Rockwell Automation technology was used to help Bausch & Lomb, one of the world’s largest suppliers of eye health products, create a framework for better enterprise-wide decision-making. We migrated Bausch & Lomb from a legacy DCS to the PlantPAx system. Using FactoryTalk Historian, we dramatically improved data storage, connected enterprise-level data with plant-level data and provided stakeholders with access to critical production and supply chain information. This automation technology has paid great dividends for Bausch & Lomb, and we will share how it can be successfully integrated.

1. Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Bausch & Lomb Leverages PlantPAx to “See Better,
Live Better” on Its Journey to The Connected Enterprise
Steve Schneebeli
Manager – Director of Engineering / IT
Malisko Engineering
Matthew Roberts
Business Development Manager
Malisko Engineering

2. AGENDA
• Introduction
• Project Goals
• Selecting a PlantPAx® Solution
• System Overview
• Results
• Lessons Learned and Recommendations
• Next Steps
• Questions

3. INTRODUCING BAUSCH + LOMB
AND
MALISKO ENGINEERING, INC.

4. WHO IS BAUSCH + LOMB?
• Founded in 1853 in Rochester, NY
• Three Core Business Units:
• Vision Care: Contact Lenses and Eye-Care products
• Pharmaceuticals: Rx and OTC Medicines for various Eye Diseases and Irritations
• Surgical: Medical Devices, Instruments
• Global company with key US Manufacturing sites:
• Rochester, NY
• Clearwater and Tampa, FL
• St. Louis, MO
• Greenville, SC
• Acquired by Valeant Pharmaceuticals Aug. 2013 (VRX)

5. B+L LENS CARE SOLUTIONS FACILITY – GREENVILLE, SC
• Aseptic Lens Care Solutions Manufacturing Facility
• Pharmacy, Compounding, Mixing, Filling, Packaging and
Palletizing
• Plant and Process Utilities
• Warehouse / DC off-site
• Originally built early 1980’s
• Volume growth of approx. 9.5% per year
• Products: Biotrue, Renu, PeroxiClear, Sensitive Eyes….
• ~ 25 Package formats and ~8 Package sizes
• 2012 Master Plan – identified DCS replacement for Risk
Mitigation – controls Process Utilities and Bulk
Manufacturing

6. WHO IS MALISKO ENGINEERING?
• Experts in manufacturing automation and validation
• Founded in 1994
• Headquartered in St. Louis, Missouri USA
• Regional Offices in Denver, Colorado USA and
Eau Claire, Wisconsin USA
• Rockwell Automation® Solution Partner for Control, Process,
Information, Industrial IT and Power Quality & Energy Management.
• CSIA Certified Member
Historic Laclede’s Landing
St. Louis, MO
Malisko Western Regional Office
Denver, CO
Phoenix Park Area
Eau Claire, WI
Control | Process | Information
Industrial IT | Power Quality &
Energy Management

7. MALISKO’S PAST PRESENTATIONS

8. PROJECT GOALS

9. PROJECT GOALS
• Legacy DCS Migration / Risk Mitigation
– Main goal of new Process Control System (PCS) was to provide functionality similar to the existing DCS system
– Two Fisher Porter System Six DCS systems - Utilities and Mixing
– System cut-over done on a tank-by-tank, system-by-system basis – not ‘rip and replace’
• Provide an interface in the new PCS for future plant-level MES system
– Production Schedule Interface
– Electronic Batch Records
• Expose process (continuous) and batch data outside of the process network
– Existing DCS was an ‘island of automation’ – No direct ties to the corporate network
– All existing reports and historian data had to be printed out
– No visibility of the process outside of the DCS network

10. CHOOSING A PLANTPAX SOLUTION

11. “TRADITIONAL” DCS VS. PLANTPAX
Criteria Traditional DCS
Local Support
Single Local Solutions
Provider
Local Eco-System consisting
of dozens of local
Integrators and Solution
Partners
Scalability
Hardware + Additional
License required for
additional I/O
No additional licensing
required
Topology
Dedicated Servers.
Software and Hardware
Upgrades Expensive
Virtualization Fully
Supported – Decoupling
Hardware from Software

12. BASIS OF DESIGN PHASE
• Basis of Design (BOD) was performed to provide enough technical and financial detail to
determine the best course toward implementation.
• BOD deliverables included:
– Proposed System Architecture and Bill of Material with options for redundancy
– Preliminary Design Drawings, including preliminary CAD drawings for Network, I/O and Power Distribution
– Detailed Analysis against current URS
– Initial design engineering (FRS 30% – 50% complete, initial DDS draft)
– Technical options or considerations (i.e. Simulation System, FactoryTalk® AssetCentre)
– Preliminary schedule
– Validation Strategy
– Cost Estimate

13. SYSTEM OVERVIEW

14. DOCUMENT EXISTING SYSTEM FUNCTIONALITY
• No formal Functional Requirement Specification (FRS) or Detailed Design Specification (DDS)
existed for the Fisher Porter DCS.
• Malisko Engineers generated the FRS and DDS using DCS code exports and interviews with
B&L production and engineering groups.
• S-88 Modeling - Define Control Modules, Equipment Modules, Phases and Units.
• Optimized Existing Sterilization Procedure. DCS had multiple phases. PCS has a single
Sterilization phase with multiple steps.
• Several review meetings with key B&L production and engineering resources to finalize
system design.

15. PLAN FOR STAGED CUT-OVER
• Production scheduling eliminated the idea of ‘rip and replace’
• Malisko had to devise a plan to stage cut over of tanks and Utilities systems
• IFM modules were placed over the DCS termination boards, prior to tank cutover. This
allowed for a tank-by-tank cutover when a tank came available, thus minimizing the downtime
occurred by the tank.
• Tank cutover time – 2.5 days.

