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Page 1 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Savings and Expertise for your plantSavings and Expertise for your plant
ALL IN ONE SOLUTION FOR THE PROCESS INDUSTRY
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Discover a new level of Data Safety for Automation Technology
in line with ISO 900x and FDA 21 CFR 11
Discover a new level of Data Safety for Automation Technology
Version Control Smart Compare
History Audit-Trail
Archiving
Check-In/Out
Access Control
e-Signature
Autom.Backupsemail Report
Reporting
Page 3 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Consistent data management- was never as important as it is today
Consistent data management
Problem
Problem
Planning, maintenance
production: vital data is
changing all the time!
It doesn‘t matter whether
you produce cars, drinks or
pharmaceutical products
Reasons for changes: Product mods., bug fixescycle time optim., safety measures, “botched mods.“...
The problem
Page 4 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Risk assessment for data management:
• How likely is it that something will go wrong?(FMEA = Failure Mode and Effect Analysis)
• How serious would the consequences be?
• How often does the risk arise?
• How many people could be affected?
• How much product could be affected?
• What are the financial implications?
• Are the effects immediate or chronic (long term)?
• What does the law require?
Risk assessment for data management
Risks
Risks
Page 5 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Risks to be controlled and prevented
Risks to be controlled and prevented:
• Are the correct software releases operating the production?
• Do software changes effect quality and safety?
• Can unauthorised software modifications be detected?
• Are all systems software secured and accessible?
• Is there control over data access and handling?
• Can a replaced device be restored in acceptable time?
and, and ......
Risks
Risks
Page 6 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Filing on HDs and server
• Backup on CD, DVD (monthly, weekly)?
• LAN integration of PCs and workstations
• LAN enabled (SoftnetTM) programming software
• Formal work instructions and procedures
.... and your actions?
Which measures have been taken?
Reality
Which measures have been taken?
Reality
Page 7 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Have you gained control?
Have you gained control?...
Reality
Reality
Page 8 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
.... or does this seem familiar?
• Where is the correct version?
• What exactly has been changed and why?
• Who has overwritten my changes on the server?
• What software version is our system really using at present?
• Why is it that nobody knows the answer...!!!
…. and now?Or does this seem familiar?
Reality
Reality
Page 9 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Enormous efforts, poor quality,
lots of risks!
Action must be taken!
The current situation?
The current situation?
Reality
Reality
Page 10 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Server based, central project data storage withuser and access management
• Copy management between workstationsand server
• Automated program editor operations
• Version control and archiving
• Change management & documentation
• Change history, reporting and audit trail
The requirements
Requirements
The requirements:
Requirements
Page 11 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Scheduled automatic backup of controller and device programs, including change detection
• Automatic change notification via e-mail
• Efficient and speedy “disaster recovery”
• Documented change process in line with ISO 900x and FDA 21 CFR 11
• Proven solution with reference sites
The requirements
The requirements:
Requirements
Requirements
Page 12 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
PLC / PC SCADA / HMI / ROBOTS
FIELD DEVICES AND DRIVES FILES / DOCUMENTS
• Indramat• SEW• Lenze• Leutze• Datalogic etc.
• .bin, .xls, • .exe, .ppt,• .txt, .mdb,• .doc• E-CAD• Specifications etc.
„A well designed concept can manage the data of any application“
The type of data to be managed?
The type of data to be managed:
Requirements
Requirements
• Siemens• Rockwell• Schneider (Concept, Unity*)• 3S CoDeSys• TwinCAT• NC, CNC, DNC (840D…)• usw.
• WinCC, ProTool, PCS 7• InTouch• Citect• Ghost Images• ABB, KUKA• FANUC, ADEPT• usw.
Page 13 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Vital data totally under control!
Vital data under total control!
