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Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DDisaster Recovery and Change Managementin a ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 2AgendaFactoryTalk® AssetCentre Case StudyDisaster Stories...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 3
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 4
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Superior Controls• Rockwell “Information Software Partner” ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Emergency Call6• May 14th 2006, 8:45AM• Plant Manager“C...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Situation7• “The PLC stopped workinglast night.”• “The ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Superior Controls Engineer Reports8• Senior Engineer, Chris...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Report from our Engineer9• “There is no back upsoftware.”• ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Costs10• 8 employees for 2weeks…per shift!• Electricity...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results11• Chris made two copies of the final software:...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results12 Where he found a copy ofthe original software!
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Rogue Engineer13• Ralph – Prides himself on writing “el...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results14• Ralph – After the second time he was caught ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Inferno15 5:00 AM Emergency Call (at my house) Polaro...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Inferno16
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Imagine a Solution17 A central, server based software solu...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 18
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Existing Change Management System Existing web based archi...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Weak Areas in Existing System20 Easier way to provide chan...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Solution Detail/Evaluation21 Rockwell provided Off the She...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Preliminary Design22 What does the network look like? Wha...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.System Architecture23From CorporateNetworkAssetCenter Serve...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Project Execution24 IT/Networking Must support network an...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results – AssetCentre Highlights25 After installation,...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results – Addressing ExistingSystem26 Engineers are au...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Project Challenges27 Interface with validated equipment I...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Recommendations28 Spend time up front during design Plan ...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?Thank you for your time!!!Rick Pie...
Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DThank you for participating!Please remember ...
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Superior Controls: Disaster Recovery and Change Management in a Validated Environment

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Transcript of "Superior Controls: Disaster Recovery and Change Management in a Validated Environment"

  1. 1. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DDisaster Recovery and Change Managementin a Validated EnvironmentCustomer Success StoryRick Pierro and Bob CoggonPresident and Sr. Project EngineerSuperior ControlsJune 2013
  2. 2. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 2AgendaFactoryTalk® AssetCentre Case StudyDisaster StoriesWho is Superior ControlsRick Pierro
  3. 3. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 3
  4. 4. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 4
  5. 5. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Superior Controls• Rockwell “Information Software Partner” (one of only 25 inNorth America)• 48 automation engineers on staff• 20 years of successful integration experience• Named “Business of the Year – 2013” by NH Business.• Named- “Systems Integrator of the Year - 2012”by “Control Engineering” and “Plant Engineering”• Design and implement turn-key automation systems forBiotech, Food and Beverage, Energy Production andMonitoring
  6. 6. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Emergency Call6• May 14th 2006, 8:45AM• Plant Manager“Control Panel is Down”“PLC not Working”
  7. 7. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Situation7• “The PLC stopped workinglast night.”• “The original equipmentvendor has been out ofbusiness for 5 years.”• “This manufacturing lineproduces half myproduction”!!!!!
  8. 8. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Superior Controls Engineer Reports8• Senior Engineer, Chris arrived on site at 10:15AM• Called me at 12:00PM with a verbal report
  9. 9. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Report from our Engineer9• “There is no back upsoftware.”• “There is no softwaredocumentation.”• “There are 135 I/O and thereare no wiring diagrams”!• “May take 3 weeks to rewritethe code”!!
  10. 10. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Costs10• 8 employees for 2weeks…per shift!• Electricity, taxes,depreciation, wages…• Over $20k to rewrite thecontrol software• No production for 2 weeksfor ½ the plant• Lost revenue from cancelledorders• Angry customers
  11. 11. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results11• Chris made two copies of the final software:- One to be stored in the Superior Controls library- One for the Plant Manager to put in a safe place• The Plant Manager placed it into the company safe
  12. 12. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results12 Where he found a copy ofthe original software!
  13. 13. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Rogue Engineer13• Ralph – Prides himself on writing “elegant” PLCcode.• Enjoys rewriting other people’s code …even if it’s been working for years …on an FDA validated PLC based system …that makes vaccines!
  14. 14. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results14• Ralph – After the second time he was caught rewriting codeon an already validated system, he was let go.• The Vaccine manufacturer now has 27 validated PLCsystems in place. They are wondering if he had made anyother unauthorized, untested, undocumented, changes.
  15. 15. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Inferno15 5:00 AM Emergency Call (at my house) Polaroid Control System is down – can I have an engineeringteam on site at 7:00 AM? Thermal Oxidizer test equipment directly below the control panelhad shorted out. Causing….
  16. 16. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Inferno16
  17. 17. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Imagine a Solution17 A central, server based software solution that stores copies ofall current PLC programs including older versions, andidentifies and alarms unauthorized changes to the code –automatically!
  18. 18. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved. 18
  19. 19. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Existing Change Management System Existing web based archive tool inplace. Master copy was backed upto CD. Engineers and Maintenance useindividually assigned laptops Periodic backups performedmanually
  20. 20. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Weak Areas in Existing System20 Easier way to provide changemanagement Monitor status of assets automatically Provide additional security measures Provide reporting of activity on system Provide centralized location fordevelopment Simplify disaster recovery procedures Integrate with existing Rockwellinfrastructure Allow for future expansion of system Must be validated
  21. 21. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Solution Detail/Evaluation21 Rockwell provided Off the ShelfPackage Can be validated Integrates with Rockwellinfrastructure Provides audit logging for RockwellSoftware Products FactoryTalk Services Platform andFactoryTalk Security FactoryTalk AssetCentre
  22. 22. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Preliminary Design22 What does the network look like? What kind of assets are there? How many assets? What development licenses arerequired? Are there any security requirements? How will change management beused? Will other file types be used? How many users will access thesystem? Are automated backups orcomparisons required, if so how often? Is audit logging required? To whatdetail?
  23. 23. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.System Architecture23From CorporateNetworkAssetCenter ServerActive Directoryand SecurityAssetCentre Client ServerwithRemote Desktop ServicesAgent ServerRouted InfrastructurePLC NetworkProtected Server NetworkFactoryTalk DirectoryandActivation ServerDatabase ServerUserPLC
  24. 24. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Project Execution24 IT/Networking Must support network andserver infrastructure Validation and Quality Assurance Owns testing documents andresponsible for validation ofsystem Engineering System end user
  25. 25. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results – AssetCentre Highlights25 After installation, system requirements were met out of the box Minimal user training required Seamlessly integrated with existing Rockwell Infrastructure Reporting for audit logs of AssetCentre and Rockwell Software products
  26. 26. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.The Results – Addressing ExistingSystem26 Engineers are automaticallynotified of changes on Plant Floor. Peace of Mind Centralized development location Simplified management Change management with versiontracking Room for future expansion Complete audit trail formodifications made to system
  27. 27. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Project Challenges27 Interface with validated equipment Integration of Siemens S7 PLCs Security requirements Compatibility issues Big Brother
  28. 28. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Recommendations28 Spend time up front during design Plan around any existing infrastructure Work to get all parties involved in the project early on Follow through with the project – Need management support Centralize development locations if possible Follow FactoryTalk AssetCentre System Design Considerations (KB57483)
  29. 29. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DQuestions?Thank you for your time!!!Rick Pierro and Bob CoggonPresident and Sr. Project Engineerwww.superiorcontrols.com
  30. 30. Copyright © 2013 Rockwell Automation, Inc. All Rights Reserved.Rev 5058-CO900DThank you for participating!Please remember to tidy up your work area for the next session.We want your feedback! Please complete the session survey!

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