Introduction to Cloud Computing for Manufacturers: Demystifying the Cloud

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How is the Cloud relevant to manufacturing? How can you securely move data to the Cloud, what compelling things can you do with it when it's there, and why? What is Rockwell Automation already doing today with customers in the Cloud? This is an introductory overview of cloud computing, and an insightful look at the new capabilities now available to manufacturing; what it is, how it works, why it's important, and where it's used are amongst the topics discussed.

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Introduction to Cloud Computing for Manufacturers: Demystifying the Cloud

  1. 1. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Introduction to Cloud Computing Using Cloud Technology in Manufacturing to Drive Innovation & Insight Connected Plant Connected EnterpriseConnected Devices, Skids, Machines
  2. 2. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2 Agenda RA Cloud Platform Demo 3 Customer Use Cases Rockwell Automation’s Cloud Capabilities The Value Proposition of Cloud Computing for Manufacturing Microsoft Cloud Overview
  3. 3. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 3 Challenges in Manufacturing Harnessing the power of data Complying with complex regulations Managing a mobile workforce Collaborating in real-time
  4. 4. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 4 Megatrends We See For Our Growth
  5. 5. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 5 Cloud Design Principles managed automatedusage basedeconomics elastic always up. always on.
  6. 6. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 6 Computing Patterns S M T W T F S Capacity Needed (Max + 20%) J F M A M J J A S O N D Capacity Needed (Max + 20%) t Compute Inactivity Period On and Off Growing Fast Unpredictable Bursting Predictable Bursting 24x7 Steady Save 20-30% Save 60-80% On and Off (30%) Growing Fast (15%) Unpredictable Bursting (25%) Predictable Bursting (20%) 24x7 Steady (10%) Your Application Portfolio – What Does it Look Like..?
  7. 7. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Microsoft Cloud OS vision Providing a modern platform for the world’s apps Customer Service provider Microsoft 1CONSISTENT PLATFORM Flexible development Unified management Common identity Integrated virtualization Complete data platform
  8. 8. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cloud Computing
  9. 9. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 9 Microsoft Differentiation COMPUTE STORAGE NETWORKING BUSINESS INTELLIGENCE DATA API managedautomatedusage based economicselastic always up. always on. hybridopen flexible New Existing + hybrid Other Service Providers Your Data Center Windows Azure
  10. 10. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. virtual machines web sites cloud services SQL database noSQL database blob storage connect virtual network traffic manager ... FrameworksServicesFabricInfrastructure N Central US, S Central US, N Europe, W Europe, E Asia, SE Asia + 24 Edge CDN Locations ... ... ... ... ... Automated Managed Resources Elastic Usage Based Microsoft Azure – The Big Picture
  11. 11. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Value of Cloud for Manufacturing The Transformation of Manufacturing  Cloud Computing is a disruptive technology force in Manufacturing  Offers creativity, innovation & differentiation for our customers  Step change in simplicity & cost of ownership for Manufacturing IT assets  Enable new business models for every aspect of your value stream  Simplified integration with other Enterprise Systems (ERP, EAM, SCM, CRM…) Big Data Predictive Analytics Analytics Intelligence Internet of Things Machine to Machine Access Insight
  12. 12. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Evolution of Software Systems 12 Traditional IT Storage Servers Networking O/S Middleware Virtualization Data Applications Runtime Youmanage Infrastructure as a Service Storage Servers Networking O/S Middleware Virtualization Data Applications Runtime Managedbyvendor Youmanage Wemanage Platform as a Service ManagedbyMicrosoft Storage Servers Networking O/S Middleware Virtualization Applications Runtime Data Software as a Service ManagedbyRA Storage Servers Networking O/S Middleware Virtualization Applications Runtime Data Our view… Customer’s view…
  13. 13. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cloud Value Prop for Manufacturing Differentiated Solutions Predictive Maintenance  Local deployments are difficult / Assets are distributed across broader geographies  Access to data to be shared across corporations  Common requirements are shared by many  Information Technology operating costs are too high  There is a lack of technical resources (Developing markets)  ―Shadow IT‖ projects need to be professionally managed  Enterprise data can be ―mashed-up‖ with public or syndicated data Empower Your Domain Experts Scalable, Multi-Tenant Access for all Stakeholders RA Accountable for Total Lifecycle Mgmt (1BTK) Creative New Business Models Better Cash Flow Management (CapEx - OpEx)