Solution
Version Control Smart Compare
History Audit-Trail
Archiving
Check-In/Out
Access Control
e-Signature
Autom.Backupsemail Report
Reporting
Page 14 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
A closed loop control for data flow
Work process
A closed loop control for data flow:- developed from practical experience -
Archive Server
WorkstationsDevices
Solution
Page 15 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Eindeutige Datenablage
Work bench:CommanderEasy-Mode
• Easy to use with the Commander Easy Mode
• Project components, including all versions
• Instant access to change history
• Filing order and structure as required
Direct overview:
Solution
Page 16 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Search function for the project tree and master data• Overview of all components which are „under construction“• Indication of the PG- and AG- Actuality• Backup- and Restoring on push of a button
Eindeutige Datenablage
Transparency and functionality:
Work bench:CommanderPower Mode
Solution
Page 17 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - S7
Version control
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
Solution
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 18 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - S7
Version control
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
Solution
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 19 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detaillierte Unterschiede - S7
• Detaillierte Darstellung aller Änderungen
• Zusätzliche Kommentierung
Eindeutige Versionierung:
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Solution
Version control
Page 20 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - WinCC
Version control
Solution
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 21 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detaillierte Unterschiede – PCS 7
• Locating all changes by using „Smart Compare“
• (SFC Smart Compare)
Complete version control:
Version control
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Solution
Page 22 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detaillierte Unterschiede – PCS 7
• Locating all changes by using „Smart Compare“
• (CFC Smart Compare)
Complete version control:
Version control
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Solution
Page 23 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - InTouch
Version control
Solution
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 24 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detaillierte Unterschiede - Schneider
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
Version control
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Solution
Page 25 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detaillierte Unterschiede - Citect
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
Version control
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Solution
Page 26 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - Word
Version control
Solution
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 27 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Detailed changes - KUKA
Version control
Solution
• Locating all changes by using „Smart Compare“
• Additional commenting features
Complete version control:
S7
WinCC
InTouch
CitectWord
... and more
Schneider
PCS 7
KUKA
CodesysTwinCat
Rockwell
Page 28 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Electronic change records – audit trail
• „Smart Compare“ between any two versions
Components history
HistoryAudit-Trail
Component history
Solution
Page 29 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Central data vault
Archiving
• User administration with account policies
• Automated file and directory management of all copying procedures (check-in/ -out)
Central data vault
Solution
Page 30 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Access controle-signature
• Unique user administration and management
• Electronic signature of specific actions
User security policy
User security policy
Solution
Page 31 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
ReleaseProcedure
• Release procedure according to the four-eye-principle for new versions:
• Electronic Signature• Escalation Management• Deputy Regulation• Email Notification• Audit Trail for all actions
Release procedure - Workflow
Sicherheitsrichtlinien für Benutzer
Solution
Page 32 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Automated Backups
Automatedbackups
Automated, scheduled device data backupvia LAN (device upload via PLC-Saver)
• Backup of PLC programs (including Soft-PLC), SCADA or HMI, robot controllers, NC, etc.
• Backup of recipes, setpoint values and parameters (for S7: according to selected words or variables)
• Backup of any files via shared network resource or FTP
• Change detection between backup and archived version
• Backup and change report via email
• Support of manual program backups for non LAN accessible devices
Solution
Page 33 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Automated change report
Change report via email
Automated change report:
• Email report
• “Smart Compare” of any change
Solution
Page 34 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
• Audit trail of all activities• Predefined and user defined selections and filtering • Time-stamped to local- and UTC time• Print functions and export to CSV-file
Project State and reporting
Audit-TrailReporting
ProjectState and Reporting
Solution
Page 35 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Highlights of VersionWorks®
Highlights
• Archiving of program- and data files on a server with secure user-, access- and copy management
• Support of all PC based data types
• Version control and archiving
• Change history and audit trail
• Scheduled automated backup of controller and device programs including change detection
• Automated change notification via e-mail
• Efficient and speedy “Disaster recovery”
• Documented change process and audit trailin line with ISO 900x and FDA 21 CFR 11
• Proven solution with reference sites:
170 companies approximately 2000 user administer approximately 20.000 devices
Highlights
Highlights of VersionWorks®
Page 36 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
What do we gain by this?
Benefits
Benefits
What do we gain by this?
