Industrial Automation and Modern Connectivity
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In an age when manufacturing is overrun with information, getting the right information to the right person at the right time is crucial. A new era of mobile devices has helped deliver the promise of greater productivity. With it comes the challenge of network security, achieving both is possible, as we’ll demonstrate.
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Industrial Automation and Modern Connectivity
- 1. Industrial Automation and Modern Connectivity
- 2. DMC Overview Established in 1996, offices in Chicago, Boston, & Denver and customers throughout the world 70+ employees & growing
- 4. Presenter Info Matt Puskala Project Director, Sr. Management Technical: Factory Automation, PC, Web, and Database Applications B.S. in Electrical Engineering Kettering University (GMI) Joined DMC in 1999 Student co-op
- 5. Agenda 1. Modern Connectivity Overview 2. Three Modern Connectivity Stories a. Automotive Story b. Candy Story c. Integrator Story 3. Security – Quick Tips
- 6. Modern Connectivity: Definition Define “Modern Connectivity” in the context of Industrial Automation.
- 7. Modern Connectivity: Definition Traditional Automation Line Interface PLC Factory Equipment
- 8. Modern Connectivity: Definition Any time you are connecting the factory line to other networks to allow data transfer (input or output). • Internet • Intranet/Subnet
- 9. Modern Connectivity: Definition Any time you are connecting the factory line to other networks to allow data transfer (input or output). Connections To: • Servers and Databases • Enterprise Systems (MES, ERP) • Internet/Remote Access
- 10. Modern Connectivity – Why? Pros ? Cons Cost Complexity Security
- 11. Modern Connectivity – Why? 1: Optimize Production Identification of productivity loss. When? Tomorrow? Immediately?
- 12. Modern Connectivity – Why? 1: Optimize Production Improve your process. Data mining.
- 13. Modern Connectivity – Why? 2: Traceability FDA Regulations Recalls
- 14. Modern Connectivity – Why? 3: Convenience Remote Support Plant floor visibility at your desk
- 15. Modern Connectivity – Why? 4: Standardize and Control the System Inputs Recipe Management RECIPE Benefits: • Consistency and Quality • Reduce Product Change Over Time
- 16. Modern Connectivity Definition? Why? Goal? Factory System Internet Intranet
- 17. Modern Connectivity - Goal Introduce new ideas or new ways of looking at old ideas to help you get the most out of Modern Connectivity with your Industrial Systems. Factory System Internet Intranet
- 20. Continuous Improvement Solving Mysteries!! 1. Identify a big problem. 2. Find the Cause. 3. Find a Solution.
- 21. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Example
- 22. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Transfer Faults Transfer Faults (dropped parts)
- 23. Continuous Improvement - Solving Mysteries Mystery: Transfer Faults (Dropped Parts) Part A27: Smallest Diameter SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 273 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
- 24. Continuous Improvement - Solving Mysteries Mystery: Transfer Faults (Dropped Parts) Simple Solution: Improve the part transfer! SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
- 25. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Jammed Station 4 Jammed Stamping Press DAILY FAULT COUNTS Fault: Count: Transfer Fault 9 Press Jam Fault 132 Low Air Pressure Fault 7 E-Stop Fault 5
- 26. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Jammed Station 4 DAILY FAULT COUNTS Fault: Count: Transfer Fault 9 Press Jam Fault 0 Low Air Pressure Fault 7 E-Stop Fault 5 Add better part queuing.
- 27. Continuous Improvement - Solving Mysteries Simple Mysteries: • Problem -> Cause • Paper data collection by operators Complicated Mysteries?
- 28. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production
- 29. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production Cause?: • Particular Part • Particular Fault • No obvious pattern
- 30. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production Real Problem?: Inconsistent Data Tracking SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
- 31. Continuous Improvement – Solving Mysteries Improve Inconsistent Data Collection? Through Automation!: • Automated Data Collection • Automated Reporting
- 32. Continuous Improvement - Solving Mysteries Daily Emails of Reports to Engineers and Shift Supervisors SHIFT REPORT Operator: Part: Jim A27 Fault: Count: Transfer Fault 3 E-Stop Fault 2 Low Air Pressure Fault 0 Press Jam Fault 5
- 33. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production What was the cause? Unmasking the culprit
- 34. Continuous Improvement - Solving Mysteries Conveyor -> Press 1 Station 1: Stamp Part Station 2: Insert Sub Part Station 5: Transfer to Presses Station 3: Inspect Insert Station 4: Stamp Part Press 2 Press 3 Press 4 Press 5 Mystery: Inconsistent Production Part Change Over Disabling presses. Reduction in throughput.
- 35. Continuous Improvement - Solving Mysteries Challenging Mystery: Inconsistent Production
- 36. Continuous Improvement - Solving Mysteries Automated Data Collection and Reporting • Consistent Quality Data • Visibility Technical Details?
