System Platform – An introduction Jaco Markwat – Wonderware SA Gauteng East Regional Manager Agenda ► Introduction ► Traditional approach versus Wonderware System Platform ► Features and Benefits of the Platform ► Considerations ► Conclusion Who is Wonderware? ► Wonderware, a business unit of British-based Invensys plc, was established in April 1987 ► Confirmed the leading supplier of industrial automation and information software solutions worldwide ► Wonderware has sold over 500,000 software licenses to date. ► One-third of the world's plants run Wonderware software solutions. Wonderware Everywhere 500,000+ Active Software Licenses 500,000 457,362 450,000 400,000 Over 52% of active Wonderware licenses date from 2005 or later 377,125 Licenses 350,000 300,000 263,812 250,000 217,475 200,000 179,512 141,886 150,000 111,212 100,000 50,000 78,252 40,899 1999 2000 2001 2002 2003 2004 2005 Cumulative Licenses 2006 2007 Industry Spread FY2008 Power Generation & Distribution Food & Beverage 19% 12% Iron/Steel/Base Metals 11% 40% Metal/Refining Frost & Sullivan Survey Automation and Control Solutions in the African Metals and Mining Industry Wonderware 33.4% Uncertainties in the Market Economic crisis Market Volatility Need for Focus Decrease TCO Continuous Improvements Accelerate ROI Protecting your investment ► Your largest investment is in engineering and customization. ► Broken upgrade paths creates costs far beyond the cost of software. ► A broken upgrade path creates a barrier for change – the system becomes stale. ► The underlying system should enable you to leverage new hardware and software without having to re-create the solution. Wonderware System Platform Benefits ► Provide flexible and robust automation solution ► Reduce life-cycle cost of ownership ► Provide building blocks for plant floor information ▪ Equipment Utilisation ▪ Production information & Reporting ▪ Vertical Integration Wonderware Software Solutions ERP (SAP, Oracle, Microsoft..) Production & Manufacturing Activities Industry Applications Industry Packs Base Template Libraries Database Applications Asset Management Specific Function Modules Specific Function Modules System Platform LIM Systems Devices Specific Function Modules Clients Microsoft Technology & Industry Standards Information/Plant Visibility Empowering All Roles in the Plant Device, Application, Enterprise Integration System Inter-operability System Platform Services Not a Server, but a Provider of Services… Browser Tablets Terminal Services HMI Device Integration Alarming Historization Trending Event Logging Security Redundancy Configuration Management Software Deployment Revision Control Facility Model PDA Panels Scripting .Net Framework Visualization SPC/SQC Telephonic Notification Reporting Data Mining Downtime/OEE Statistical Analysis Business System Integration Deployment Model Phone Pager Empowering All Roles in the Plant Enabling operational breakthroughs IT & Infrastructure Engineering Operations Issue: Needs: Amount of information Visibility to disparate data sources Empower operations personnel with actionable views of Robust & Reliable Compatibility with Legacy system information Consistent enterprise-wide Clutter free and intuitive Limited screen size Built-in diagnostics and Status Empowering All Roles in the Plant Enabling engineering breakthroughs IT & Infrastructure Engineering Issue: Needs: Save valuable engineering time Customization Collaborative Enable engineers to build intuitive, reliabledevelopment and maintainable Amount of Scripting Reduce implementation errors for operations Maintaining many applications Adv. Graphics tools and reusability applications Standardization, Secure & intuitive Operations Empowering All Roles in the Plant Enabling IT breakthroughs IT & Infrastructure Issue: Needs: Integrate with other IT apps Central Management Make it much easier, less time-consuming and less costly Newer Technology - .NET etc.do Extensibility Common tools, Application Integration this Diagnostics High Availability, Security Patch Mgmt Large scale deployment Scalability on multiple dimensions Engineering Operations Device, Application, Enterprise Integration Enabling interoperability breakthroughs Needs: ERP (SAP, Oracle, Microsoft..) IT & Infrastructure Database Applications Asset Management Engineering Operations LIM Systems Devices