Product Suite Overview
July 2003
Impacts of Unmanaged Change
• What is the cost of downtime in each part of your
environment?
• What is the cost of non-compliance with laws and
governmental regulations?
• Is product liability a concern?
• Is there a threat of vandalism or corporate espionage?
• Can damage to life or property be caused by uncontrolled
change?
July 2003
Maintenance Today
Maintenance challenges
–
–
–
–
Reduce MRO costs
Improve uptime
Experienced maintenance staff retiring
Automation landscape is increasingly complex
• Distributed Architectures
• More configurable, intelligent devices
• Integration with information systems
Maintenance needs
– Maximize uptime by proactively avoiding downtime
• Cost constraints require automated systems
• Utilize device intelligence for maintenance purposes
– Maximize uptime by minimizing downtime
July 2003
• Maintenance systems point to cause, not symptom
• Automatically generate work orders
• Automatically suggest corrective actions
RSMACC Architecture
Common Architecture
– RSMACC Server for collaboration
– RSMACC Client common to all
applications
– FactoryTalk-enabled
Plug In Components
– RSMACC Change Management
• Authenticate, audit, archive, and
verify device configuration
– RSMACC Network Health
• Monitor, report, and diagnose
device and network health
– RSMACC Enterprise Online
Condition Monitor
• Integrated automation condition
monitoring
– RSMACC Automated Asset Manager
• Automate preventive, predictive,
and reactive maintenance
July 2003
RSMACC Change Management
Managing Device Configuration
July 2003
Could Your Facility Recover?
May 8, 2003 Oklahoma City, OK
A F-4 tornado ripped through the GM Plant located in
Midwest City, OK devastating the facility. The west wall
of the 4 million-square-foot plant was peeled off. GM
officials have no specific word on damage to the
equipment inside. The plant's paint shop was heavily
damaged. Plant operations have been suspended
indefinitely.
- Online News story
July 2003
Changes Cause Problems When…
• They are not documented
• The old configuration can’t be recovered
• The changes are not accessible to all who need
them
• Access to configurations is not controlled
• Multiple versions exist without accurate
identification
• Multiple people are making independent changes
July 2003
Changes Cost Money when…
• Obsolete configurations get mistakenly
loaded or reloaded
• Legitimate changes are reversed or
overwritten
• Effects are not fully understood
• They break regulations
• Product has to be scrapped or reworked
• Production time is lost
July 2003
RSMACC Change Management
Solution
July 2003
RSMACC Change Management Solution
• RSMACC Change Management
starts with the core
infrastructure common to all
RSMACC-enabled solutions
July 2003
RSMACC Change Management Solution
• Allows you to control who can
use an application and what
actions they can perform while
using the application
Access Control/
Authenticate
July 2003
Maintenance Desktop Applications
• Authentication Module (Security)
– Rockwell Software's Security Server capabilities are incorporated into RSMACC.
– Restrict product functionality by user or workstation
July 2003
RSMACC Change Management Solution
Archive
Access Control/
Authenticate
July 2003
• Provides a system wide
repository for historical storage
of your application configuration
files, or any other file you add
Archive Module
July 2003
RSMACC Change Management Solution
Archive
Access Control/
Authenticate
July 2003
Audit
• Gives you the ability to know
exactly who has modified a
control system configuration or
application parameter, what they
changed, where they did it from,
and when the change was
made.
Audit Database
July 2003
Event Database
July 2003
RSMACC Change Management Solution
Archive
Access Control/
Authenticate
July 2003
Audit
Verification
• Allows you to ensure that the
control system configuration you
think is running your application,
is running your application
• Supports application restoration
following a catastrophic event
(lightning strike, flood, fire, etc.)
Verification
July 2003
RSMACC Change Management Solution
Report
Archive
Access Control/
Authenticate
July 2003
Audit
Verification
• Allows you to generate views into
the Change Management
system for more detailed
analysis of configuration
changes
Reporting
July 2003
• Having the ability to reproduce
past configurations
• Keeping records of
modifications to control system
configurations and why the
modifications were necessary
• Periodically archiving (back-up)
control system configurations
• Periodically verifying control
system configurations’ accuracy
• Securing access to control
system configurations
July 2003
VALUE
“Managed Change” Means…
Access Control
Prevention
PROACTIVE
Authentication
Control
Archive
Accountability
Audit
Detection
Verification/Recovery
Reconciliation
REACTIVE
Reporting
The Value of Change
Management is greatest
when applied proactively
rather than after the fact
Summary
• Is your organization challenged by any of the following?
