T90 - New Strategies to Monitor, Optimize and
Support Your Machines - Leveraging the Cloud
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PUBLIC - 5058-CO900H
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
GLOBAL MANUFACTURING
Today’s Scenario
10 million
$ 62 Billion
2/3
jobs with manufacturing
organizations cannot be filled
today due to a growing skill gap
of process automation
systems are nearing the
end of their useful life
By 2030, two-thirds of the global
middle class will be residents of
the Asia-Pacific region
Source: World Economic Forum
Source: ARC Advisory Group
Source: Ernst & Young
62%
65%
4/10
of manufacturers saw
productivity increases as
vital to meeting growth targets
Increase, on average, of the
cost per hour of downtime
between 2010 and 2012
In 2015 out of the top 10
largest economies, 4 will be
emerging countries.
Source: Deloitte report
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Source: Dick Csaplar - Aberdeen Group
Source: McKinsey
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Challenges Facing Manufacturing
Asset and Plant
Optimization
The Skills
Gap Challenge
 Death of
qualified personnel
 Capacity
1
 Achieving productivity
goals
 Aging infrastructure
 Lack of staffing to
expand operations
expansion/upgrade of
existing plants
 Increased downtime costs
2
 Energy management
Speed and
Innovation
 Increased demand in
developing countries
Improve time
to market
 Adopt advanced
technologies
IT/OT
Convergence
 Integration of new
technologies
 Security against cyber
and physical attacks
 Integrate: customer
demand, supply chain
and industrial processes
 Lack of expertise
(1) ARC Supplier Provided Automation Services
(2) Aberdeen Group
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Opportunities for a Connected Enterprise
The Transformation of Manufacturing
“… The Internet of Things is the third great wave of innovation after Ethernet and the Internet.”
Dr. Elgar Fleisch, Director of the Institute of Technology Management at the University of St. Gallen
 Cloud Computing is a disruptive force in Manufacturing
 Offers new capabilities, creativity and innovation for this industry
 Step change in simplicity and cost of ownership for Manufacturing IT assets
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
The Transformative Value of IoT in Operations
SaaS Reduces the TCO of and Simplifies Manufacturing IT
Service
 Remote Service and Support
 Enhanced customer service
 Predictive maintenance
Finance
 OpEX vs. CapEx
 Predictable costs
 Flexibility
Operations
Engineering
 Consumables
 Asset and operations performance
 Information exchange with your supply chain
 Minimize manufacturing IT
 Product/process design
 Scalability
Fewer SME’s
Supporting
More Assets
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Business Model
Flexibility
Scale Up
Scale Down
Security
“Zero”
Infrastructure
to Support
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Remote Monitoring and IoT Services
Secure Remote Access and Monitoring for Your Critical Assets
Information is power. The Industrial Internet of Things introduces opportunities to increase
productivity and optimize production through greater connectivity and information sharing.
Let us demonstrate how we can empower you to “Get Connected”
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Remote Monitoring & IoT Services
Get Connected
Connect the right people with
collaboration tools to reduce cost.
Get Informed
Collect the right information and
make more data driven decisions
Get Ahead
Optimize your operations and transform
how you do business.
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Get Connected
Secure Remote Access – Minimize Risk & Maximize Productivity
Secure
SecureAuthentication
Authentication
 Centralized access control
 Access control lists
 Dual authentication between server
and site
 Limit access by user/site/device
 Complete end-user control
