2012 Honeywell Users Group EMEA. Sustain.Ability. John Schofield, Honeywell Improved Reliability, Safety and Compliance with Management of Change

Transcription

1 Honeywell Users Group EMEA Sustain.Ability. John Schofield, Honeywell Improved Reliability, Safety and Compliance with Management of Change

2 Is your intellectual property Is your intellectual property retiring with him? him? DOC4000

3 DOC4000 Reliability Technical Risk Planning Protect and Optimize Intellectual Property 3

4 Minimize human error Increase system availability Implement best practices across the enterprise Reliability 4 Up to 70% Savings Each Year Over Manual Documentation Methods

5 Technical Risk Planning Identify integrity issues Reduce troubleshooting time and effort Avoid costly shutdowns 5 Restore Operations up to 7 Days Faster and avoid loss of Daily Profits

6 Protect and Optimize Intellectual Property Capture tacit knowledge Aggregate and contextualize critical data Visualize and access key information % Productivity Improvement for Automation Professionals

7 Introduction In today s competitive environment, proper automation system documentation and change tracking are essential for effective troubleshooting, faster problem resolution, and incident avoidance As the complexity of control system platforms continues to increase, systems and subsystems must be properly documented and tracked throughout their lifecycle With the retirement of experienced staff, it is critical to protect intellectual property 7

8 Challenges Facing Plants Industrial organizations recognize that efficient change control is the only way to ensure they can rapidly adjust systems and processes so as to stay competitive and continually improve effectiveness and quality Managing changes will have a major impact on any company s future success Until now, there was no comprehensive solution available on the market to document and holistically manage change across the plant automation architecture 8

9 What is Honeywell s Approach? Honeywell s DOC4000 software provides an innovative solution for automation lifecycle documentation and change management DOC4000 is intended for use with a wide range of automation platforms Experion Process Knowledge System (PKS) TotalPlant Solution (TPS) TDC3000 platform Honeywell advanced solutions Third-party DCS Advanced solutions Safety systems Instrument databases 9

10 What is Honeywell s Approach? (Cont d) DOC4000 offers an automated way to help your organization assess, monitor, manage and control automation information and configuration data By enabling traceability, notification of changes and regulatory compliance, DOC4000 drives increased efficiency of your personnel, and as a result, your productivity DOC4000 offers a host of robust, best-in-class features for automation information management Web-based Interface Secure Data Access Robust Data Collection Flexible Licensing 10

11 What is Honeywell s Approach? (Cont d) DOC4000 aggregates and contextualizes configuration databases, programs and user interfaces, and simplifies visualization and management of information in plant control systems Comprehensive documentation Integrated change tracking System-wide data audits Lifecycle automation management Integrity issue identification Support for OSHA and FDA 21 CFR Part 11 11

12 What is Honeywell s Approach? (Cont d) DOC4000 provides a consistent method for documenting your automation environment, including greater cross-support of multiple systems Reduces interpretation of complicated control schemes by providing a graphical representation of each control interconnection Assists control engineers with system troubleshooting during critical process upsets Provides immediate access to data needed to investigate and resolve situations Reveals behind-the-scenes gotchas left behind by third-party contractors working on the system 12

13 What is Honeywell s Approach? (Cont d) DOC4000 significantly improves engineering productivity in the typical industrial plant Verification and creation of system documentation Tracking configuration changes to increase quality and reduce troubleshooting time Efficiency improvements across the operation 13

14 How Does the Solution Work? DOC4000 enables closer collaboration of your plant operations, maintenance and safety staff to minimize human error and simplify work processes Common access to the configuration information of disparate control systems, databases and advanced applications Platform for capturing tacit knowledge, contextualizing it, and making it accessible from the operator console where plant personnel work Captures experiential knowledge and makes it available to everyone who needs it 14

15 How Does the Solution Work? (Cont d) DOC4000 allows users to add, edit, and contribute to plant knowledge Provides the ability to incorporate electronic media files into the knowledge base and search for relevant plant information in external files such as spreadsheets, documents and s Unique mapping capabilities significantly reduce migration and systems integration project time, rework, and time spent on factory acceptance testing (FAT) 15

16 How Does the Solution Work? (Cont d) DOC4000 generates accurate documentation of configured automation systems that can be automatically updated, tracked and accessed enterprise-wide to enable productive collaboration between operations, maintenance, and safety personnel Cross-reference reports can be run to quickly identify relationships between various system components, and thus minimize engineering effort and avoid maintenance incidents 16

17 How Does the Solution Work? (Cont d) DOC4000 also meets today s demanding requirements regarding regulatory compliance obligations by recording and tracking changes across automation systems FDA 21 CFR Part 11 (Electronic Records and Signatures) OSHA (PSM Management of Change) 17

18 How Does the Solution Work? (Cont d) When paired with Honeywell s integrated Management of Change (imoc) solution, DOC4000 helps ensure effective management of change (MOC) across your entire operation Unlike homegrown MOC tools, imoc is an integrated add-on module that runs on top of DOC4000 to map the automation genome of industrial plants 18