– excess costs from downtime
– extended product release cycles or other costs from non-compliance
with laws or regulations
– product liability concerns
– terrorism, employee vandalism, or corporate espionage
– managing employee efficiency
– life or property liability caused by uncontrolled change
– recovery from a natural disaster or catastrophic event
RSMACC Change Management provides a robust set of
manufacturing configuration management tools to address
these challenges
July 2003
Introduction to
RSMACC Network Health
July 2003
What is RSMACC Network Health?
• Centralized management and monitoring of the health
maintenance of networked assets (enterprise-wide)
coupled with distributed access to the tools and facilities
needed to maintain those assets.
• Each asset’s health record is maintained in a central
data store but consumers of this data (maintenance and
production staff) can make use of this data, even act
upon it, from anywhere in the enterprise.
July 2003
What is RSMACC Network Health?
• “Next Generation” of RSNetWorx MD
– Provides diagnostic monitoring, fault detection, and troubleshooting for networked
control devices
– Runs in the background based on user-defined schedules
– Provides access to the full suite of interactive RSNetWorx MD configuration,
diagnostics and troubleshooting
• RSNetWorx provides configuration editing
• RSMACC Server provides enterprise coverage
– Add service modules as needed for auto diagnostics
– Messages from all networks logged to one centralized RSMACC database
• Currently supports DeviceNet, ControlNet and EtherNet/IP
July 2003
How Does RSMACC Network Health Work?
NetworxMD
DeviceNet Services
Client Workstations
Service Monitoring
Networked Services
Networked Services
NetworxMD
Event Repository
Diagnostic Repository Ethernet Services
ControlNet Services
NetworxMD
July 2003
Diagnostic Logging
• Centralized logging to RSMACC Diagnostics and Health Log
(plant-wide, enterprise wide).
– Records all diagnostic messages from all instances of Network Health Services
that are “plugged into” RSMACC
• View troubleshooting information for a particular error message
from within the Diagnostic Log
• Change the status of a diagnostics message from within the
RSMACC Client to: Open, Closed, Deferred, Follow Up or Ignore
• Use RSMACC search engine to produce reports on plant-wide
diagnostic data
July 2003
Where Does RSMACC Network Health Fit?
• Configuration Time
– Initial health assessment and configuration verification
• Planned Maintenance
– Perform periodic health snapshots
• Corrective Maintenance
– As needed when device and/or network problems arise
• Preventive Maintenance
– Background unattended diagnostic monitoring (probing)
– Device replacement detection
July 2003
Maintenance Offerings/Brands
RSMACC Enabled
Products and Solutions
Emonitor Family
(Odyssey/Enshare)
Entrx
MAXIMO
July 2003
The XM™ Solution
Ethernet
Data
RSMACC
Client
FLEX IO
509 -BOD
24vdc
July 2003
EDITOR’S CHOICE AWARD
2002
“…service to the industry, technological
advancement, and market impact.”
Plant Services
INDUSTRY WEEK
2002
2002
MRO PRODUCT OF THE YEAR
TECHNOLOGY OF THE YEAR
Gold Medal Winner
“…innovations that have the potential to abruptly
change the conventional order of things.”
The Industry’s Most Flexible H/W Architecture
Ethernet
Gateway
Ethernet/IP
Modbus/TCP
Direct To Host
DeviceNet
Direct To Controller
ControlNet
DeviceNet
Networked
Industrial
Bus Gateway
HOW?
DeviceNet
Profibus
Standalone
4-20mA Outputs
Integral Relays
Buffered
Outputs
RSMACC Enterprise Online Condition
Monitor (CM)
July 2003
Current Limitations of CM Systems
CM Software systems are powerful and effective tools
for condition monitoring; however, these systems are:
― Typically used only by the maintenance department and machine
―
–
–
–
July 2003
health information is not shared effectively throughout the
organization in a timely and efficient manner
Very specialized and require substantial training to master.