 Remote access audit, notification
and surveillance
Secure Connection
Secure Connection
 CPwE compliant
 Outbound only data flow
 Data encryption using SSL
 Multiple security certificates
 Secure tunnel to
individual devices
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Get Connected
Secure Remote Access and Monitoring for All Sanctioned Stakeholders
Troubleshooting
and Maintenance
Tools
Need to:
 Solve issues faster
 Reduce cost of downtime
 Connect subject matter experts
 Improve employee efficiency
 Connect islands of automation
How:
 Common collaboration platform
 Secure remote access to your devices
 Quickly troubleshoot and fix issues
PLCs
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Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Informed
Analyze Data to Make Smarter, More Informed Decisions
Asset Performance
Management
Need to:
 Gain visibility in to your operations
 Assess asset performance
 Increase maintenance efficiency
 Increase productivity
 Reduce or prevent downtime
How:
 Make decisions that are based on real data
 Asset performance dashboards and reports
 Provide the right information to the
right people
 Use data to be more proactive and
less reactive
Asset
Health
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System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Informed
Analyze Data to Make Smarter, More Informed Decisions
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Informed
Analyze Data to Make Smarter, More Informed Decisions
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Informed
Get the right information to the right people
Empowering PEOPLE to make SMARTER, more INFORMED decisions
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Get Ahead
Optimize Your Operations and Transform How You Do Business
Access and Information Integration
Need to:
 Optimize asset performance
 Minimize risk
 Protect your brand
 Enable new business models
How:
 Analyze real-time data from your systems and
take appropriate action
 Get the right information to the right people at
the right time
 Access and share rich data from your business
ecosystem
Centralized
Business Data
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Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Ahead
Optimize Your Operations and Transform How You Do Business
Rockwell
Automation
Support
Corporate
Headquarters
Machine Builder A
Prod/Proc
Designers
Machine Builder B
Quality Org
Machine Builder C
Support Org
A
Supplier A
Supplier B
Data Sources
B
C
Customer 1
Utilities
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Weather
Forecast
Customer 2
Customer 3
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Asset Performance Management
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Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Get Ahead
Transform your Business Model
Support and Maintenance Services
•
•
•
•
•
Post warranty support and service contracts
Preventative maintenance
Reliability services
Parts replacement
Sell consumables
Service Level Agreement Contracts
•
•
Performance based contracts
Machine leasing
Increase Cash Flow
•
•
•
Supply chain integration
Order Entry
Invoicing
COMPANY INTERNAL — CONFIDENTIAL
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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IoT Maturity Model
Where are you?
Level 3
Get Informed
Level 2
Get Connected
Level 1
Unconnected
COMPANY INTERNAL — CONFIDENTIAL
Connect to Assets
• Reactive Support
•Troubleshooting
•Fix
•Maintain
Collect Information
• Contextualize Data
• Make Smarter Decisions
• Become Proactive
• Decrease Cost
• Increase Productivity
Level 4
Get Ahead
Optimize
• Centralize Information
• Layer Data Sources
• Supply Chain Integration
• Reduce Risk
• Transform your Business
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
Remote Monitoring and IoT Services
How We Can Help
Get Connected
Get Informed
Get Ahead
CUSTOMER BENEFITS








