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Discrete MFG IoT Factory of the Future

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Working with the Mainstay team, the Cisco IOT Manufacturing Marketing team combined research from manufacturing trade associations, management consulting research and an internal benchmarking project to create an Executive Briefing Presentation that would educate CxOs on the opportunities IOT can provide. This content was also repurposed to create a manufacturing IOT whitepaper to provide an asset to entice prospective customers to consider Cisco’s IOT offerings.

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Discrete MFG IoT Factory of the Future

  1. 1. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 1 Discrete MFG IoT Factory of the Future August 28, 2013
  2. 2. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 2
  3. 3. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 3 * “The Truth About Robotics White Paper,” Seegrid Corporation, Fall 2013 ** “US Manufacturing Nears the Tpping Point: Which Industries, Why and How Much, BSG April 2013 *** “Manufacturing Moneyball: using big data and business intelligence to spur operational excellence”, Forbes 11,2011 **** From slide #77b – check sourrce Robot Advancements, Additive Printing NPI Convergence Manufacturing Onshoring Plant Flexibility Manufacturing Big Data Converged Plant Networks Robot Advancements, Additive Printing Plant Flexibility Manufacturing Onshoring NPI Convergence Manufacturing Big Data Converged Plant Networks U.S. Competitive Drivers Source: “The next big thing in Manufacturing? On-Shoring”, Logistics Viewpoints; Michael Rackley, April 2013 Input Costs Natural Gas 75% Cheaper Wage Gap Asian Wages Increasing 15–20%/year Productivity U.S. Productivity Runs 3–3.5% Higher Supply Chain Simplicity Domestic Production Reduces 8 Weeks of Inventory Profit
  4. 4. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 4 Sensors Everywhere | Machine-to-Machine | Pervasive Intelligence | Automation RobotsPersonal Devices Sensors Security Devices Real Time Analytics Ruggedized Wireless AP Industrial Routers & Switches Industrial Security Hardened Mobile M2M Gateway Access Points Designed to Mobilize your Factory Network Solutions That Reduce Factory TCO & Downtime User & Control Level Factory Security Industrial Plug-n-Play OT/IT Connectivity
  5. 5. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 5 Before  $3B process/discreet Industrial Co had neglected its US plants  Heterogeneous PLC/Network w/miles of blue hose & long outages  Quality issues (operator errors) from paper-based work orders  Plant security vulnerabilities were a board level concern Solution  Standardized on converged Cisco and Rockwell network and PLCs – VLANs ( physical segregation) – Managed switches – Cisco Firewalls US Plant Average OEE 2011 2012 50% Improvement Results US Plant Ave Line Mean Time to Fix 2011 2012 Hours/Days to <30 Mins After  Quality Increase: – Production and order integration via SAP and PLC integration – Electronic Customer orders on HMI  Reduced Safety Downtime: Cut machine vs. whole line (keeping boilers warm etc…)  Reduced Electrical Downtime: Instantly locate problem vs. searching hours or days (i.e. grounds)  Now investing in US plants: Viewed as strategic investment
  6. 6. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 6 Automation Robots Flexibility Wireless
  7. 7. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 7
  8. 8. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 8 Physically Segmented Network Converged Plant Network Air Gapped Plant Security Plant & Controls Level Security Resource Constraints Resource Mobility/Productivity Trapped & Siloed Data Real-time, Big Data Mfg Operational Silo Mfg linked w/SC, R&D, Sales Plant in Isolation Virtualized Production Factory Today Factory of the Future • TCO savings • Downtime reduction • Production flexibility • Risk Mitigation • IP theft • OT to IT damage • Plant downtime • Plant OEE increase • Plant cost reduction (energy, inventories, maintenance) • Operator productivity • Flexible manufacturing • OEE – Fast Response
  9. 9. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 9 • Industrial Plug-n-Play OT/IT Connectivity creates access to the universe of factory data • User & Control Level Factory Security to ensure protection from IP theft and malicious attacks • Wireless Access Points that mobilize access to data, adding productivity to the factory workforce • Network solutions that reduce factory IT TCO while simplifying the integration of the factory to the corporate systems Resiliency Flexible Production Visual Factory Visibility Manageability SpeedAutomation New Services Open Port Remote Access MalwareProximalPhysical Mobile Control Room Remote Access Wireless Machines Mobile Task Management Guest Worker Access Virtualized Production Real-time Supply Chain Energy Management Traceability ERP/MES/P LC Integration Predictive Maintenance Collaboration in Factory Apps