- 37. Technical Details – FactoryTalk Metrics • Data Collection • Reporting • Preconfigured Reports and Wizards • Open System
- 38. Technical Details – FactoryTalk Metrics PLC 1 PLC 2 PLC 3 Reports
- 39. PLC 1 PLC 2 PLC 3 Reports Technical Details Part Number Fault Number Operator Good Part Rejected Part Rejection Cause Tags System State Part Created PLC 1 Running Faulted Setup (Change over) Test Mode Starved (Up Stream Problem) Blocked (Down Stream Problem)
- 40. Technical Details PLC 1 PLC 2 PLC 3
- 41. Technical Details Report Expert Built in basic reports. View Vabielew baby lWe beyb WBreobw Bsreor wser Full Power of MS SQL Server SMT APd Svearnvceerd/Complex Reports
- 42. Automotive Story Recap! • Why? - Optimize Production • How? – FactoryTalk Metrics and Advanced Customizations • Automated Emailed Reports • Visibility!
- 44. Recipes produce variety on a single machine Recipes
- 45. Innovate
- 46. New Crossover Recipe: Global Implementation
- 47. Global Platform Variety 1998: USA Plant 1 2007: China Plant 2012: USA Plant 3 2010: India Plant 2002: USA Plant 2 2000 2005 2010
- 48. New Crossover Recipe: Global Implementation
- 49. Cost of Implementation? 5 Months $100,000+ Ready for the next new product? Better way?!!
- 50. A Better Way! • Single Website • Uniform Recipe Management System • Keep Existing Control Hardware and Software
- 51. New System Update Recipe? 1. Log In To the Website 2. Select Plant 3. Select Production Line 4. Select Existing Recipe and Edit OR Create New Recipe Technical Details?
- 52. Technical Details - Overview Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
- 53. Technical Details Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
- 54. Technical Details: Intranet Website DNN: a Content Management System (CMS) Built on the Microsoft Stack: • ASP.NET • SQL Server Database
- 55. Why Content Management System? Proven Pre-existing Functionality: • Security • User Management • Hundreds of Third Party Tools
- 56. Why Content Management System? • Easy to Add Pages and Features • Up and Running Fast
- 57. Technical Details Intranet Website Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service DNN Tables Custom Recipe Tables Custom Functionality
- 58. Technical Details Intranet Website USA Plant 1 USA Plant 3 India Plant Custom Service
- 59. Interface 1 5.3 15.2 3.1 .2 .3 Technical Details PLC Legacy System Select Recipe: 1 Tags Recipe Number Sugar (kg) Gelatine (kg) Water (L) Flavor 1 (kg) Flavor 2 (kg)
- 60. Technical Details Interface PLC Select Recipe: New System 1 Tags Recipe Number Sugar (kg) Gelatine (kg) Water (L) Flavor 1 (kg) Flavor 2 (kg) 1 Custom Service 5.3 15.2 3.1 .2 .3
- 61. Technical Details Custom Service 5.3 15.2 3.1 .2 .3 1 PLC DNN Tables Custom Recipe Tables OPC Server USA Plant 1 USA Plant 3 India Plant
- 62. Technical Details OPC Server: • Standard: Support for 100s of Industrial Platforms • 1996 • OPC: “OLE for Process Control” • OPC: “Open Platform for Communications”
- 63. Candy Story Recap! • Why? • Standardize and Control the System Inputs • Convenience • How? – Cost-Effective Custom System • Flexible – Feed Multiple Platforms
- 66. Onsite Commissioning - Chemical
- 67. Onsite Commissioning - Chemical I/O Issues Interface Pump 1 System REV FWD Pump 5 REV
- 68. Onsite Commissioning - Chemical I/O Issues: • Hundreds of I/O Points • Trial and Error Debugging
- 69. Onsite Commissioning - Chemical Slow 2 Person Job Controls Pumps 100’
- 70. Onsite Commissioning - Chemical Days? WEEKS?
- 71. Onsite Commissioning - Chemical Simple Idea!
- 72. Onsite Commissioning - Chemical Controls Controls Pumps
- 73. Technical Details Interface System: Pumps Valves Feedback PLCs Mobile Interface
- 74. Onsite Commissioning - Chemical
- 75. Onsite Commissioning - Chemical
- 77. Integrator Story Recap • Why? – Convenience • Remote Desktop Protocol – Simple and Cost Effective!
- 79. Security Considerations Security is Complicated 1. Three Quick Recommendations 2. Some Resources
- 80. Recommendation #1: Back Up Control Software • Any time any change is made! • Archive or software repository is best.
- 81. Recommendation #2: Isolate from Outside • Use VPN for External Access • Be wary of WiFi • Remove internet access all together?