19 What are the Benefits to Customers? Supported through Honeywell s Global Technical Assistance Center, the DOC4000 solution offers important benefits to Honeywell customers around the world Improves day-to-day operations that can result in higher production and profitability Increases the productivity of plant personnel, avoiding process upsets and plant shutdowns, and complying with laws, regulations, and international quality standards Helps personnel spend less time on tedious, low-value work and devote greater effort to high-value work such as implementing new projects, maintaining equipment, and tuning regulatory control loops 19

20 What are the Benefits to Customers? (Cont d) DOC4000 also reduces the time required for data gathering, investigating system databases and identifying automation integrity issues that could potentially lead to plant upsets or shutdowns Enables system, process and control engineers to turn their automation data into action and more effectively troubleshoot, plan and optimize plant performance Provides easy access through Web browsers, thus increasing the number of personnel who can benefit from information Helps IT understand complex interactions in automation elements that may tie into the business level network 20

21 What are the Business Results? DOC4000 software solution can have a significant impact on your bottom line Reduces costs by 10% the first year, and 70% each subsequent year, compared to a full-time staff member documenting and compiling automation system changes Eliminates up to $1M per day of lost profit by helping to resolve incidents faster than a manual investigation Provides savings of 10-30% of the typical cost of as-built configuration documentation 21

22 Conclusion With the DOC4000 solution, automation lifecycle information can be tracked and accessed enterprisewide to allow collaboration between different personnel within an industrial organization improving operational performance Increased plant safety and reliability Greater overall productivity Improved regulatory compliance Better project and maintenance planning Expanded data visibility Improved disaster recovery Reduced time for system migrations 22

23 Honeywell s imoc Solution Optimizing Management of Change in Industrial Plants

24 The Impact of Change MVC MVC MVC Historian MVC MVC MV MV MV Tags Calculations MV MV CV CV CV Applications History CV CV I/O I/O I/O I/O Graphics I/O I/O Emerson Delta V CL Apps TAGS Controllers Discrete Experion CL Apps TAGS Controllers Discrete TDC3000 CL Apps TAGS Controllers Discrete Standard Graphics Standard Graphics Standard Graphics Graphics Logic Blocks Indicators Logic Blocks Indicators GUS Logic Blocks Indicators Graphics Graphics Sub Sub Sub Alarms Others Alarms Others Pictures Alarms Others Increasing integration and interoperability Button Button Button Configs Configs Configs and lack of configuration integrity PLC Instrument Shutdown PLC Instrument Shutdown PLC Instrument Shutdown 24

25 The Impact of Change Do you worry about unknown changes disrupting your process? Lack of Adequate Change Tracking 25

26 The Impact of Change Is your intellectual property retiring with him? Loss of knowledge and critical skills 26

27 What Should a Best Practice Solution Do? Document Tracks changes Exposes interdependencies Identifies configuration errors Production Management Production Planning Operations Management Yield Accounting Advanced Applications Advanced Process Control Optimization Historians Control Systems DCS & Basic Regulatory Control Safety Instrumented Systems Programmable Logic Controllers Field Instruments Sensors Control Valves Analyzers Transmitters Switches Wiring

28 Advantages of MOC Improves safety Meets regulatory compliance Increases efficiency Increases profitability 28

29 Save time searching for information and analysis time automatically For your entire plant-wide automation solution Fully customizable, closed loop MOC workflow Detects and reports unauthorized changes Provides automatic reconciliation of changes with approved MOC cases Honeywell s imoc 29

30 Customer Scenario

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32 Production Losses ($150,000) Regulatory Fines ($25,000) 32 Honeywell

33 All this COULD have been prevented 33 Honeywell

34 Impact to Your Business Safety and compliance Reliability Economic Benefits 34

35 Introduction Process plants contain an astronomical amount of data from disparate systems, measurements and applications Each system contains a unique and complex collection of tags, programs, databases, and user interfaces similar to the information encoded in the DNA of natural organisms Unlike natural organisms, automation genomes evolve daily and the data from one system often propagates to others through integration 35

36 Introduction (Cont d) Improper changes to automation systems can have a tremendous negative impact upon plant safety, availability, and compliance Personnel sometimes change control system tuning, alarms and configurations outside of approved constants posing the risk of upsets and incidents, while making it more difficult to recover from downtime With the threat of new viruses, all automation configuration changes must be detected and reconciled with standard procedures 36

37 Why is MOC Important? (Cont d) A well-designed Management of Change (MOC) process is an essential loss prevention tool for industrial manufacturers MOC applies to any company seeking to avoid future losses resulting from today s changes Effective MOC collects relevant data within a process plant, gives it context, and presents this information to personnel where and when they need it 37

38 Why is MOC Important? (Cont d) In a typical industrial operation, the approval process for major rework does not always address specific changes within the automation layer Most MOC systems tend to be either paper-based, or an electronic version of the paper-based system, and utilized in conjunction with a work order Current MOC methodologies often result in changes being filed away and forgotten after the change has been implemented 38

