process unit overview for installed smart devices and their respective process unit status. No easy Insight (event history) per smart device and NO indication for predictive maintenance based on event history. No relevant and too many mail notifications.

22 Why IIoT Cloud Analytics? Current Cloud based Asset Information Management application Portal) is not able to cover 100% Asset Integrity. (Difference between installed and registered devices) Common Equipment Record (CER) Private Cloud As-Is Public Cloud Asset Information Management Portal) Sync PO x Asset Information Management (W@M Enterprise)

23 Why IIoT Cloud Analytics? Current Cloud based Asset Information Management application Portal) is not able to cover 100% Asset Integrity. (Difference between installed and registered devices) Common Equipment Record (CER) Private Cloud PO y As-Is +1 Public Cloud Asset Information Management (W@M Portal) Sync Asset Information Management (W@M Enterprise)

24 Why IIoT Cloud Analytics? Current Cloud based Asset Information Management application Portal) is not able to cover 100% Asset Integrity. (Difference between installed and registered devices) Common Equipment Record (CER) Private Cloud As-Is Public Cloud Asset Information Management Portal) Sync Asset Information Management (W@M Enterprise)

25 Why IIoT Cloud Analytics? Current Cloud based Asset Information Management application Portal) is not able to cover 100% Asset Integrity. (Difference between installed and registered devices) Common Equipment Record (CER) Private Cloud To-Be Public Cloud IIoT Cloud Analytics IIoT Cloud Analytics provides 100% smart asset registration

26 Timeline MSD location Oss 2017 Initial kick-off field trial IIoT Cloud Analytics Realization Cloud based Installed Base Analysis by means of out of the box IIoT Edge device 2016 Enterprise Asset Management (EAM) upgrade Infor Datastream D7i replaced by SAP PM (Plant Maintenance) nd phase IIoT Cloud Health Realization Cloud based Asset Health Monitoring by means of IIoT Edge device and smart devices

27 MSD Simplified Network Architecture Common Equipment Record (CER) cer.endress.com Private Cloud IIoT Cloud Analytics iiot.endress.com Public Cloud Asset Information Management Portal) portal.endress.com Siemens Process Control System 1 29 Intelligent PROFIBUS Gateway 1 29 Endress+Hauser (92%) Samson (11%) PROFIBUS DP (313) PROFIBUS PA (895) PR electronic (5%) Knick (4%) Remaining (1%) Device Configuration Management (FieldCare) Asset Information Management (W@M Enterprise)

28 Why IIoT Cloud Analytics? No overall plant overview of ALL smart assets and their respective status. As-Is Intelligent PROFIBUS Gateway

29 Why IIoT Cloud Analytics? No overall plant overview of ALL smart assets and their respective status. To-Be IIoT Cloud Analytics provides consolidated plant dashboard of all smart assets and their status

30 Why IIoT Cloud Analytics? No process unit overview for installed smart devices and their respective process unit status. As-Is

31 Why IIoT Cloud Analytics? No process unit overview for installed smart devices and their respective process unit status. IIoT Cloud Analytics assigns smart assets to process units and provides process unit status. To-Be As-Is

32 Timeline MSD location Oss 2017 Initial kick-off field trial IIoT Cloud Analytics Realization Cloud based Installed Base Analysis by means of out of the box IIoT Edge device 2018 > 3 rd phase IIoT Cloud Health Realization Cloud based Calibration Monitoring by means of self calibration smart temperature devices (TrustSens) 2016 Enterprise Asset Management (EAM) upgrade Infor Datastream D7i replaced by SAP PM (Plant Maintenance) nd phase IIoT Cloud Health Realization Cloud based Asset Health Monitoring by means of IIoT Edge device and smart devices

33 Kennismaking IIoT Cloud Analytics MSD IIOT CLOUD ANALYTICS INSIGHTS

34 Key elements for effective IIoT implementation Legacy equipment Take inventory of the devices and equipment across the network. How old are they? Do they need to be replaced or upgraded (e.g. PROFIBUS Profile 2.0)? Is legacy equipment able to communicate with newer equipment? Communication protocols What protocols are being used by networked devices (e.g. HART, PROFIBUS, Modbus, )? How many are in use? Location and environment Can each device be monitored? Are broadband or fiber-based networks available? Is industrial-grade equipment that is designed with wide environmental ratings and industry certifications being used?

35 Key elements for effective IIoT implementation Security How can sensitive data be protected when it is collected and transferred? What security measures are in place for the systems to collect, monitor, process and store IIoT data? Are there any regulations regarding the protection of data and information? Staff As more technology-based devices are added to the network, is the rights IT staff on hand?

36 MSD Lessons Learnt Now that we know how our installed base look likes, it s easier to order new instruments and keep the variety of different types under control. Although the natural gap between OT and IT is getting smaller, assigning responsibilities remains a challenge. Ensure that all systems and components are up-to-date. The more I have learned about industrial communication standards, the more I realize that there is still a lot I don t know. Technically an IIoT Cloud Application could be cyber secure but acceptance is determined by MSD policy.

37 Information Jaap Westeneng Architect Solutions Endress+Hauser B.V. Nikkelstraat AJ Naarden jaap.westeneng@nl.endress.com T M Plant Asset Management solutions Industrial Communication Technologies