Cisco presentation in RAOTM 2012, HCMC Vietnam

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Smart+Connected Manufacturing

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Cisco presentation in RAOTM 2012, HCMC Vietnam

  1. 1. Cisco Smart+Connected Manufacturing Operations Excellence Phan Thanh Son CTO, Cisco VietnamPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 1
  2. 2. My IT, Communication, Industrial Convergence Communications IT Industrial 1988 1989 1994Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 2
  3. 3. Achieving Operations Excellence for more Flexibility and Productivity  Make more informed business decisions using improved collaboration with real-time production visibility linked to business context  Enhance event response, with immediate collaboration for faster resolution to downtime and production issues  Improve productivity—quality, performance, cost—of production and people with unified communications and control infrastructurePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 3
  4. 4. Complex Manufacturing Environment Globalized Operations Need Efficiency, Agility Machine Raw Power Plant Materials/ Builder Exploration Manufacturing Plant Headquarters Supplier Distributor Supplier Retailer  Rising energy costs  Flat world competition Pain  Aging and remote workforce  Product proliferation  Globally distributed operations  Asset optimization Points  Customer support time zones  Rapidly changing demandPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 4
  5. 5. Manufacturing Operations Business Pressures and Priorities Reduce Production Reduce Costs Variability Optimize Asset Ensure Quality Utilization Competitive Improve Advantage Collaboration Synchronize Plant Profitability and Corporate Targets Objectives Globalization Visibility for Decision Making 0 10 20 30 40 50 60 0 10 20 30 40 50 60 All Others All Others Best in ClassSource: Manufacturing Performance Management, Aberdeen Group, May 2009 Top Business Priorities for Top Strategic Actions to Manufacturing Operations? Achieve Business Objectives? Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 5
  6. 6. “This is about a business change, to make our manufacturing facilities more flexible, more agile and more lean.” Kirk Gutmann, Global Information Officer, Manufacturing and Quality, General Motors CorporationPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 6
  7. 7. Operations Excellence What If Production Issues Could Be Identified and Collaboratively Resolved Immediately?Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 7
  8. 8. Industrial Automation 3.0: Converged Plant Architecture Integrated Real-Time Enhanced IT and Collaborative Mobile and Sensor Business and Asset Security and Control Tools and Remote Enabled Plant Data Tracking & Personnel System Processes Workers Manufacturing …Multi-Site Monitoring Tracking Flexibility Traditional Plant Plant of the Future Restricted and Real Dynamic, Integrated Isolated Mobile, Real-Time Static Environment Time Connected Environment “Solid State” “Liquid State”Source: AMR, Industry Week, Cisco AnalysisPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 8
  9. 9. Challenges in Achieving Operations Excellence  Communication and collaboration across the value chain and down to the factory floor  Integrating innovation processes with operations  Converging plant floor automation with business networks and systems  Real-Time access to information and knowledge  Security “Manufacturers must integrate product innovation with operations excellence to deliver complete customer value. An improper balance often leads to new products that are unprofitable to deliver or high-margin products that lack differentiation or strategic market impact.” Source: AMR ResearchPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 9
  10. 10. Manufacturing Excellence Availability Training Communications Safety Automation Energy Risk Delivery Asset Sales Procurement Smart + Connected Manufacturing Service Visibility Satisfaction Warehousing Collaboration Communication Intellectual PropertyPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 10
  11. 11. What Is Smart+Connected Manufacturing? “Intelligent, timely information and collaboration in Definition context for superior business results” Benefits Solutions Portfolio  Accelerate time to market for new  Continuous Innovation products  Create a consistent, differentiated  Customer Intimacy customer experience  Adapt your supply chain to changing  Supply Chain Agility markets  Improved operations efficiency  Operations ExcellencePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 11