Not given the full recognition they deserve since other
departments within the organization do not have easy access to
machinery health information
Not always able to gather data when and where needed due to
regulatory and/or man power limitations
Not typically integrated with other plant information systems
What is the RSMACC Enterprise Online Solution?
It is a machinery health information
display system that takes digital
images of your plant equipment and
combines them with live data from the
XM and Enwatch family of online
monitors as well as other plant
information systems
using FT LiveData.
July 2003
RSMACC Enterprise Online
• Online configuration
capability
• Graphical or hierarchy
display of network devices
in configurator
• Live Time data display from
any XM channel
– Trend, Spectrum,
Waveform, Waterfall,
Polar, Orbit, ShaftCenterline
• Mimic display with live data
and alarm status
July 2003
RSMACC Enterprise Online Benefits
• Reduces human exposure to dangerous situations (lives)
– Hard to access areas of a machine, machine train or line
– Hazardous environment areas are avoided
• Allows people to concentrate on problem-solving instead of
manual data collection (time)
– Consistent collection technique
• Enables data acquisition to be scheduled more frequently for
earlier fault diagnosis (machinery)
– Capture more data, more frequently and from a wider array of sources
• Compact size of hardware allows it to be installed close to the
machine under surveillance reducing costs ($)
• Allows “non-PdM experts” a snapshot overview of the plant
machinery health
– Allows staff to respond quickly to machine problems to minimize costly
downtime
July 2003
RSMACC Enterprise Online Benefits
• Gives intuitive visual display of the plant status at a glance
• Transfers data over existing Ethernet LAN for sequential
monitoring of machines distributed throughout the plant
• Offers remote monitoring of equipment anywhere in the
world via the Internet
– Performs “live-mode” monitoring of spectra, time waveforms, trends,
spectral maps, orbits and polar plots as well as transient types of data
– Allows data from any channel of a specified unit to be transferred,
processed and displayed on your workstation
– Permits people to quickly diagnose machines in alarm
condition without having to walk out to the machine
with a portable data collector to troubleshoot
July 2003
RSMACC Automated Asset Manager
RSMACC Integration with MAXIMO
Critical Issues Affecting Business
•
•
•
•
•
•
•
•
Improve Yield
Improve Availability
Improve Production Rate
Reduce Maintenance Cost
Extend Asset Life
Defer Maintenance Actions
Decrease MTTR
Increase Machinery Uptime
•
•
•
•
•
•
•
Reduce Time to Market
Reduce Asset Base
Reduce Inventory
Safety
Regulatory Compliance
Meeting Delivery Schedules
Increase Operating Earnings
Overall Equipment Efficiency Impact
• At a large cement manufacturer, a one point improvement
in OEE is estimated to improve operating earnings by
$10M annually.
• Since installing an integrated solution, a large consumer
products company improved OEE from 63 to 93! In
addition, planned shutdowns have now been reduced from
one day a week to one day every six weeks!
Improving the Bottom Line
• How can RSMACC improve OEE?
– Automated Asset Manager
• Provides the means to reduce the time required for maintenance
actions
• Improves uptime by allowing for better maintenance planning and
scheduling
• Improving OEE helps achieve business goals
What You Have
Change Management
Network Health
Device Health
Network Statuses
Audit Trail
PLC Program Archive
Asset Management
Meter Readings
Preventive Maintenance
Process Data
Condition Monitoring
Work Orders
Vibration Data
Thermo-graphic Data
Oil Data
System Concept
•
•
•
•
Move data from plant systems to MAXIMO
Move information from plant systems to MAXIMO
Move analyses into MAXIMO
Consolidate the connections to MAXIMO
– Standard Interfaces
– One system handles the integration
• No need to setup interface multiple times
• Track status of work orders and data
– Plan for work based on status and changes
– Adjust schedules and priorities of planned work
The Old Way
•
•
•
•
Paper Transactions
Maintenance is an island
Work done not effectively tracked against conditions
Integration between various systems often cumbersome
and expensive
• The causes of maintenance problems often go unsolved
due to lack of resources
The New Way
• Every system communicates information and data along a
common infrastructure
• Upgrading software does not break integration links
• Work done is correlated with asset condition
– Work effectiveness is easily determined
Automated Asset Manager Architecture
Complete Automation Integration
RSMACC Automated
Asset Manager
MAXIMO Server
(Web Server)
OPC Data
Work Order
Information
Work Order
Information
OPC Server
PLC and Meter
information
Condition Monitoring – Predictive
Maintenance System
Other Automation Systems (Network
Health, Change Management…)
System Architecture
Ethernet
RSMACC Automated
Asset Manager®
FLEX IO
509 -BOD
24vdc
RSMACC Automated Asset Manager Data
• Preventive Data
– Primarily metric, from PLC,s etc.