- 82. Recommendation #3: Isolate from Inside • Consider using internal Subnets and Firewalls
- 83. Resources 1. Recommended Practices https://ics-cert.us-cert. gov/Recommended-Practices
- 84. Resources Recommended Best Practices “Improving Industrial Control Systems Cybersecurity with Defense-in-Depth Strategies” https://ics-cert.us-cert. gov/sites/default/files/recom mended_practices/Defense_in_De pth_Oct09.pdf
- 85. Resources 2. List of Vulnerabilities https://ics-cert.us-cert.gov/ics-archive/
- 86. Recap! Modern Connectivity and Industrial Automation: • Defined • Why? • Optimize Production • Traceability • Convenience • Standardize and Control the System Inputs Factory System Internet Intranet
- 87. Recap! Stories: Factory System Internet Intranet
- 88. Recap! Security Factory System Internet Intranet
- 89. Thank You!
Editor's Notes
- Thank you all for coming to the IMTS show and coming to these presentations! Introduce myself. I work for a company called DMC. Industrial Automation and Modern Connectivity
- We are an engineering solutions company that focuses on software. We’ve been around since 1996, Growing! In addition to Chicago Boston Denver
- We typically break the work we do into 4 areas. We work in a lot of different fields, but more than 60%+ of our business is in Factory Automation and Integration. PLCs, Servos and Motor Control, Robotics. We also do a lot of custom software development for PCs, for the web, for databases. Today I’m talking about Modern Connectivity so we really are talking about the intersections of these worlds.
- Kettering University – formerly General Motors Institute. It’s a Co-op school! So I joined DMC as a Senior in College, basically as a co-op or an intern. I’m part of our Senior Management
- Overview – frame the discussion Stories – what they did, and why. TECHNICAL DETAILS! Security – hot issue!
- Before we get started, we need to define what we are talking about.
- Look at traditional factory line: Interface connected to the PLC which controls the entire system. And that’s it. Island – not connected to anything else.
- What are we connecting to?
- Why add modern connectivity to our factory system? We want to make sure it makes sense. Nothing is free and there are always costs.
- Reason 1! Optimize your production
- If I tweak the temperature or tweak the recipe, what happens?
- Traceability – knowing where your product came from.
- “I hope to introduce some new ideas or some new ways of looking at old ideas to help you get the most out of Modern Connectivity.”
- A good friend of mine works for the automotive industry. He’s an engineer at a supplier.
- Every Monday morning he has a continuous improvement meeting. He’s responsible for his set of machines that produce automotive parts and making sure they are running at optimal performance.
- Every Monday morning he has a continuous improvement meeting. He’s responsible for his set of machines that produce automotive parts and making sure they are running at optimal performance.
- For some quick examples. This is a machine where parts travel along a conveyor, Some stamping and inspections are done. Now the press station over here takes a lot longer (bottleneck) so there are more of them. The transfer station puts each part into one of the available presses.
- A lot of transfer faults at the press.
- They noticed that every time they ran part A27 they had a high number of transfer faults. This part had the smallest diameter.
- They redesigned the end effector of the part transfer station to better handle these smaller parts.
- A large number of faults at station 4. Caused by 2 parts getting stacked on top of each other. Watched the system, noticed that station 3 was running fast and allowing 2
- Fixed the problem by adding better part queuing.
- Okay – so those were easy mysteries. On this machine their Production was all over the place.
- On this machine their Production was all over the place from day to day.
- Nothing correlated. No obvious pattern.
- The real problem is they didn’t trust their data. It was recorded by hand by operators via paper.
- Consistency Quality
- Every day the engineers and shift supervisors get emails of machine performance broken down by dozens of different factors: Production Data By machine, by Part Fault Data Downtime Data
- So after sifting through all the data, what was the cause of the issue?
- When an operator switches from producing one part to another, the equipment needs to be adjusted as well. Tracks along the conveyor adjusted for the diameter. The Presses need to be adjusted for the new part. Getting to each press is difficult – there is limited space for the operator and adjusting each one is a tight fit. The operator was disabling certain presses rather than go through the effort of setting them up for the next part during change over. The presses are the bottleneck so this caused a large drop in productivity.
- Consistent Automated Data Collection and Reporting Correlating was straightforward
- This was a good investment. Better armed for future mysteries.
- Allen Bradley PLCs Rockwell Automation Solution: FactoryTalk Metrics! Automated data collection and reporting. Base functionality can be easy to set up (preconfigured options, tools, wizards). Customizable – Fully utilize it!
- Broad overview – pulling data from multiple PLCs using FactoryTalk Transaction Manager Storing data in a database Viewing the data through reports
- PLC 1: Tags or Variables that tell the current state of the machine. Basic Tags Create a tag that keeps track of anything that might be relevant.