  12. 12. Portfolio of Solutions to Enable Converged Plant Architecture Ethernet to SAFE for Secure Context Aware the Factory Process Control Wireless Plant Solution Integrated plant and  Protect critical control  Integrated sensor and  Visibility into material business networks system assets WLAN networks and asset status Secure visibility and  Secure visibility and  Improved productivity  Accurately locate remote access remote access through mobility people and assets Control system  Enable new applications flexibility Video-Enabled Industrial Wireless Unified Plant VoWLAN Collaborative Video Surveillance Communications Production Management Intelligent video  Access experts in  Improve productivity  Collaborate and share monitoring and security real-time and issue information, video, and response time voice to solve issues on  Collaborate with design the plant floor teams and suppliers  Enable effective mobile communications  Extend remote SME across the globe  Share knowledge and best practicesPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 12
  13. 13. Architecture for Manufacturing Communications and Controls Network Architecture for Manufacturing Convergence Stand-Alone Networks, Information Silos, Go From Single Purpose, Proprietary Corporate Network Of f ice Applications, Back-Of f ice Internetworking, Mainf rames Data Servers, and Servers and Storage Control Network Gateway Human Machine Programmable PC-Based Interf ace Logic Controllers Controllers Motors, Drives, and Actuators Robotics Control Network Device-Level Network Sensors and Other Ethernet Input/Output DevicesPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 13
  14. 14. Architecture for Manufacturing Communications and Controls Network Architecture for Manufacturing Convergence Integrated Platform, Standard Architecture …To Enabling Real-Time Visibility and Collaboration Corporate Network Of f ice Applications, Back-Of f ice Internetworking, Mainf rames Data Servers, and Servers and Storage Industrial Video Human PC-Based Programmable Machine Controllers Robotics Interf ace Logic Sensors Controllers and Other Input/Output DevicesPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 14
  15. 15. Architecture for Manufacturing Communications and Controls Network Architecture for Manufacturing Convergence Reduced Standard Remote Manufacturing Global Support for Downtime Architecture Faster MTTRPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 15
  16. 16. Ethernet to the Factory “How-it-Works” Example 1 2 3 4 Visibility into  Log into automation  Check network  Access automation production system with secure status through system and devices performance issue remote access FactoryTalk to identify and at one plant capability integration resolve issue  Improves visibility into production systems for faster issue identification Business  Reduced travel time and cost  Faster response and resolution to issues reduces downtime Value  Prevents security incidents and unauthorized access Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 16
  17. 17. Improve Operations Efficiency Connecting a World Wide Manufacturing Operation Standardize operating model Network is a key part globally of the infrastructure to build and deliver vehicles All devices in the plant are connected to the central system, including robots and PLCs  Single system to see what’s going on in all the plants  Reinvent how GM makes cars and trucks Business  Get access to the right people at the right time to fix issues quickly Value  Reduced network downtime 95%  Moved from chaos and firefighting to innovationPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 17
  18. 18. SAFE for Process Control Disparate Networks, Limited Visibility, Go From Control Network Security Issues  Limited real-time information visibility  Multiple networks  Downtime and productivity issues due to security incidents  Poor asset utilization and performancePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 18
  19. 19. SAFE for Process Control Secure Connectivity Between Plant and Business …To Systems, Visibility Into Production Systems  Secure connectivity between plant and business systems  Real-time information visibility  Secure architecture  Remote accessPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 19
  20. 20. SAFE for Process Control Quicker Better PlantImproved Response to Reduced Performance Asset Production Downtime with Real-Utilization Issues time VisibilityPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 20
  21. 21. Drivers for Manufacturing Wireless Applications More Points of Visibility and Control  Eliminating Wires and Cables Increase reliability Reduce installation cost  Remote Device Monitoring Troubleshooting/maintenance Instrumenting existing machinery  Tracking Assets RFID Real-Time location services  Enabling Portability and Mobility Mobile HMI (People) AGVs (Equipment) Communications (VoWLAN)  Video Surveillance Security and process monitoring  Guest AccessPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 21