16. STAGED CUTOVER I/O PANEL PICTURES

17. PLANTPAX SYSTEM CHARACTERIZATION
Characterization verifies that the system
provides the required performance.

18. SYSTEM ARCHITECTURE
• Three Physical Servers with eight virtualized images
– FactoryTalk® View Servers (Primary and Secondary)
– ACP ThinManager Remote Desktop Services (RDS) Servers (Primary and Secondary)
– FactoryTalk® Batch Servers (Primary and Warm Backup)
– FactoryTalk® Historian
– Microsoft SQL Server
– Seven FactoryTalk® View SE Thin Clients
• Two Engineering Workstations
• Cisco Stackwise Switches between Data Center and DCS I/O Room
• Device-level Ethernet Ring
– Utilized for all I/O Chassis
• Separate network cards for connection to B&L business network for domain authentication.
– Controlled by access rules on B&L corporate switches
• VPN Connection into system for Remote Support

20. LIBRARY OF PROCESS OBJECTS
• V3.0 process objects
• “Out of the Box” PlantPAx AOIs
• “Enhanced” Global Objects (Valves, Pumps, etc)

21. HMI SCREEN SAMPLE (EXISTING DCS)
• 19” 4:3 Monitors
• 1024 x 768 resolution
• Ability to move main process screens
utilizing Windows pop-up functionality

22. HMI SCREEN LAYOUT (PLANTPAX)
• 24” 16:9 Monitors
• 1920 x 1080 resolution
• Ability to move main
process screens
utilizing Windows
pop-up functionality

23. FACTORYTALK BATCH
• Primary and Warm Backup Servers
• 30 Unit License – 19 units used
• 33 Phases across two processors
• Validated default recipes
• Using ‘off the shelf’ Rockwell Batch Overview
screen for viewing and controlling batches
• Developed custom screen for starting orders read in
from future B&L MES system

24. REPORTING
• Reporting done through SQL Server
Reporting Services allowing Web-based
access to reports
• Data taken from SQL tables and
FactoryTalk® Historian SE
Confidential

25. DATA HISTORIAN AND SQL SERVER
• 1,000 tag FactoryTalk® Historian SE server with
redundant FactoryTalk® Live Data interface nodes
• Historian data gathered from both PCS
ControlLogix® processors and stand-alone skids
• Ability to import Historian data into Excel using
DataLink add-in
• SQL database used to store FactoryTalk® Batch
data, FactoryTalk® Alarms and Events, and
FactoryTalk® Diagnostics data utilized for reporting
• Future connectivity of SQL and FactoryTalk®
Historian to upcoming FactoryTalk® VantagePoint®
installation

26. BIOMETRICS FOR USER AUTHENTICATION
• DigitalPersona U.are.U 4500 Readers
• Utilizes U.are.U Software Development Kit
• VB .Net application used to detect and log-in users into FactoryTalk View SE
• Users can enroll up to two fingerprints
• Challenge of getting reader to work with ACP ThinManger Thin Clients
VB.Net App
Interprets data
from Reader and
sends FT Login
Credentials
Fingerprint Read
from Reader
FT User is
Logged into
System

27. RESULTS

28. IMMEDIATE RESULTS
• Robust, redundant system including servers, PLCs, application software, and networking (I/O
Ring and Server to Client utilizing Stackwise switches)
• Local Rockwell support and readily available replacement parts
• Remote access for troubleshooting support if needed
• Built on a standardized set of process objects (PlantPAx)
• Easier for maintenance and engineering to learn and troubleshoot the system

29. LONG TERM BENEFITS
• PCS system provides the framework to get data exposed to the corporate level
• Roll-out of VantagePoint to display and analyze data on the desktop (process users or engineers)
• Provide standardized programming environment following site standards
• S-88 model utilizing Phase Manager opens up options for further automation of the Mixing
System
• Ability to interface with future B+L MES system to pass production orders down to the batching
system, and feed critical production data for Electronic Batch Records

30. LESSONS LEARNED
AND
RECOMMENDATIONS

31. LESSONS LEARNED AND RECOMMENDATIONS
• DCS replacements require planning and communications if not ‘rip and replace’
• At the mercy of Production, so scheduling needs to be flexible
• During initial design, factor-in framework for new enhancements, even if replacing with
similar functionality.
• While laying your framework for the Connected Enterprise, have early and often
conversations with plant IT groups. Make them part of the design process.
• Spend time with operators on the existing system. Don’t just ‘reverse engineer’ the old DCS
code.

32. B&L LESSONS LEARNED AND RECOMMENDATIONS
• Create a comprehensive URS – approved by key stakeholders; incorporate inputs from SME’s
• Include and fund a BOD phase if appropriate
• Follow a formal vendor selection process; evaluate proposals against critical criteria
• Align vendor capabilities with business needs
• Create and follow a detailed Project Plan in partnership with your vendor(s)
• Include SME’s in Design Reviews
• Understand Change Order process
• Include Contingency Plans

33. NEXT STEPS
• Work towards bringing other isolated systems into the new Process Control Network
• Determine data to be collected via Historian (continuous) and SQL (events)
• Roll-out ‘Data to the Desktop’ initiative. Utilize FactoryTalk® VantagePoint and Historian
DataLink.
• Look for ways to automate existing manual processes

34. Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
THANK YOU
Steve Schneebeli
Malisko Engineering Inc.
Director of Engineering / IT – St. Louis, MO
sschneebeli@malisko.com
Matthew Roberts
Malisko Engineering Inc.
Business Development Manager
mroberts@malisko.com