Architecture Flexibility Scalability Data Access, Clients Capability Standardization Independent of hardware Common Configuration Engineering Reusability Common platform for HMI, Supervisory, SCADA, MES, EMI Apps. Agenda ► Introduction ► Traditional approach versus Wonderware System Platform ► Features and Benefits of the Platform ► Considerations ► Conclusion The Good Old Days… The 1990’s Operator HMI Displays PLC’s Machines Operators: ► Immediate access to real-time information ► Close to the process to do something about it… Rest of business: ► Run on paper (latency)… Manufacturing Systems Legacy ERP, Maintenance, Office Systems, Reporting MES Data Collection, Traceability, Asset Monitoring, Reporting, LIMS, Production Analysis, Scheduling Plant Area 1 SCADA / HMI • Gap between ERP and Manufacturing Systems • Custom Integration • Difficult to Integrate • No Unifying Architecture • High cost of ownership (Multiple Apps) • No Flexibility Plant Area 2 SCADA / HMI Bulk of System Investment in the last decade was here! SCADA / HMI Production Process Alarming Scripting Security Alarming Scripting Security Alarming Scripting Security PLC’s PLC’s PLC’s Standard Control Modules Standard Control Modules Standard Control Modules • Poor Standards Management • Limited Scope Today… Businesses are run so much faster The 1990’s Operator The 2000’s Plant Roles Operations HMI Displays Engineering Web Based Reports Trends KPI Dashboards Data Sources PLC’s Machines Plant Mgt Info Displays HMI PLC’s Maintenance Databases Planning Systems Lab Systems Plant Assets Machines Lines Sites Maintenance Applications Wonderware System Platform Approach ERP, Maintenance, Office Systems, Reporting • SAP xMII (NetWeaver) • WWEI • MS .NET Plant 2 Economy of SCOPE Plant 1 ArchestrA Standards Based (S95) Integration SAP xMII / Web Services / XML / MS .NET Product Tracking & Genealogy: Dispatching Production Units: Process Management: Resource Allocation and Status: Data Collection Performance Analysis: Quality Management: Other ….. • Security Security Application Development • Application Development Services Production (~MES) and Performance Management (Modular Approach) • Unified Architecture • Single Plant Model Info Delivery & Visualisation • Information Delivery & Visualisation Services Information Management• Information & Data Management Services Industrial Domain Features • Industrial Domain Features (Redundancy) S/W & Device Connectivity • Software and Device Connectivity Economy of SCALE PLC’s PLC’s PLC’s Standard Control Modules Standard Control Modules Standard Control Modules • Standards & Engineering Reuse. Wonderware Architecture Equip Performance Equip Operations Mfg Quality Mfg Performance Mfg Exec Batch Exec Reporting Client Toolkits Enterprise Connectivity Production Services Production Content Production Model Production Analysis Client System Platform Application Server Historian Information Server (Portal) Connectivity (to Foreign Data Sources) Unified Engineering & Admin Tools 3rd Party Data Bases 3rd Party S/W Applications 3rd Party Controllers InTouch HMI Wonderware Clients (Desktop or Web) Modules Real world? Plant Model • Plant & Equipment context • Alarm structure • Online additions & changes Plant 1 Area 1 Area 2 Site Plant 2 Area 1 Area 2 Area 3 Architecture Development MS SQL Galaxy Repository Runtime Plant 1 IDE Plant 2 Historian DB IDE SQL IDE Site Mines Smelter Shaft 1 Milling Shaft 2 Flotation PLC PLC Control Modules Control Modules One Application (Galaxy) Extensive New Feature Set Compelling New Value Engineering Effectiveness IT Effectiveness Operational Effectiveness • Allow New ArchestrA graphics, Graphics tools,reliable New Editor engineers to build intuitive, and • maintainable Standardization,HMI, Templates andand instances, SCADA, MES applications • Change Propagation, Collaborative team development, using a single, high-productivity software platform • Scripting support, Custom Properties, that helps reduce time / costs and errors. • .NET controls, NET container, Data aware controls • • • • • • Central Deployment Make diagnostics, it much easier, less time-consuming and Built-in Security, less costlywith to integrate and manage secure, Compatibility other systems Central repository, Commonapplications Configuration,- Integrated integrated operations on an platform Node by node