  22. 22. Secure Wireless Plant Secure Wireless Network for Sensors and Advanced Solutions Expensive Sensor Deployments, Multiple Isolated Go From Networks, Limited Worker Mobility and Asset TrackingPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 22
  23. 23. Secure Wireless Plant Secure Wireless Network for Sensors and Advanced Solutions Integrated Wireless Sensor and Information …To Network, Plant Wide Mobility and AccessPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 23
  24. 24. Secure Wireless Plant Secure Wireless Network for Sensors and Advanced Solutions Efficient Deployment of Improved EnhancedIncreased Plant Wide Asset Worker Visibility Wireless Utilization Productivity Applications (Location, etc.) Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 24
  25. 25. Context Aware Manufacturing Lack of Information, Lost WIP Assets, Go From Unresponsive Supply Chain, Regulatory Challenges High Scrap Rate Lost Inventory Safety Challenges Labor InefficienciesPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 25
  26. 26. Context Aware Manufacturing Holistic View of Assets, WIP, Inventory and People with …To Interactive Real-Time Responsiveness In-Use Status Location Over Cisco Unified Wi-Fi Network ConditionPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 26
  27. 27. Context Aware Manufacturing Use Case “AeroScout eliminated the manual scanning process and removed human error.” says Matt Miesner, Six Sigma Blackbelt at Viracon, “We went from between several hours to several minutes to find a carrier, down to less than a minute.”* Matt Miesner is a Six Sigma Blackbelt at ViraconPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 27
  28. 28. Context Aware Manufacturing “How-it-works” Supply Chain (WIP) Example 1 2 3  MES system provides  System provides rack  Visual blinking indication next Job number and lot location on tag speeds up is displayed on map detection  Reduces several minutes per each operation, over hundreds of process Business steps over previous manual operator search process Value  Significant improvement in production throughput over manual systemPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 28
  29. 29. Improve Operations Efficiency Cisco Context Aware Solution 1700 critical parts, plus tools and machines in the factory have RFID Advanced wireless tags and can be technology from Cisco located instantly used to overcome dead spots in the building Because each component has a unique tag, items can be better identified to resolve service issues  Improved productivity due to ability to quickly locate parts and tools Business  Enhance parts traceability and reduce cycle time to solve in-service issues Value  Reduced production delays and government finesSource: Cisco® Customer Systems, Inc. Transformation GroupPresentation_ID © 2009 Cisco Business All rights reserved. Cisco Confidential 29
  30. 30. Industrial Wireless Video Surveillance Limited Plant Wide Security Visibility, Disparate Go From Security Networks, Expensive Deployments  New security and compliance requirements  Difficult remote equipment and process monitoring  Expensive, disparate video systems  No plant wide visibilityPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 30
  31. 31. Industrial Wireless Video Surveillance Integrated Video Surveillance Systems, …To Efficient Deployment, Improved Security  Industrial video surveillance  Efficient deployment on Cisco wireless architecturePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 31
  32. 32. Industrial Wireless Video Surveillance Open Industrial Improved Integrate Architecture GradePlant Safety Into Plant for Efficient Security andand Security Applications Deployment Monitoring Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 32
  33. 33. UC for Manufacturing Provides Collaboration Across the Value Chain for Improved Shop Floor Communications Real-Time Emergency Contacting Production Performance Tracking MES Interfacing; Equipment ERP Interfacing; Inventory/Supply Downtime Alerts to Phone Chain Alerts to PhonePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 34
  34. 34. Plant Voice over Wireless Multiple Communication Devices and Networks, Go From Limited Access and Communication on the Plant Floor  Limited communications outside of control rooms  Separate networks for “walkie talkies”  Multiple devices and missed communications  Limited access to applications and dataPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 35
  35. 35. Plant Voice Over Wireless Real-Time Collaboration Across the Plant, …To Mobile Application Access, Integrated Networks  Effective communication across the plant  Single device for desk and mobile communication  Access to data and applications on IP phone or other mobile device  Support for Cisco and partner devicesPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 36