  14. 14. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Analytics Process Insight Predictive Maintenance Big Data RA Cloud Solution Security Object Model Data Storage Event Detection Alerts & Notification Workflow Portal Dashboards & Reports RA Cloud Solutions Moving from traditional software deployment to Software as a Service 14 Site 1 Site 2 Site n Cloud Gateway Secure, smart efficient transfer of plant data to the RA Cloud Platform Wired Wireless Cell Satellite Control Systems CloudPlatformDataTransportDataSource Performance Mgmt Performance Mgmt Equipment & Process Behavior & Optimization
  15. 15. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RA Cloud Gateway Capabilities 15 Data Sources Connector Plug-In Connector Plug-In Connector Plug-In Data Conditioning Filter / Event Detection Transform Aggregate Cloud Adapter Formatting Compression Authentication Connection Mgmt Transition to/from Store & Forward Local Storage Buffer Store & Forward Data Pump Thread Communication Thread Variety of Form Factors wired : wireless : cell : satellite : gps
  16. 16. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cloud Application Platform 16  Model for the application  Security associated with unified model  Common set of (web) services  Application services operating against the model  Time Series Services and history storage  Calculation  Scripting  Business Logic - Eventing & Notification  Common UI (property grids, namespace explorer, …)  Common clients (Manager, Trend, XY Plotter, Excel Integration)  Cross-platform Thin UI  Workflow execution
  17. 17. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cloud Security 18  Object level security  Role based ACL (Access Control List)  ACL can be inherited from the parent  Authentication via federated security  Live IDs  Google IDs  Yahoo IDs  Integration with Active Directory  Server-side users (managed by us)  Other providers can be added
  18. 18. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Rockwell & Microsoft Infrastructure Security
  19. 19. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. B A Supplier A OEM A Support Org Customer 1 RA Support Utilities Corporate Headquarters OEM B OEM C Supplier B Prod/Proc Designers RA Cloud Platform Cloud Gateway Secure, smart efficient transfer of device data to the RA Cloud Platform Customer 2 Customer 3 Data Sources Quality Org Simple, Secure Access for Key Stakeholders
  20. 20. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Model Driven UI Complex Object 21 Model driven thin UI has driven most of the improved efficiencies in project execution…
  21. 21. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Model Drive UI Mobile Ad-hoc Reporting Application 22 select report properties browse model hierarchy view current values view history trends
  22. 22. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cross-Platform Visualization 23 Simple Graphics
  23. 23. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cross-Platform Visualization 24 Dashboard
  24. 24. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cross-Platform Visualization 25 Trending
  25. 25. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Cross-Platform Visualization 26 Basic Workflow
  26. 26. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Powerful On-Premise Clients Ad Hoc Analytics  Trend, XY Plotter
  27. 27. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Powerful On-Premise Clients Ad Hoc Reporting  Excel Add-in
  28. 28. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Software as a Service Solution Components Application Configuration Model Development Dashboard Development Business Rule Configuration Workflows Non-Recurring-Eng Costs Per Site/Asset Cloud Gateway Hardware Optional Cellular svc contract GPS capability SaaS Subscription Fee* All ‘Compute’ infrastructure All ‘Data Storage’ infrastructure RA Cloud SW Platform (per Asset) Support SLA Optional Cell or Satellite Connection Fee * Invoiced quarterly, annually (minimum 3 year contract) Each of these components can be built into the subscription fee
  29. 29. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. PUBLIC INFORMATION Use Case 1 High Volume, High Value, Highly Distributed Assets Supermajor O&G Producer
  30. 30. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Pump Motor Performance Monitoring Note: This is one of many equipment types with specific performance techniques. There are dozens others. This one is selected as a moderately complex example with well understood broadly applicable physical principles.  Millions of Motor/Pump combinations in our customer base  Typically poorly monitored  Maintenance is usually reactive rather than proactive  Single customer estimates > $100M annual wastage  Calculate Motor Power from electrical inputs  Calculate Pump Power from fluid inputs  Compare dynamically  Notifications and alarms  Reporting and visualization