- Closer look at the Windows Server and FactoryTalk Metrics
- Getting data from the system! Report Expert – you can browse to it. These are the simple preconfigured reports I mentioned before. But for this system, they wanted detailed analysis of the data. SQL Server Reporting Services. SQL Queries. Email configuration is simple.
- Optimize – not just to fix this problem but to give them the data they need for future continuous improvement Visibility – getting the information to the key people.
- When it comes to candy, you can get a lot of variety by just slight tweaks to the ingredients. For example, for chewable candy, you add sugar, water, and gum or gelatin. If you vary the amount of moisture or gelatin you can get anything from a soft chewy gummy bear to a jujube – it’s almost more of a hard candy that you suck on. The other component is the coloring and the flavoring.
- As a result, you can create a wide variety of products and flavors from a single system by varying the recipe.
- The candy industry isn’t immune to the pressures of globalization and competition. They have to always be innovating, coming up with new flavors, new ideas, new recipes.
- The global engineering group for one of our clients was responsible for implementing a new recipe all around the world, a soda flavoring cross over.
- These plants are all over the world, they were all built in different eras, using different PLC hardware.
- So for each location around the world they had to either fly out a team or find some local integrators.
- There has got to be a better way.
- Windows Server Intranet Website: Login to Update or Change a Recipe Database: Where the Recipe Data is Stored Custom Service (Application): Updates the recipe variables on the PLCs
- Technical Details of the website
- There are a lot of other Content Management Systems out there – Joomla!, Drupal to name a few. We at DMC are Microsoft Gold Certified Partners, we love Microsoft’s tools – DNN is built on Microsoft’s stack so it makes sense.
- Out of the box! Third Party Examples: Database editing tool. Graphing/Charting Tool. Reporting tool.
- I can get a DNN installation up and running in 1 – 2 hours.
- Base functionality of DNN on both the ASP.NET and SQL Server side. We built an top of that using ASP.NET and SQL Server for the recipe management system.
- Next let’s look at how the active recipe gets updated on a PLC.
- Well first let’s look at how the system used to work before the upgrade. There is a PLC with all these Tags or registers that tell the system how to make that recipe. The operator selects the recipe from the interface and all of these variables get updated.
- Now on the new system… The active recipe is still selected from the interface. The Custom Service running on the server reads the active recipe and then updates all the tags with the appropriate values for that recipe.
- We wrote the Custom Service to pull in recipe data from the database. But how do we communicate to all of these different PLC platforms? We write to the PLCs using an OPC Server.
- OPC Foundation
- Why? How? Built from Off-the-shelf and scratch components. CMS and OPC servers and the custom software that links them all together. They didn’t have to revamp their control systems.
- As integrators at DMC we have to travel a lot. My coworker Jimmy had a rough first year.
- Over his first year, he was in the office for a total of 43 days.
- Jimmy was finishing up a long trip, onsite commissioning for a new line at a chemical plant. It felt like he was so close to being done.
- Jimmy was testing the I/O and of course everything was wrong. He commanded Pump 1 to go Forward and Pump 5 went in reverse. He commanded Valve 3 to close and Valve 6 opened.
- It was a complex system with hundreds of I/O points. Typically you would look to activate each I/O bit one at a time and see what happens.
- But of course the control panel is a hundred feet away from these pumps. Typical 1 person at the controls, another at the system, signaling back and forth.
- With a lot of the system left to test, what he thought would be days was looking like it would be weeks.
- Jimmy gets a simple but powerful idea. He employs a connectivity idea that we use in the office all the time, that’s been used in IT for years.
- Bring the controls right next to the pumps. How do you do this?
- Your interface is running on Windows, in this case iconics. Use Remote Desktop Protocol to bring your interface onto your Windows, Android, or iOS device.
- Using this tool Jimmy shaved a lot of time off and got to go home.
- The client uses a tablet now as a remote interface to control the pumps when they have to go outside to connect the tankers.
- This can be done on any interface software that runs on Windows.
- No “One Size Fits All” Plan A lot of variation in cost and complexity depending on what you are protecting and what you are protecting against.
- Security is Challenging.
- If you do nothing else for security, do this. Production down time is typically the biggest concern.
- In my experience, this is not done very often. Stuxnet, Target Breach (Credit Cards), J.P. Morgan and some other banks breach from Russia? -> in all of those cases damage could have been prevented or mitigated if these practices had been in place.
- Known vulnerabilities
- Automotive Story about Automating Data Collection and Reporting Purpose: Optimize Production Candy Story about a Global Recipe Management System that Communicates with Different Platforms Purpose: Standardizing the System Inputs Integrator Story about a simple trick to create a mobile interface for your system Purpose: Convenience
- Security Tips and Tricks and some great resources that the Dept of Homeland Security has to offer.
- I hope today you leave with some new ideas or new ways of looking at old ideas.