  36. 36. Plant Voice Over Wireless Efficient Reduce Improved deployment unplanned communication Eliminate on Cisco stoppage for issue silos of Unifiedtimes by up notification communication Wireless to 50% and resolution Network Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 37
  37. 37. Increasing Productivity and Cost Metals and Mining Savings on the Plant Floor Using UC Major Use Case 1 2 3 Smelter operator needs  Pulls up critical  Makes process change to check process data to production data on PDA accurately and rapidly make adjustments via PDA  Calls operator in another location to discuss change using soft-phone on PDA  Eliminated three to four wasted hours walking to control room per shift per operator Business  >80% faster operator decision making Value  50% reduction of physical control roomsPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential Source: Cisco® Customer Business Transformation Group 38
  38. 38. UC Can Help Reduce US Refining the Response Time in Crises Major Case Example: Responding to Equipment Failure in the Refinery 1 2 3 4 5 Equipment failure  Partner extension to  Enter the meeting  Meeting Room  Conduct meeting in the refinery that MeetingPlace to through touch- appears on your PC with ‘show and tell’ can cause quickly initiate a screen on IP bringing together all of equipment set-up production loss and blast dial for phone key participants in and action plan safety issues emergency minutes personnel with up to 3 pre-populated phone numbers per individuals  Improved employee safety Business  Faster incident response and resolution Value  Higher refinery uptime and production Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 39
  39. 39. Video Enable Collaborative Production Management Limited Visibility and Collaboration with Plant Floor, Go From Inefficient Resolution of Production Issues  Globally distributed operations  Limited remote access and collaboration across global production sites and suppliers  Slow, expensive issue resolutionPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 40
  40. 40. Video Enable Collaborative Production Management Real-Time Collaboration Using Voice, Video, and Web …To Conferencing Across Global Plants, Enterprise, and Suppliers  Streaming mobile voice and video from the plant floor  Share video across company and with partners using WebEx  Find experts using TelePresence  Integrated with Unified Communications & Cisco WLAN for efficient interoperabilityPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 41
  41. 41. Video Enable Collaborative Production Management Improve Capture and Quickly Productivity Share Videos Resolve and Reduce Extend SME for BestIssues to Costs Across the Practice and Reduce Due to Globe KnowledgeDowntime Reduced Sharing Travel Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 42
  42. 42. Enabling Faster and More Effective Response to Plant Floor Issues Alert Connect withPlant Floor Issue Engage Employee central support Camera OnsiteRemote Expert Onsite Expert Need to FindResources/ and/or CUPC An ExpertCentral Technical audio/video InternallySupport call Share via Need to connectInternal TelePresence* with SupplierExperts and WebEx ExternallyExternal IM and WebEx Publish on PortalSuppliers with Supplier Show and Share *TP/WebEx integration and multi-conferencing need testing and validation Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 43
  43. 43. TelePresence for Manufacturing Accurate planning can be Use TelePresence for Improved business agility, hampered by inefficient more efficient, effective reduced supply chain communications communication and costs and improved collaboration forecast accuracy  Distributed participants  Short timeframe to act TelePresence Value  Collaborative decision has high business impact  Complex information to share  Multicultural participantsPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 44
  44. 44. Converged Plant Architecture Plant Floor Safely and Securely Connected with the Enterprise  Integrated key expertise through voice, video and access to applications improving operational efficiency  Increased information on plant process and assets by extending sensor network and adding location determination  Reduced cost by relying on standard network Security and Network Administration Wide AreaPlant Wi-Fi Network Plant DMZ Plant IT Network Network Wireless Location Controller EngineIndustrial Wi-Fi Mesh and Location Receivers Core Video Routers Plant Floor Si Si Managers, Terminal Engineers Server Distribution Manufacturing Routers Si Si Router Location Chokepoint Access Location Switches Tags ERP, etc. Automation and Enterprise Wi-Fi Voice Control Applications Industrial Switch InternetWireless Sensor Cell/Area IT ServersNetwork Automation and Control Devices Wireless, Video and Voice Servers Sensor Mesh Teleworkers/ Network Video Customers and Partners Voice Ethernet Remote Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 45