  10. 10. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 10 Gbps Link for Failover Detection Firewa ll (Activ e) Firewall (Standb y) Layer 3 Route r Layer 3 Switch Stack Layer 2 Switch Driv e Controlle r Controlle r Driv eHMI Controlle r Driv e HM I Distributed I/O Distributed I/O Level 0–2 H MI Cell/Area #1 (Redundant Star Topology) Cell/Area #2 (Ring Topology) Cell/Area #3 (Bus/Star Topology) Cell/Area Zone Manufacturing Zone Level 3 Demilitarized Zone (DMZ) Demilitarized Zone (DMZ) Enterprise Zone Levels 4 and 5 Windows 2003 Servers • Remote desktop connection • VPN FactoryTalk Application Servers • View • Historian • AssetCentre • Transaction Manager FactoryTalk Services Platform • Directory • Security Data Servers Flexibly Meeting Demand Shifts Enterprise Ethernet Proprie tary Ethern et To next machine I/O FieldbusMotion Net Safety Net STAR FIBER RING DAISY CHAIN TRUNK/DROP Multiple segmented plant networks (up to 6!) • Excessive cabling • Data integration complexity • Data routing limitations (not real-time) • Multiple data directories • Multiple topology rules, protocols, configs Increased Line Uptime Reduced Network IT TCO by 18% “I need a flat network so I can save money and get big data from machines without having to reprogram every PLC.” With Cisco Reliably Converge Network with managed switches that offer: - Quality of Service (QOS) - VLAN vs. physical segments - Storm control - IGMP, NAT, DHCP, POE, etc. - Configuration Smart Ports - MAC ID Port Security - IEEE 802.1x Security - Rockwell/Cisco validated design
  11. 11. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 11 Resiliency Flexible Production SpeedAutomation Visual Factory Video Collaboration 1 • High speed • Lower latency and jitter • QOS Automation 2 • Flexibly shift sequencing and inputs vs. hard coding • Change production recipes from managers office at click of a button • Enable new product innovation Flexible Production 4 • Provide next- generation, omni-channel customer experience seamlessly across all channels • Develop fully interactive, secure, and automated banking tech Visual FactoryVisibility ManageabilityManageabilityVisibility “We reduced line downtime from hours to minutes” Plant Engineer 3 • Greater visibility and manageability (“we’re flying blind today”) • In operator tools for quick response • Granular control over shut-downs • Resiliency and faster recovery (REP) Resiliency 6 • Mobility • Visualization • Machine monitoring • Physical security New Services 5 • Ethernet speeds new line set up (e.g., ebugging 10 stations with 12 robots takes 2 days vs. 1–2 weeks) • Collaborate between plant and R&D to speed NPI and ECNs Speed
  12. 12. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 12 Harley-Davidson’s smart factory uses Cisco’s industrial Ethernet, wireless networks, and integrated video/digital signage to produce multiple models on same assembly floor while improving worker training Stakeholders view/make decisions based on what’s happening on factory floor New processes enable centralized location-driven “ubiquitous display” Digital media content creates world-class “visual factory” Video monitors relay real-time visual information to key stakeholders People Machine People
  13. 13. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 13 Use Case 1: Converged Plantwide Ethernet TCO Comparison Fieldbus / Profibus (Serial) Ethernet (Unconverged) Ethernet (Converged) Example Automation Cell Components Each Robot: 1 controller interface (1 port) 1,000$ 1,100$ 10$ Profibus IP Interface Card 1 IO interface (8 ports) 2,000 2,400 2,400 Coper wiring IO to sensors/cameras/actuators 400 360 360 1 safety IO (8 ports?) 