– Can be in the form of meter readings, cycles, process data
– Represents data that defines predefined maintenance schedules
• Oil Change
• Reactive Data
– Allows immediate action on any event in RSMACC system
– As events occur, work orders are generated
• Network device fails
• Predictive Data
– allows for scheduling and minimal disruption
– Condition monitoring, predictive maintenance
• Bearing life estimations, cycle & pattern analysis
• Status screens in RSMACC client
– Instant feedback
Sources of Data
• Sources of Data and Information
–
–
–
–
–
–
RSMACC Network Health
RSMACC Enterprise Online Condition Monitor
PLC’s
Motor Control Centers
Any data node
Events
• Data Flow
– Pass through to external system
– Evaluate to generate work request action
RSMACC Automated Asset Manager Interface
RSMACC Automated Asset Manager Interface
Industry Metrics
• Better manage maintenance practices
– Conservative estimates
• 10% extra maintenance staff exists due to poor planning,
unnecessary PM tasks and not involving operators
• 25% extra administrative staff due to lack of EAM integration
• 5% of capacity lost due to poorly managed maintenance practices
– By automating the work request creation process,
the efficiency of creating and managing work orders
increases
(source: Strategic MRO, MacInnes & Pearce, 2002)
Industry Metrics
• Integrate Production and Maintenance Planning
– Average 35% labor utility in maintenance department
– 30% excess MRO inventories
• Wrench Time for a typical work order is 20-25%
– Opportunity to save 80% of typical work order time
(source: Strategic MRO, MacInnes & Pearce, 2002)
Workflow Terminology
Demand
Communication
Process Delay
Work
Request
Batch
Delay
Work
Order
Approval
Process
Delay
Work
Order
Batch
Delay
Work
Order
Cycle
Time
Supply
Lead Time
Failure
Predicted
or
Occured
Potential or
Actual Failure
Communicated
GOAL –
Reduce the
time from
Failure
Prediction or
Occurrence
to Asset
Restoration
Asset
Restored
* From Strategic MRO, MacInnes & Pearce, 2002
Industry Example
Food Manufacturer
The seal on a mixture pump is failing, causing incorrect pressures
and mixture settings in the final product area. The scheduled
collection of data isn’t due for a week, when a manual
collection occurs. By the time the pressure reading is
recorded, four batches of final product is already ruined.
• RSMACC Automated Asset Manager ‘automates’ the process of
data collection. This can be done at shorter time intervals.
Because this data is entered directly into the system that
makes decisions about maintenance schedules, the corrective
actions can be quickly and efficiently executed.
• RSMACC Automated Asset Manager Value Proposition
– Automated, timely data acquisition
Current Customer Installation
• Factory Environment
• Using AAM to monitor the cycles on 64 Wall Dampers
• Want maintenance performed after 20 hours of operation
– During a given time frame, one damper may operated for 20 hours, while
another may operate for 0 hours
• Time based maintenance not very efficient
– Takes 8 hours to get to a wall damper to determine if it needs maintenance
– On the average, only 50% of dampers need maintenance
– Assuming industry labor rates to be $45/hour, then
8 hour * $45/hour = $360/Wall Damper * 64 Wall Dampers = $23,040
– Assuming only 50% needed $23,040/2 = $11,520 saved each quarter
System Value Summary
• Automates data collection process
– Less expensive than walk around data collection
– Accurate data collection
• Direct from sensor to database
– Data is collected and stored on a regular basis
• Work orders triggered automatically based on events in
system
• Reduces the time between the presentation of a
maintenance issue and its resolution
System Value Summary
• Work orders generated as soon as a problem presents
itself
– No delay between reporting the problem and initiating the solution
• Track status and effectiveness of work practices
• Interface does not ‘touch’ customer’s MAXIMO database
– No database triggers or other custom work
– No database modifications
July 2003