OT Convergence

LOVE THIS LIFE
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The IT \ OT
Convergence
Hugh Roddy
Vice President Global Engineering
& Project Management
February 2016
2
“WE BELIEVE
PEOPLE HAVE
GREAT TASTE.
THEY JUST NEED
GREAT OPTIONS.”
3
33
OUR MISSION IS BETTER
FOOD FOR MORE PEOPLE
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OUR BELIEF
“We challenge the status
quo, because the status
quo isn’t good enough.”
5
66
MAINTAINING
LEADERSHIP
IN A GROWTH
CATEGORY
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IT\OT Convergence,
1. Difference between IT & OT
2. Infrastructure Old & New
3. Developing Internal resources and external
vendor partnerships
4. Leveraging new technology with existing
technology to maximize ROI and integrate
Process and Business systems seamlessly
5. Tips & Tricks
6. Simple and Effective Monitoring constant
monitoring
7. Utilizing you infrastructure for
Energy Management
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The View of IT vs OT in the Industrial Control System
Important stuff that
we really don’t
know much about
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Network and Communications
How many times have we cut corners or let our system integrators
take lead on our process network infrastructure?





Unmanaged network
No diagnostics
No way to prevent network outages
We have our own IP Addresses??
Performance issues… “Hey the HMI is SLOW!”
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Example of Redundant / Hiper-Ring
199.100.43.180
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Primary Coupler
A Simple and Clear Topology
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Hype versus Reality
Everyday Automation “Buzz Words”
•
•
•
“Synergy”
“The Cloud”
“KPI”…
The truth is, all of the HYPE is true!
Main Goal at the end of the day!!!!;
1) Increase productivity,
2) Reduce downtime,
3) Faster Changeovers,
4) Meet and exceed regulatory demands.
And still be dynamic, flexible for growth and maintain
product diversity, while supporting business demands.
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Infrastructure & Standardization
Chobani leveraged a fundamental global strategy within our controls infrastructure.



Look the same
Behave the same
Feel the same
Key\Trick is to actually accomplish this goal.
Focusing on key elements of the infrastructure that directly impact operations
was the key.
2 key areas of Infrastructure:
•
Process Automation Hardware and Programing – PLC hardware\HMI Software and
standardizing with naming conventions and controls standards etc.
•
Network and Communications – the communications process is critical to the functionality
of the plant. Not just the daily functions but startup, testing, expansion to existing locations,
remote and local support, etc…
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What Did We Do at Chobani?
•
Solid network and communications - Managed network, Full VLAN
Segmentation, Full Control and Monitoring
•
Choose a Process Automation Network solution provider – with expertise and
knowledge in not just IT but industrial process controls
•
Server and Software Platforms to support constant and dynamic growth and
demand
•
Innovative and out of the box approach to Energy Management and Process
tracking using virtual metering and integrating third party systems data to
process oriented systems.
•
Integrating processes and third party systems under a single interface and
providing collaborative tools for every aspect of company
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How:
Internal Resources / Vendor Relationships
•
Qualified and well trained internal staff as well as partnerships with the best
vendors in the business.
•
Identify mission critical processes and align resources with those processes
•
Identify technologies that are critical to the process and solicit vendor
expertise in training of core or fundamental support concepts
•
Leverage collaboration tools and technology to advance support and project
efficiency
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The Partnership Continues
•
•
Need to dissect supplier \ vendor offerings to leverage their strong points
Leverage other packages to compensate for their weakness or lacking capability.
Process Automation Control and Visualization
 PLC - Rockwell Automation etc.
 HMI - Wonderware \ Rockwell \ Effi-Drive etc.
 Networking (Process) – INS \ Hirschmann
 Business Intelligence \ Process Integration
- Ignition\ Zarpac\ ICIS \ INS
Business / Corporate / ERP –
 MS Office,
 MS Lynx
 Microsoft Dynamics
 ETQ
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So Where Are We Today???