1,000 - - 6 Tecnology modules (drives, timers, etc…) 3,000 1,500 1,500 Stratix managed switch 400 600 Cables modules to switch (with no DLR) 750 1,350 1,350 With Resiliance ETAPs Cables from switch to PLC 150 135 135 PLC IO cards 2,100 2,200 1,100 Cost per Robot 10,400$ 9,445$ 7,455$ Number of Robots 8 8 8 Total Cost of Robots for Example Cell: 83,200$ 75,560$ 59,640$ Each End Affector: 1 control IO -$ -$ -$ 1 diagnostic IO 2,000 2,400 2,400 1 safety IO - - - Cables from robot to PLC - - - PLC IO cards - - - Cost per End Affector 2,000$ 2,400$ 2,400$ Number of End Affectors 8 8 8 Total Cost of End Affectors for Example Cell: 16,000$ 19,200$ 19,200$ Machine conveyers, sensors, etc.. (assume using DLR topology to reduce wiring & IO cards) Ports in machine 50 50 50 Cable ringing devices, IO, PLC, Switch 2,500$ 2,250$ 2,250$ Copper cable from devices to IO 1250 1250 1250 # of ETAPs at device level 0 0 0 # of IO blocks 8 8 8 Switch (assume IP67 switch) 1000 2000 Interface cards 3100 2200 1650 Box, connectors, enclosures (assume IP67 switch) IO blocks cost 3200 3520 3520 Total Cost of machine (non-Robot) for example cell 10,050$ 9,220$ 8,670$ Control/supervisor level switching # of switch ports needed Switch -$ 1,000$ 1,800$ Switch ETAP 250 250 Cabling to Aggregation Level Switches 2500 2500 2500 Extra switch/hub to reach aggregation switch 250 250 250 Total Cost of Control/supervisor level switching for cell 2,750$ 4,000$ 4,800$ Transition to IT Aggregation level switching and security from cells with Robots Aggregation level switches (e.g., 3750s) 192,500$ 192,500$ 192,500$ Firewalls (2 at plant level 3) 20000 20000 20000 Security policy and identity managers 40000 40000 40000 Cabling to MES/Historian systems 1000 1000 1000 Total Cost of Aggregation level switching and security for cell 1,014$ 1,014$ 1,014$ Total Network Related Hardware Cost for Example Cell 113,014$ 108,994$ 93,324$ Managed -3% Auto Converged Platform TCO Analysis • Resiliency • Management • Big Data • Low Cost WEAK WEAK WEAK WEAK WEAK WEAK MEDIUM WEAK STRONG STRONG MEDIUM WEAK STRONG STRONG STRONG STRONG Plus better performance with converged network (1 IO per PLC with vLANs) EQUIPMENTCOSTS(inmillions) Profibus (Serial) 25 20 15 10 5 0 Ethernet (Unconverged, Unmanaged) Ethernet (Unconverged, Managed) Ethernet (Converged) $22.6 $21.8 $22.3 $18.7 Example of Auto plant with 200 robotics cells – Lower Cost
  14. 14. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 14 Reduce HW cost (3 switches to 1) Shrink cabinets Reduce wiring Reduce design cost Reduce points of failure and unmanaged switch ports (E-tap)
  15. 15. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 15  Removable SD card stores config for quick, plug & play replacement by anyone  Install and configure in Logix Product Installation and Replacement Diagnosis and Troubleshooting Management  Resiliency protocols (REP <50 msec recovery) avoiding application time out downtime  Rapid debug and troubleshooting with managed switches - CIP in switches enables network visibility and mgmt in Rockwell apps - Predefined Logix tags Help Alarms Configuration Status Trending  Coming: Integration w/ Rockwell Asset Center. See and recover from undesired config changes - Manage switch configs in same tool as other machines and& devices on line - See changes, see histories, back-up
  16. 16. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 16 • New class of industrial focused security solutions - Identity and Policy • Centrally managed • Enforced at switch and AP level - Coming: In-line protection of critical machines via deep packet inspection of application traffic • Today’s control’s environments have “soft middles” • Increasing trend of disrupting critical infra controls - Stuxnet: Siemens Controls (via USB) - Shamoon: Schneider (Telnet) client - Others: Flame, Duqu ,etc. • Today’s solutions not geared to protect against threats like APTs
  17. 17. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 17 2012 Industry Cyber Attacks (Percent of Total Attacks) Source: Internet Security Threat Report – 2013; Symantec Corporation, April 2013 PERCENTAGE OF TOTAL ATTACKS 0% 10% 20% 30% Energy Government Sevices Finance Manufacturing • #1 attacked industry — 24% of total • 2x increase against critical infrastructure • 32% increase for MFG in last 6 months Intrusion Protection Detection & Response Remote Access Firewall & VPN Content Security SPAM/ Web Filtering Endpoint Security Host IPS/AV Solutions Network- Attached Device Nexus® 7000 Switch 802.1X Protected Resources IP Phones Supplicant Cisco® Catalyst® Switch Users, Endpoints Campus Network Guest User ISE • Growing business risk • Stolen IP (e.g., car design) • Downed production (RasGas) • OT attack spread to IT (Aramco 30,000 PCs) • Defense in depth with: • ISE Policy • Switch enforcement • Central management of ACLs • Strong security across IT & OT
  18. 18. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 18 Manufacturing Device, Managed Asset Security Camera G/W Agentless Asset MAC: F5 AB 8B 65 00 D4 Francois Didier Corporate Headquarters— Remote Access 6:00 PM Group: Manuf Group: Facility Group: Guest Time and Date Posture Location Device Type Access Type Broad Access Limited Access Guest/Internet Quarantine Deny Access Track Activity for Compliance