39 Why is MOC Important? (Cont d) Effective Management of Change must provide: Protection of intellectual property associated with control strategies, graphics, interfaces, interlocks, and alarm management strategies by capturing and documenting knowledge Business continuity assurance with quick root cause analysis and business operations recovery of critical process automation knowledge Intelligent management of change workflow instructions for making and approving changes 39

40 What is Honeywell s Approach? Honeywell s intelligent Management of Change (imoc) solution is an innovative workflow process management application for those concerned with meeting enterprise-wide MOC and compliance requirements Provides a unified and efficient way to manage change, security and compliance across plant control and safety systems while improving reliability through risk mitigation Designed for use by plant supervisory personnel with access to modify critical systems, controllers and databases Distributed control systems Safety systems Programmable logic controllers Field instrumentation databases Advanced solutions 40

41 What is Honeywell s Approach? (Cont d) Unlike homegrown MOC tools, imoc is an integrated add-in module that runs on top of DOC4000 software to map the automation genome of industrial plants Leverages Web 2.0 technologies to facilitate information push and collaboration Aggregates and contextualizes configuration databases, programs and user interfaces Simplifies the visualization and management of information in plant automation systems 41

42 What is Honeywell s Approach? (Cont d) With imoc added to DOC4000, Honeywell customers are able to manage proposed changes through an automated and highly organized approval process imoc solution is either specific to the user s control system environment or integrated with an enterprise-wide MOC infrastructure 42

43 How Does the Solution Work? imoc leverages context-based information in the DOC4000 database to create a robust and automated MOC process for industrial control systems Automatically compiles the initial information and documentation needed to start an MOC process Changes are reconciled in the system to those outlined in the MOC package End user defines the workflow and process so the solution is endlessly configurable to meet the needs of a particular site or facility 43

44 How Does the Solution Work? (Cont d) Together, imoc and DOC4000 provide a complete solution for managing changes from their inception all the way to completion, as well as verification that changes were made properly Customized workflow process definition and checklist Detects and reconciles automation changes Configurable checklist ensures approval is facilitated properly Automatically pushes information to next person required to take action Routes MOC package for approval Integrates with existing MOC processes 44

45 What s the Value to Customers? Supported through Honeywell s Global Technical Assistance Center, the imoc solution offers important benefits to Honeywell customers around the world Manufacturers who need to meet compliance requirements for MOC and avert incidents that can be costly to production and reputation Industrial organizations seeking to avoid problems, mitigate the risk of environmental incidents, and accelerate restoration of operations as part of disaster recovery 45

46 What s the Value to Customers? (Cont d) Unlike MOC strategies limited to change tracking only, Honeywell s approach enables industrial facilities to: Avoid making mistakes (by adding the pre-approval requirement) Know what changes have been made to their systems Assess what happened to cause a situation Resume operations after recovering from incidents or downtime Boost project implementation productivity 46

47 What are the Business Results? imoc enables increased safety and compliance by effectively managing changes and approvals Supports enhanced workflow management, including workflow process definition, checklists, transitions and information push Protects against threats of cyber attacks and safety hazards Improves handling of critical issues, including undocumented changes Improves regulatory compliance Reduces error-prone MOC tasks and unauthorized changes that increase risk 47

48 What are the Business Results? (Cont d) imoc captures and protects intellectual property at 45%* less cost than manual methods Detects all automation changes Reconciles MOC cases to changes in the automation system Automatically generates reports of un-reconciled changes Documents all changes made to the system, allowing for fast root cause analysis to ensure business continuity Saves days of investigation and potentially significant financial impact to production imoc also reduces project costs by as much as 15% by using automated documentation capabilities to create as-built configuration documentation *Analysis over 3-year period compares cost of software, implementation and ongoing support 48

49 Conclusion If automation assets are part of your plant s critical infrastructure, then an effective MOC solution is a key necessity Proper MOC is also a best practice from both a safety and economic viewpoint Honeywell s imoc solution for the process industries prevents incidents, which improves safety, reliability and profitability, and helps ensure regulatory compliance 49

50 imoc Lifecycle planning Reliability Safety and compliance 50 Avoid Future Losses Resulting from Today s Changes

51 Lifecycle Planning PROTECT INTELLECTUAL PROPERTY Automate collection and management of asset information Avoid reliance on error prone manual entry or knowledge lost with employee attrition 51 45% Less Cost to Manage Assets versus Manual Methods

52 Reliability Increase system availability by minimizing incidents caused by human error Implement best practices across the enterprise % Productivity Improvement

53 Safety and Compliance Avoid hazardous situations caused by human error Enact automated approval processes Meet enterprise-wide MOC requirements 53 Automated Approval Process Helps Eliminate Vulnerability

54 Explore imoc

55 Do you worry about unknown changes disrupting your process?

56 Questions 56

57 Sustain.Ability. Honeywell Users Group EMEA