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Time to Rethink Process  Automation Systems      (CPAS 2.0)                  Dave Woll               VP Consulting        ...
From CPAS to CPAS 2.0CPAS conceived in 2005 Issue: The introduction of internet technology to manufacturing  forced most ...
Top 10 Automation Business Drivers1. Create proactive culture2. Improve asset utilization3. Enhance human reliability4. Im...
CPAS Guiding Principles                 Principles       CPAS Response                    ROA                             ...
CPAS Looks at Automation Holistically From…                  To…                                                     Busin...
We Need Smarter Field Devices 50 -75% of device downtime is caused by lack  of confidence in measurement Most field devi...
Systems Need to Become Truly Distributed Current leading Distributed Control Systems  and the original CPAS are not true ...
System Resources Need to Operate AutonomouslyWhen Necessary Functionally changes the control level  (reconfigure) at run-...
IEC Standard 61499 Supplements IEC 61131   Single Model with Distributed Processing and    Independent Services   Exampl...
Control Strategies are not Tied toSpecific Hardware Control Strategies Must Transcend  Hardware Required to support auto...
Secure On-Line Version Upgrades At least one major version                Load New                                       ...
Need Business and Operations Unification– Business to Planning Normally the integration of disparate information  is larg...
Need Business and Operations Unification– Real-time Planning to Production                                                ...
Thank You.For more information, contact the author atdwoll@arcweb.com or visit our web pages at             www.arcweb.com
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Time to Rethink Process Automation Systems

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Time to Rethink Process Automation Systems

  1. 1. Time to Rethink Process Automation Systems (CPAS 2.0) Dave Woll VP Consulting ARC Advisory Group dwoll@arcweb.com
  2. 2. From CPAS to CPAS 2.0CPAS conceived in 2005 Issue: The introduction of internet technology to manufacturing forced most of the suppliers to change their Control LAN and ultimately innovate their entire systems. Users asked what to value “everything looked the same” Purpose: Develop an ARC vision of the ideal evolution of current process automation systems. The Collaborative Process Automation System (CPAS) Deliverable: A detailed Outlook StudyCPAS 2.0 conceived in 2009 Issue: There has been an absence of real innovation in both the system and field devices. Users have asked how to value what is needed next Purpose: Develop an ARC forecast of the ideal functional evolution of process automation systems Deliverable: A detailed Outlook Study 2 © ARC Advisory Group
  3. 3. Top 10 Automation Business Drivers1. Create proactive culture2. Improve asset utilization3. Enhance human reliability4. Improve equipment reliability5. Unify business and operations6. Respond to uncontrollable external variables7. Responsible care requirements8. Prevent cyber security threats9. Deal with loss of experienced staff10.What is the potential value 3 © ARC Advisory Group
  4. 4. CPAS Guiding Principles Principles CPAS Response ROA Extraordinary Performance Operational Excellence Continuous Improvement Proactive Execution Flawless Execution Common Actionable Context Single Version of the Truth Automate every thing that Autonomous Automation should be automated Facilitate Knowledge Workers Manage All Automation Common Infrastructure Robust, based on Stds Precision 4 © ARC Advisory Group
  5. 5. CPAS Looks at Automation Holistically From… To… Business System Enterprise System Production Manufacturing Management Work ISA S95 Transactions Operations Processes Management Sensors, Actuators and Logical Devices ISA S88 Real-Time Control & Events Single Model with Distributed Processing and Shared Services 5 © ARC Advisory Group
  6. 6. We Need Smarter Field Devices 50 -75% of device downtime is caused by lack of confidence in measurement Most field devices do not quantify health or estimate remaining usable life Precludes operations from deciding run/shut down. Lost critical measurement usually results in shut down Active research, dearth of Products • One product based on SEVA (self evaluating technology BSI 7926) 6 © ARC Advisory Group
  7. 7. Systems Need to Become Truly Distributed Current leading Distributed Control Systems and the original CPAS are not true DCSs Current DCSs are based on IEC61131-3 which specifies programming languages and architecture The architecture is limited to a single domain with all resources operating in unison Resources cannot act autonomouslyCurrent DCSs are a single model with distributed processing and shared services 7 © ARC Advisory Group
  8. 8. System Resources Need to Operate AutonomouslyWhen Necessary Functionally changes the control level (reconfigure) at run-time Provides the foundation for “zero downtime automation systems” and sustainable operations Supports the utilization of high level autonomous agent (FIPA), reasoning and modeling Potentially offers the highest value 8 © ARC Advisory Group
  9. 9. IEC Standard 61499 Supplements IEC 61131  Single Model with Distributed Processing and Independent Services  Example: The Smart Watchdog from Intelligent Maintenance Systems IMS) DCS Fieldbus PLC IEC 61804 IEC 61158 IEC 61131-3 Configurability Open Connectivity Configurability Distributed Functionality Standard Programming Languages Function Blocks Industrial Process Measurement and Control Systems (IPMCS) IEC 61499 High Level Function Truly Distribution Blocks Reasoning Autonomy 9 © ARC Advisory Group
  10. 10. Control Strategies are not Tied toSpecific Hardware Control Strategies Must Transcend Hardware Required to support autonomy and reconfiguration Eliminates the need to position functions into highly secure system levels Runs across disparate platforms complimented single size resource scaled by number Provides the opportunity to optimize hardware cost and performance 10 © ARC Advisory Group
  11. 11. Secure On-Line Version Upgrades At least one major version Load New Load Version upgrade every year Now requires a shut-down or at Evaluate least a major vendor supported Abort custom revision ARC supports a three step on- Go line version upgrade Revert Three step has crucial value determining the new version is Accept operating predictably before committing to the process Finished 11 © ARC Advisory Group
  12. 12. Need Business and Operations Unification– Business to Planning Normally the integration of disparate information is largely custom work This is the case when integrating SCM targets to operations planning Reference standards can eliminate the majority of this customization. Specifically:  The SCOR model has been accepted as the primary SCM reference model  S95 has been accepted as the primary Operations Management reference model There is a high correlation between the two This integration will deliver higher Business to Planning performance 12 © ARC Advisory Group
  13. 13. Need Business and Operations Unification– Real-time Planning to Production Market Signals Capable/Profitable to Model Update (10/Day) LPLP Planner Planner Promise in Real-time 24/7 Optimization, Minimal Human Involvement Real-Time RTO Optimization Autonomous Transition Management Operator involvement: - On/Off - Operating Band Supervisory Supervisory Supervisory Controller 1 Controller 2 Controller 3 (DMC) (DMC) (DMC) Dynamic Planner Dynamic Planner Short Term Production Planning Based on Market Demand and Production Capabilities 13 © ARC Advisory Group
  14. 14. Thank You.For more information, contact the author atdwoll@arcweb.com or visit our web pages at www.arcweb.com

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