  19. 19. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 19 Key Characteristics:  Ruggedized, DIN-Rail platform  FW, VPN, Application whitelisting, and DPI for Industrial Protocols  Ease of use — zero-touch deployment  By-pass (bump in the wire) and reliability  Security Information & Event Management (SIEM) integration (e.g., Prism and SIO)  Policy Management integration
  20. 20. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 20 • Have to walk down line to see machine status • Manual, paper-based warehouse processes • Security concerns with wireless guest access • Plant downtime from line set up changes taking longer due to needing to rewire • Empower plant workers with mobile controls access • Automate warehouse processes with mobility • Drive integrated wireline and wireless security • Wireless machines for next gen manufacturing flexibility
  21. 21. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 21 Maximizing Workforce Productivity (Mfg Labor Output vs. Compensation) • Manufacturing labor productivity continues to grow to an all time high as compensation hits a record level • Manufacturers must continue to find ways to increase the productivity of these resources as they hit limits under legacy factory processes *Bureau of Labor Statistics, “Economic News Release - 3/2012; Appendix Table 4. Durable MFG sector: Productivity, hourly compensation, and unit labor costs 80 85 90 95 100 105 110 115 120 1 2 3 4 5 6 7 8 9 10 Converged Plant Wireless Impact Improved Uptime Productivity: Save 10%-40% Mobile Voice Cost Savings Labor output per hour Labor compensation Managers are confined to control room; engineers need to make trips to/from office for equipment/communications Today’s Plant There is a free flow of people and resources across all areas of the plant Converged Plant
  22. 22. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 22 Source: Cisco® Customer Business Transformation Group Metals and Mining Major Use Case 1 • Smelter operator needs to check process data to make adjustments • Makes process change accurately and rapidly via mobile device 32 • Pulls up critical production data on hardened PDA • Calls operator in another location to discuss change using soft-phone on PDA Source: Cisco® Customer Business Transformation Group Business Value • Eliminated three to four wasted hours walking to control room per shift per operator • >80% faster operator decision making • 50% reduction of physical control rooms
  23. 23. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 23 • Operator able to see virtual HMI on iPad without having to walk down the line • Can locate trouble spot with more granularity saving potentially hours in searching (e.g., “which of 50 grounds”) Event Occurs: ALARM Control Room Mobility NOC HQ R&D Contractor SME
  24. 24. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 24 Source: Motorola
  25. 25. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 25 Cell / Area Zone Level 0 – 2 Drive HMI Cisco IE Cell/Area # (Ring Topology) Controller Discrete M. Wireline Access Configs Introduced w. CISS Rel.1.5 Cell/Area #1 (Redundant Star Topology) Drive Controller HMI Distributed I/O Controller Drive HMI Distributed I/O Cell/Area # (Linear Topology) Drive HMI STRATIX Cell/Area # (Ring Topology) Layer 2 Access Switch with Resilient Ethernet Protocol Controller Discrete Mfg. Wireline Access Hardened WiFi Factory & Wireless sensors Ntwk. Enterprise Zone Level 4 - 5 Manufacturing Zone Level 3 Manufacturing Di-Militarized Zone Catalyst 3750-X Catalyst 4500/6500 Enterprise / Campus Core Patch Management Terminal Services Data Share Application Server AV Server ASA 55xx-X (Active) ASA 55xx-X (Standby) Real–Time Control Fast Convergence Traffic Segmentation and Management Ease of Use Site Operations and Control Multi-Service Networks Network and Security Management Routing Application and Data share Access Control Threat Protection Enterprise/IT Integration Collaboration Wireless Application Optimization • Wide Area Network (WAN) • Physical or Virtualized Servers • ERP, Email • Active Directory (AD), AAA – Radius • Call Manager, etc. Plant Firewalls: • Inter-zone traffic segmentation • ACLs, IPS and IDS • VPN Services • Portal and Terminal Server proxy Web DNS FTP Catalyst Switch Internet Layer 2 Access Switch with Resilient Ethernet Protocol Cisco 5500 WLC Cisco WLC Anchor Cisco WLC SiSi SiSi Future Release Future Release Future Release Discrete M. Wireless Access Opt. & Adv. Security Asset Management HMI Server Manufacturing Execution Historian Cisco Prime Network Services Remote Access Server ISE 34xx Catalyst 2960-X Catalyst 2960-X Catalyst 2960-X Catalyst 2960-X IE2000