upgrade, Extensibility ongoing basis. Migration and coexistence •Empower New animations, scalable faceplates,with Clutter free screens, operations personnel intuitive views and feel, symbol collection ofNew thelook right enterprise-wide information in order to •improve Application Integration efficiency, reduce training operational • Quality and status information, costs, and minimize unplanned application • Multi-monitor support, downtime. Agenda ► Introduction ► Traditional approach versus Wonderware System Platform ► Features and Benefits of the Platform ► Considerations ► Conclusion Strengths of Wonderware System Platform ► Scalability ► Security ► Standards ► High Availability ► Software Management Scalability Application Object Server Only Integrated Single Node Distributed Peer to Peer Single Server Multi Client Distributed Multi Server Multi Client ► Application can grow as requirements change ► I/O measured as external I/O only (excludes internal) Strengths of ArchestrA ► Scalability ► Security ► Standards ► High Availability ► Software Management Security ► Either dedicated or can use Microsoft Domain security ► Benefits ▪ New staff added to “Operator” group get the ▪ ▪ ▪ right authority When staff leave and are removed from the domain they are no longer able to access the automation application Simplifies management of user logons One password Strengths of ArchestrA ► Scalability ► Security ► Standards ► High Availability ► Software Management Equipment centric objects: Powerful and multi-faceted Inputs/Outputs Graphic symbols Logic/Scripting Faceplates Historical Information Alarms and events Security Inheritance Application Model Application Standards XV101 XV102 $Valve-3Way XV103 $Control Module $Valve-2Way XV104 TEMPLATES (CLASSES, PARENTS) INSTANCES (OBJECTS) DEVELOPMENT Strengths of ArchestrA ► Scalability ► Security ► Standards ► High Availability ► Software Management Application layer availability Non-redundant system 1. The server handles all data. 2. If the server is lost then the clients lose connection to data. • • • Client Server Architecture InTouch InTouch InTouch InTouch InTouch InSQL Other AOS Nodes Redundant System 1. 2. 3. Redundant servers maintain synchronized data through dedicated network. If the primary server is lost the backup server will take over where the primary left off. The switch is transparent to the clients. Configuration is done through a check box on the AppEngine. AOS PLC Historian Redundancy configuration ► AppEngine ▪ Enable Redundancy ▪ Set up parameters Strengths of ArchestrA ► Scalability ► Security ► Standards ► High Availability ► Software Management Software Management ► All software developed and deployed from galaxy repository. ▪ Multiple developers ▪ Provides audit trail and security ▪ Software installation ► Develop functionality using true object based environment ▪ Simplifies development across multiple devices and process monitoring points. ► Object Viewer provides diagnostic support from any computer on the control network (with security) Agenda ► Introduction ► Traditional approach versus Wonderware System Platform ► Features and Benefits of the Platform ► Considerations ► Conclusion Ordering System Platform Step 1: System Platform - Select the appropriate Galaxy IO with History level for the System Platform. Step 2: System Platform Options-Additional Platforms, Historians, DA Servers Step 3: Wonderware Client Parts Choose One or More Step 4: Select Customer Support Order Wonderware Clients ► InTouch for System Platform Visualization Client ▪ With Trending ▪ Without Trending ▪ Read-only ► Web Information Client ▪ Information Server v3.0 Advanced Reporting and Analysis Client License ► Reporting and Analysis Client ▪ ActiveFactory 9.2- Trend, Excel, Reports Local ArchestrA Certified Systems Integrators Quad ► Formal Wonderware Product exams ► Submit a successful ArchestrA project Agenda ► Introduction ► Traditional approach versus Wonderware System Platform ► Features and Benefits of the Platform ► Considerations ► Conclusion Conclusion ► Reusable Standards and Ease of use reduce total cost of ownership by design. ► Strongly aligned with Microsoft (no duplication of technology) ► Make production information available to all role players ► Large local and international installed base Powering intelligent plant decisions in real time.