  45. 45. Converged Plant Architecture Plant Floor Safely and Securely Connected with the Enterprise  Integrated key expertise through voice, video and access to applications improving operational efficiency  Increased information on plant Safe and Secure Plant Integration process and assets by extending sensor network Response location determination Improve Operational and adding  Reduced cost by relying on systems  Tightly manage access to plant standard network  Key experts respond to issues with access to plant  Control flow of traffic and data between key zones Security and Network Administration access to voice and video applications and  Mobile technicians stay in touch and have accessWide AreaPlant Wi-Fi Network Plant DMZ to key data Plant IT Network Network Wireless Location 1 Controller EngineIndustrial Wi-Fi Mesh and Location Receivers Core Video Routers Plant Floor Si Si 1 Reduce Terminal Support Costs 3 Managers, Engineers Server Distribution Manufacturing  Rely on IT for support on standard networks Routers Si Si Extend Visibility into Plant Processes Location Router Chokepoint 2  Reduce the number Access of technologies supported  Location Improve operational efficiency with more Switches Tags information by cheaply deploying additional 3 ERP, etc. sensors and devices Automation and Enterprise Wi-Fi Voice Control Applications  Reduce loss and search time with location context of mobile assets and product Improve Support Industrial Switch and Decision Making InternetWireless Sensor Cell/Area IT ServersNetwork  Enterprise-based users access up to date Automation and Control Devices operational status  Enterprise applications integrate real-time 2 with plant floor applications Wireless, Video and Voice Servers Sensor Mesh Teleworkers/ Network Video Customers and Partners Voice Ethernet Remote Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 46
  46. 46. Roadmap to Operations Excellence SAFE for Context-Aware Secure Wireless Industrial Wireless Process Control Solutions Plant Video Surveillance WebEx Achieve real- Efficiently Boost efficiency Communicate in time visibility Locate and track expand plant- and security of real-time, and integration valuable assets monitoring manufacturing regardless of with business and resources capabilities assets location systems Deploy rapidly Protect and Integrate data, Optimize the Improve and cost- secure voice, video, movement of efficiency and effectively in production and sensor material and mobility of harsh assets networks people communications locations Ethernet to the Secure Wireless Location-Based Industrial Wireless Plant VoWLAN Factory Plant Services Video SurveillancePresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 47
  47. 47. Smart+Connected Manufacturing Operations Excellence Benefits Business Results Operations Excellence  Create flexibility to react to  Provide real-time changes in demand and market communications to factory needs floor personnel  Improve efficiency, reduce cost  Manage operational risk and and decrease idle time improve compliance  Identify and respond collaboratively to process exceptions in ERP workflowPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 48 48
  48. 48. Additional Material Cisco and Rockwell Automation Alliance  Website http://www.ab.com/networks/architectures.html  Design Guides CPwE DIG 2.0  Education Series  Whitepapers • Securing Manufacturing Computer and Controller Assets • Production Software within Manufacturing Reference Architectures • Achieving Secure Remote Access to Plant Floor Applications and DataPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 49
  49. 49. Cisco & Rockwell http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.htmlPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 50
  50. 50. Reference materialsPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 51
  51. 51. Cisco Vietnam Opened office in Vietnam since 1999 60 people in HCMC and Hanoi offices: Hanoi office is moving to VN tallest building by end of July 2012 HCMC office: 9th floor Saigon Trade Center, 37 Ton Duc Thang, HCMC Web site: http://www.cisco.com/VN/ Toll free: 1800 585807, vn-support@external.cisco.com Distributors: Ingram, FPT Distribution Partners and resellers: more than 300 Segments: Service Provider, Public Sector, Enterprise, Mid-market, SMB and Consumer IT: 45 Mbps HCMC-Singapore, 20 Mbps Hanoi-Singapore, TP, VC, etc. Cisco & Rockwell: http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 52
  52. 52. Connected Manufacturing Book http://www.cisco.com/web/about/ac79/docs/wp/ctd/ConnectedManufacturingFINAL.pdfPresentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 53
  53. 53. XIN CÁM ƠN!Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 54

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