  26. 26. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 26 • Real time visibility into machine level performance (“what is happening in the plants now”) • Enable move to build to order versus build to stock production models (real time flexibility, ATP) • Automated and Proactive Maintenance can impact factory profitability by as much as 30% • Only 19% of manufacturers state they have an effective link between plant and business KPIs* • Only 4% of factories in the machine tool industry monitor their equipment* • High machine unplanned downtime and maintenance cost from “blind” fixed schedule maintenance *IDC Manufacturing Insights 2012; N=83
  27. 27. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 27 Converged Plant Operations Impact Reduced Energy Use Today’s Plant Converged Plant Reduced Maintenance Cycles Order to Production 10% DSOs NPI Cycle Time 20-50% Source: IDC Manufacturing Insights 2012. N=81 Make to order Make to stock Engineering to order Assembly to order/Build to order 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 21% 39% 29% 11% 9% 34% 35% 22% Today 5 Years JourneytowardMake-to-Individual
  28. 28. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 28 Alarm alerts operator of peak load utility penalties threshold Checks MES real time prod vs. plan & energy threshold Reduces variable speed drive to avoid peak Operator checks co-gen capacity Raises output to avoid peak load Real-time gap visibility – adjusts supply chain, MRP, and factory build plan to shift prod to plant with capacity w/o impacting ATP or inventory Leverage Cisco collaboration tools to quickly decide and act cross silo Business Value Plant Productivity: Reduce energy costs (typical first year -— 20% with new Software/Devices/Ethernet NW) Challenge Real time operator decision making tools across multiple variables, applications, and sites in a complex supply chain (many factors to simultaneously consider)
  29. 29. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 29 Challenge • Manual sales processes delayed order to prod response and was prone to manual errors • Orders are passed to inside sales person creating transcription issues, dirty orders, and 4-day delay in order processing time • Lack of visibility to order details at customer site • No access to configurator, order promise, status of existing orders all limit ability to close business Solution • Fully integrated process from Opportunity to ATP to Order to Plant Floor Production • SFDC integrated with Oracle EBS, configurator and plant floor visibility via plant floor Andon screen • Eliminates order entry errors, reduces order processing time, electronic order is immediately confirmed with ATP engine and visible at plant floor Sales: Remotely track orders from opportunity to configuration to ATP to order status Inside Sales: Eliminates manual order entry - focus on new business creation Factory: Real-time order visibility; reduce dirty orders; electronic orders Management: Real-time reporting of sales, order and production performance Results • $3M in annual sales increase • DSO reduction of 2% • 75% reduction in Order Entry Cycle Time • Reduced dirty orders reduced • Improved NetPromoter Scores • 6 FTE inside sales productivity gain
  30. 30. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 30 Device Network PLC MES/S cada Historian DMZ ERP Data Velocity: Data Quality: Data Security: Real Time (<1 second roundtrip) Push every 2 to 9 Hours Nightl y? Today up/down data flow not real time: ?? Auto- configuring of tags and profiles Open, unmanaged ports. USB ports ??? No network visibility or resiliency (reducing data quality) PLC backplane limits real time pass through (“every 9 hours”) Vulnerabilitie s to man in middle, USB, PC, HMI client attacks Segmented physical networks required hard coded mappings Segmented physical networks required hard coded mappings Vulnerabilitie s to man in middle, USB, PC, HMI client attacks Segmented physical networks limit data availability and quality Batch updates to send upstream every 20 to 30 minutes?? ?? Segmented physical networks limit data availability and quality No security or block all but limited data feeds No security or block all but limited data feeds No security or block all but limited data feeds Not real time Poor data quality from plant & lack of device taxonomy Devic e Network PLC MES/ Scada Historia n DMZ ERP Data Velocity: Data Quality: Data Security: Real Time (<1 second roundtrip) X seconds? X secon ds? X secon ds? Today up/down