Resolve issues faster
Helps prevent unneeded maintenance activity
Reduce and prevent downtime events
Reduce cost of downtime
Augment your workforce
Data driven based decisions
Scalable, cost-effective and flexible
Asset optimization
Centralized
Business Data
Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
Asset
Health
System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
PLCs
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Optimize operations, improve employee efficiency and increase productivity
COMPANY INTERNAL — CONFIDENTIAL
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
19
XaaS
Augment Your Capabilities with Our Enabling IIoT Technologies
Get Connected
Connect the right people with
collaboration tools to reduce cost
Get Informed
Collect the right information and
make more data driven decisions
Centralized
Business Data
Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
Asset
Health
System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
PLCs
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Get Ahead
Optimize your operations and
transform how you do business
Helping customers around the world to minimize risks and maximize productivity
COMPANY INTERNAL — CONFIDENTIAL
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Self Serve to Managed Services
Augment your capabilities with our experts
3,400
ENGINEERS/PROJECT MANAGERS
80+
Centralized
Business Data
Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
COUNTRIES
13+ Years
Asset
Health
System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
AVERAGE AUTOMATION
EXPERIENCE OF ENGINEERS
Global Support with a Local Address
PLCs
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform





7 Remote Support Centers – over 350 Engineers
100+ Consultants
18 Repair/ Remanufacturing Centers –
9 Exchange Hubs
550+ Field Services Professionals
Over 200 Training Courses
Helping customers around the world to minimize risks and maximize productivity
COMPANY INTERNAL — CONFIDENTIAL
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
21
Atlas Copco Mafi-Trench Company
Cloud-based Plant and Equipment Performance Monitoring
Cloud Monitoring was our logical step to handle torrential machine data from this plant.
CHALLENGES
RESULTS
Business challenge
 Monitor plant and machine performance remotely
and back-up data
 Status quo
 Expensive on-premise solutions
Environmental / Economic Challenges
 Strict Canadian regulations
 React proactively to abnormal situations that would
affect performance
COMPANY INTERNAL — CONFIDENTIAL
DELIVERED SOLUTION
Solution delivery/execution description
 Installed in 2 hours with zero downtime, running
since Oct. 2012
Technology solution description
 Cloud Agent technology was integrated to existing FactoryTalk®
HistorianSE data collection, BI/analytics tools on top of Big data
Support plan description
Centralized
Business Data
 Resilient
and scalable
infrastructure Cyber
Patch
PID Loop cloudRole-based
Management
Diagnostics
Reporting
Security
Supply Chain
Integration
Achieved scalable, cost-effective,
real-time
plant and
performance
monitoringInstalled
to
Asset
System
Alert equipment
Archive/Disaster
Dashboards
Health
Notifications
prove SLA complianceHealth
Recovery
Base
Collected machine data is backed up in cloud storage for compliance and R&D
Cloud analytics encapsulated ACMTC’s knowledge for use in future sales and machine design
PLCs
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
22
New Business Model – Supplying Consumables
Innovation in a Conservative Industry
M.G. Bryan
Fracking Truck
Manufacturer
Revolutionizing Fracking
 Consumables, maintenance
 Enable real-time invoicing
 Maintenance accountability
COMPANY INTERNAL — CONFIDENTIAL
Centralized
Business Data
Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
Asset
Health
System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
PLCs
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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The Cash Machine of the Oil & Gas Industry
Removing the Potential for Error
Trigg Technologies
L.A.C.T. Unit
Manufacturer
COMPANY CONFIDENTIAL
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The Cash Machine of the Oil & Gas Industry
Asset Performance and Transactions
Supply Chain
Integration
COMPANY CONFIDENTIAL
Centralized
Business Data
Patch
Management
PID Loop
Diagnostics
Role-based
Reporting
Cyber
Security
Supply Chain
Integrations
Asset
Health
System
Health
Alert
Notifications
Dashboards
Archive/Disaster
Recovery
Installed
Base
PLCs
Drives
Drives
Operator
Interface
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Hilcorp
Augmented Their Workforce and Decreased Downtime
CHALLENGES
DELIVERED SOLUTION

Installed Rockwell Automation® PowerFlex® 7000 Medium
Voltage drives on oil rig off the coast of Alaska

Rockwell Automation® Remote Support delivered Virtual
Support Engineers to monitor 16 PowerFlex® 7000 drives

Cost of downtime reaches $300,000 per day

Respond to any warning or fault with 10 minutes

Support staff not completely comfortable with new technology


Critical asset that would stop production if fails
Monitor key performance indicators such as:
● Power
• Speed
● Current
• Voltage
RESULTS
Centralized
Business Data
PID Loop
Diagnostics
Fast ROI:
Automated detection and notification of four incidents –
In the first two weeks!Asset
Alert
System
Notifications
Health
Health
Issues that are addressed within minutes
Savings have already paid for the contract for
several years
PLCs
COMPANY INTERNAL — CONFIDENTIAL
Patch
Management
Drives
Operator
Interface
Role-based
Reporting
Cyber
Security
Supply Chain
Integration
Dashboards
Archive/Disaster
Recovery
Installed
Base
Network
Infrastructure
OEM
Machines
Secure Remote
Access Platform
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
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Remote Asset Performance Management
Liquid Natural Gas Terminals
Supermajor O&G
Building & Managing
LNG Retail Stations
COMPANY INTERNAL — CONFIDENTIAL
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Product Serialization
Minimize Counterfeiting and Diversions of Specific Foods & Medicines
Global Dairy
Company
Brand Protection
PLCs
COMPANY CONFIDENTIAL
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