Growing and accelerating fast and expanding rapidly…
• IT & OT communicate seamlessly together 24/7
• With our managed networks and diagnostics we are recognizing 99%
uptime on communications and controls
• We are empowering people from the ground up!!!!
• Our Power Management and Virtual metering systems provide us
immediate cost savings and forecasting for resource planning.
• Systems integration is allowing collaboration between every department and
entity in the company, allowing for effective communication and data mining
and sharing for deterministic planning.
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Business Intelligence \ Process Integration
•
Utilizing the power of Inductive Automation’s Ignition & Zarpac (ZPI) along with
internal Dashboards to integrate our business systems with our process oriented
systems.
•
Wrap process system visualization and monitoring into web based interfaces.
•
Allow the ability to add flexibility that traditional systems lack, such as mobile
development and utilization (iPad, Android, etc..).
•
Empower the people from the plant floor all the way to the CEO
Mobile Users
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OEE, KPI, Downtime, Forensics
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For Example….
Some of the projects we took on this year…
• Material tracking and process management – using our ERP system, open
source programing and partnerships with our integrators
• Plant Metrics – with virtual metering and integration of third party process
systems
• Management Of Change / Project Management Systems – using existing
systems and process, we integrated typical spreadsheet and flat file managed
process to relation database operations with single unified interface
• Collaborative integrations between IT and Process systems and networks:
 LSL
 Chodash Enterprise
 Company Power Management
 Integrated ERP and Process based operations
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The End Result…
Fully Integrated and Platform Agnostic User Interface based systems that bring Business Systems,
Process Systems, Energy Management Systems and local flat file processes together. Using IT managed
security with Active Directory:
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Simplistic, but Effective Screen
We approached the primary user interface with the a simple 3 Click
approach… Get the data you want and from any place you want in 3 clicks or
less…
Tier 2 - Navigation
Tier 1 - Navigation
Tier 3 - Navigation
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Utilizing Mobile \ Dashboard Technology
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Real Time End of Line Production Tracking
and Low Cost Displays For Improved
Production
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Integrated Energy And Utility Management
Across All Plants a Single Click Away…
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tant Data at the Operators Finger Tips
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and Process…
is an example of PLC data from an OPC based system directly talking to an IT related labeling
base integrated directly to the ERP system… Notice real time IO working hand in hand with the
ng request and relational database…
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art Tools for Monitoring
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fining Patterns with Combined Diagnostics
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nitor the Monitors
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apex Home\ Dashboard
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ample Project: Budget, Forecasting All project Details
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uments from anywhere with embedded PDF viewers
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C Home \ Dashboard
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mple MOC
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ty to add attachments directly related to an MOC for all to see able at anytime and anywhere, whether on the IT or OT network
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namic embedded reports
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Automation
and Energy
Management
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ergy Management Challenges
e knew at a very high level what our carbon footprint and energy usage was based on
ectricity, Gas and Oil billing from suppliers
e did not know what, where and who was using this energy across any of our facilities
e challenged ourselves to adopt an ISO50001 model and gain a grip and understanding of
r energy usage across the facilities
e decided that our New York Facility would be our starting point for a program, as after a
mber of audits, we identified that it had a greater challenge to overcome
e site itself had limited or no Metering of any energy usage
 Limited Power Metering at distribution board level
 2 Water Meters (Supply to Site and Return to Waste Water
Plant)
 Zero Steam Metering
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ergy Management Policy
developed our Energy Policy, which is divided into the Five Pillars of excellent energy
agement:
mmit - Commitment to energy management by the organisation was made
tify - Develop a real understanding of our energy use and identify our users
- Plan how to put our policy goals and savings opportunities into action
on - Implement our energy changes
ew - Constantly monitor and review our systems
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ergy Management System Requirements