  31. 31. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Motor Performance Calculations  Control System Inputs  Motor Speed (rpm): N  Motor Voltage (V)*: E  Motor Amps (Amps)*: I *Mean of 3 phases  Motor Power Factor: PF  Phase Angle: phi (if not measured lookup as Fn{L})  Constants  Nameplate rate current I_r  Nameplate rated voltage E_r  Calculated Outputs  Motor Load (%) L I*E/I_r*E_r*100  Efficiency, Motor eff_m 2D lookup table as Fn{L}  Motor Power (hp) mhp sqrt(3)*I*E*eff_m*(abs(cos(phi)))/746
  32. 32. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Pump Performance Calculations  Control System Inputs  Pump Flow (gpm) Q  Pump Discharge press (PSI) Pd  Pump Suction press (PSI) Ps  Constants  Specific Gravity SG  Calculated Outputs  Efficiency, Pump, Expected eff_p_exp (Pd-Ps)*(2.31/SG)  Efficiency, Pump, Actual eff_p_act hhp/mhp  Head, Actual (ft) H_act 3D lookup table Fn{Q,N}  Head, Expected (ft) H_exp 3D lookup table Fn{Q,N}  Pump Hydraulic Power (hp) hhp Q*(Pd-Ps)/(1714)
  33. 33. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Visualization Example
  34. 34. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Using Intelligence to Transform an Industry Use Case 2
  35. 35. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. What is a L.A.C.T. Unit  The Lease Automatic Custody Transfer (L.A.C.T.) unit is a critical system designed for the automatic transfer of ownership of liquid hydrocarbons (crude oil and petroleum products) between the buyer and seller  On land – at every junction between production facilities, trucks, railcars, pipelines or storage tanks  Offshore - into pipelines, barges, and tanker loading and offloading operations  The main objective of LACT unit is to accurately measure, sample and transfer the hydrocarbons from between buyer and seller
  36. 36. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. The Value of a L.A.C.T. Unit  The greatest effect on volume is temperature — typical crude oil will expand and contract at the rate of 2% per 40º F temperature change  The accumulation of errors present in the tank gauging may be as high as 1%  The potential annual losses in revenue, based on daily lease production and on $100 USD per barrel oil, would be as follows: Daily Lease Production Lost Revenue/Yr @ 1% 500 $182,500 1000 $365,000 2000 $730,000 3000 $1,095,000
  37. 37. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Frustrations with the Current Approach 38  Visibility and access limited to site visits  Remote sites miles away  Operator errors go unnoticed  Delayed billings for Producers  No accountability for operations  Support/maintenance is difficult
  38. 38. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. RA Cloud Platform Security Object Model Data Storage Event Detection Alerts & Notification Workflow Portal Dashboards & Reports A Perfect Solution - Asset Performance Management from Rockwell Automation 39 Remote Monitoring & Support Real Time System Alarms/ Faults Event/Notification Mgmt Predictive & Preventive Maint Asset Performance Management Performance Mgmt Improve LACT Efficiency Improve Profitability Cloud Gateway Secure, smart efficient transfer of plant data to the RA Cloud Platform
  39. 39. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. High Level Asset Status 40 USA Locations North Dakota - Bakken S1120 - Bakken S1290 - Bakken N2415 - Bakken N2416 - Bakken N2417 - Bakken S3305 South Dakota - Harding W4451 - Harding N2225 - Harding N2115 - Harding W1175 Oklahoma - Hunton W7664 - Morrow S8874 Texas - WT.W115 - WT.N9971
  40. 40. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. L.A.C.T. Unit: Key Performance Indicators 41
  41. 41. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Real Time Alarm/Event View 42
  42. 42. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Key Process Variables 43
  43. 43. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Transaction Overview & Summary 44
  44. 44. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Conclusions 45  Savings in supporting their installed base  Significant new revenue because of accountability for custody transfer  New levels of access to their equipment to:  Improve the performance of their equipment in the field  Improves the profitability of their supply chain  Reduce their support costs  Exciting new business/services opportunities  Differentiated capabilities & business model
  45. 45. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Competitive Differentiation; Building a New Services Offering Use Case 3
  46. 46. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. Looking Forward…
  47. 47. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Zdenek Kodejs RA Cloud Platform Application Demo
  48. 48. Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. www.rsteched.com Follow RSTechED on Facebook & Twitter. Connect with us on LinkedIn. PUBLIC INFORMATION Any Questions?

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