data flow not real time: ?? Auto- configurin g of tags and profiles Still need integrated controls security Full visibility and resiliency protocols VLAN 1 stop routing by passes any bottleneck s?? Still need integrated controls security Converge d Plant NWs Less hard coded integration s than with segmente d NWs Less integration than with segmente d physical networks Batch updates to send upstream every 20 to 30 minutes?? ?? Less integration s than with segmente d physical NWs Policy, identity, easier central managem ent Policy, identity, easier central managem ent Policy, identity, easier central managem ent Memory resident real time processin g Large SI integration and data clean up work still needed • Batch applications can delay MFG visibility for hours • Segmented physical networks require mappings and hard-coded integrations • Significant security risk (e.g., man in the middle, DMZ vulnerabilities) • Limited visibility to data flow/availability • Converged network simplifies data path • Integrated management provides real time data flow visibility • Single, unified architecture creates near real-time visibility to MFG performance • Joint architecture addresses security risks and removes barriers
  31. 31. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 31  Integrates different sources of real time data all the way to sensors in the end machine  Used by both machine manufacturer and operator  See source of problems real time to: – Lower costs (e.g., dispatch technicians with spare parts needed) – Get more efficiency (e.g., reduce “hard” downtime) SAP is a leader in big data and real time analytics with HANA Cisco is working with SAP to enable better quality and quantity of data to allow faster reaction and better decisions SAP Windpower Video
  32. 32. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 32
  33. 33. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 33 Unmanaged, Unconverged Ethernet Converged Plantwide Network Multi-Service Platform Step 1 Step 2 Step 3 Starting Point: - Fieldbus - Proprietary - Serial • Real time distributed control • Resiliency • Richer sensor data • Converge separate physical networks with managed switches • OT Ethernet Upgrade — line equipment moves to Ethernet to reduce TCO and add flexibility • Converge OT/IT Networks to further reduce plant TCO, unlock big data • Factory of the Future — virtualized production, real-time IT/OT monitor/management • Manufacturing Strategy • Business Case • Proof of Concepts / Showcases • Plant Architecture Design • Implementation • Controls security • Control Room Mobility • Video & Collaboration • Remote Monitoring & Control • CLOUD, FOG • Software Defined Plant Networking
  34. 34. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 34 Lifecycle Services Industry-Leading Partners Business Risks Reduced Faster Deployment, Better ROI Q. Top barriers to implement your factory of the future strategy Source: IDC Manufacturing Insights 2012. N=81 PERCENTAGE OF COMPANIES Processes not consistent across multiple sites Low maturity/lack of production technology Change management Finding skilled people No factory of future strategy Difficulty in demonstrating ROI / Cost 74% 73% 73% 71% 61% 58%
  35. 35. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 35 Best of Both Worlds to Change the Industry Best of Cisco  Cisco IOS™  Catalyst™ switch architecture and feature set  CLI and Device Manager  Secure integration with enterprise network Best of Rockwell Automation  Common Industrial Protocol (CIP) interface to Rockwell Automation Integrated Architecture™  RSLogix 5000™ for configuration via Add-on Profile (AOP)  Predefined logic tags for diagnostics  FactoryTalk™ view faceplates Best for the Plant Floor  Compact flash for “zero-config” replacement  Industrial environmental ratings  Default configurations for Industrial Automation  Easy to maintain A Unique Product in the Market… …Integrating the Enterprise and Manufacturing Environments
  36. 36. © 2013 Cisco and/or its affiliates. All rights reserved. Cisco Confidential 36 Discovery Workshop with OT and IT • Business challenges • Best practice sharing • Use case brainstorming and prioritization • Run POCs in a Showcase manufacturing facility to prove the value and technology • Document future state architecture (e.g., 3 to 5 years out), gaps with today, change management, and phased plan to get there • Quantification of top value opportunities for senior management (TCO, OEE, and overall benefit models) POC Design TCO or OEE Opportunity Quantification End State Architecture Assessment

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