e needed a system that would be flexible enough to support any existing infrastructure available to
s
e
needed
a
system
that
offered
an
efficient
installation
with
minimum
pact to manufacturing operations
e wanted a system to report on all our energy types including
e wanted something that could be rolled out seamlessly to all our facilities
e needed a cost effective solution that would support our projects and offer us a strong return
n investment
needed to be intuitive enough for non-technical personnel to utilise and powerful enough to
fer detailed analytics
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ergy Management Solution
ter a detailed selection process we decided to implement the ICIS Plant Energy Solution
ww.icissoftware.com)
IS have been in the Energy Management software business since 2008 and specialise in Manufacturing
cilities and have installations with organisations such as Pfizer, LA LA Dairies, Coca Cola and GSK to
me a few
e ICIS offering provided us with something completely unique that no other solution could provide: Virtual
etering
IS showed us how we could leverage our Automation systems and current infrastructure in such a way
at we could remove the capital cost expenditure of a traditional metering system
ey detailed how we could install and commission the entire project with zero downtime and build complete
ergy maps and carbon footprints of our entire facility and most importantly link all this to production
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ergy Management Architecture
Architecture Leverages our Wonderware Historian, PLCs, BMS (Evapco), Metering and
geration Systems (Frick)
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ergy Management Configuration
e utilized existing Meters to measure energy where possible
e created over 300 ICIS Virtual Meters to map the energy distribution across the entire site saving over $1.8M on
rdware costs and most importantly manufacturing downtime
veraging our Historian and Process Data for valve and motor control ICIS calculates Power, Water and Steam
nsumption for non-metered areas across the facility with tolerance ranges of 1% - 5% accuracy
e were able to backfill energy data with ICIS using our Historian information so we had an instant energy baseline
d did not need to wait for future data collection
e linked our production and cleaning batch processes to the system and gained complete maps of energy
age versus production
Annotate Energy Consumption
See Daily Profiles
Consumption Performance
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ergy Management Data 1
e now have a complete understanding of our energy usage and reasons behind it
e’ve mapped energy users across the facility tracing Power, Water and Steam Distribution
us we’ve linked usage to our production and cleaning processes
e now have live maps and reports on Energy and Carbon data and the ability to analyse
nd reduce were we need
Live Dashboards
Energy Distribution Mapping
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ergy Management Data 2
e have over 30 analytical tools at our disposal for analysis of our Carbon footprint and Energy usage
e now profile our energy usage and intensity across production and cleaning processes helping us refine
r process control to make energy usage and production more efficient
e now have the tools at hand to present the case for capital project investment in programs such as new
ocess improvements and sustainability projects
Energy Intensity Heat Maps
Live Mimic Displays
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uilding and Site Dashboards
Chart Annotations and Storage
corecard Status and Drill Down Functionality
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ergy Management Summary
We completed the entire project within a 6 Week schedule
We had zero downtime or manufacturing impact during the project
We saved over $1.8M on project capital costs implementing ICIS
We estimate an ROI of less than 3 months on the actual project
We’ve leveraged our existing Automation systems in ways we never thought possible
We now have production and energy metrics defined and tracking across the site
We are aiming for a 15% reduction of Energy consumption and Carbon Emissions over
he next 18 Months
We are now in Phase 2 of our program rolling the ICIS platform out to our Idaho facility
take away point:
tilizing your Automation systems and existing infrastructures you can implement a
cessful energy management program with minimum capital expenditure and maximum
50
mmary
ortant Things to Consider:
T Convergence - We must work seamlessly together at all times - but they don’t
d to sit on the same media or platform in order to have a successful relationship.
t is most important:
Have the correct network for the environment it is controlling and the appropriate
resources and vendor relationships to support it.
How We Connect Our Businesses
How We Protect Our Customers
How We Advance the Lives of Our Customers and Employees
How We Advance Our Industry Through Consistency and Change
How We View Our Careers and Professional Lives Striving To Achieve
Excellence
re is no secret formula for IT\OT convergence or Manufacturing Automation
cess, but rather a dedication to methods, processes and excellence that
ps us sharing our visions, failures and successes to create a great product
end result.
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QUESTIONS
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THANK
YOU!
Hugh Roddy
Vice President of Global Engineering
& Project Management
www.chobani.com
@chobani
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