Page 37 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Quality improvement due to VersionWorks®
Benefits
Quality improvement due to VersionWorks®
• Complete version control and archiving of all data and software releases as a foundation for “disaster recovery”
• Exact reproducable production conditions
• Association and traceability of software releases and product batches
• Secure user and access administration
• Electronic signature for all relevant actions
• Documented change process and audit trail in line with ISO 900x and FDA 21 CFR 11
• Automated change check and e-mail reporting
Benefits
Page 38 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Cost reduction due to VersionWorks®
Benefits
Cost reduction due to VersionWorks®
• Reduction of production down time
• Prevention of down time and bad product, due to accidentally activated old software
• Prevention of financial loss, due to loss of vital data
• Prevention of loss of know-how, due to personnel changes/movement
• Quick training of new personnel
• Time saving for the searching of valid Software releases
• Extreme improvement of daily procedures and routines
• Short amortization time (ROI)
Benefits
Page 39 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
Referenzen - Automobilindustrie
References
References
DaimlerChryslerRastatt, Wörth, Mannheim
AudiIngolstadt
BMWDingolfing
BMWLandshut, Leipzig
BMWRegensburg
BMWMünchen
DaimlerChryslerBerlin, Bremen
DaimlerChryslerGermersheim
DaimlerChryslerMettingen
Automotive Industry
FordKöln
VolkswagenBrüssel (BELGIEN)
VolkswagenHannover, Braunschweig
VolkswagenWolfsburg
FAW-VWChangchun (CHINA)
Automotive Associated Industries
BehrMühlacker
BroseCoburg
Continental TevesFrankfurt
Continental TevesMechelen (BELGIEN)
Continental TevesCulpeper (USA)
Continental TevesMorganton (USA)
CorningKaiserslautern
KS AluminiumNeckarsulm
LuKBühl
Mann + HummelMarklkofen
DaimlerChryslerSindelfingen
Shanghai GMShanghai (China)
Page 40 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
References – Food Beverage/Parma
References
References
BavariaLieshout (HOLLAND)
Beck’sBremen
CarlsbergNorthampton (UK)
DanoneOchsenfurt
IndagEppelheim
KrombacherKreuztal
Langnese-IgloReken
Molkerei Alois MüllerFischach
Food and Beverage Industry
NestléHamburg-Wandsbek
NestléBiessenhofen
Nordwest GetränkeSoest
TetraPakGlinde
VeltinsMeschede
WagnerNonnweiler-Braunshausen
WarsteinerWarstein
Pharmaceutical and Chemical Industry
BASFMinden
Boehringer IngelheimIngelheim
FreseniusSt. Wendel
MerckGernsheim
NovartisBasle (SWITZERLAND)
RocheMannheim
RochePenzberg
Salutas PharmaMagdeburg
Wacker ChemieBurghausen
WellaWeiterstadt
Page 41 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
References - Various
References
References
Steel and Metallurgy Industry, Machine builder and various Industries
AluNorfNeuss
AlstomBirr (SWITZERLAND)
DatevNuremberg
Eckart-WerkeVelden
EKO StahlEisenhüttenstadt
Forbo LinoleumAssendelft (HOLLAND)
Franz Viegener IIGroßheringen
Gebr. HellerNürtingen
KnaufImmingham (UK)
Kocher-PlastikSulzbach-Laufen
MieleGütersloh
NECSAPelindaba (SOUTH AFRICA)
Salzgitter FlachstahlSalzgitter
SAPSt. Leon-Rot
Sekurit Saint-GobainHerzogenrath
Schott RohrglasMitterteich
Schweizer ElectronicSchramberg
StihlWaiblingen
VA Tech ElinLinz (AUSTRIA)
Neumag SaurerNeumünster
Page 42 of 33
Problem - Risks - Reality - Requirements - Solution - Highlights - Benefits - References
BIConsulting Inc.Miami, USA9050 Pines Blvd. Suite 480Pembroke Pines, FL 33024Tel.: +1 (954) 272-6120Fax.: +1 (954) 885-6503E-mail: [email protected]
Contact Information
BIConsulting C.A.Valencia, VenezuelaCentro Comercial Paseo TarbesPlanta Alta, Oficina PA-4Valencia, VenezuelaTel.: +58 (241) 8242139Fax.: + 58 (241) 8242139E-mail: [email protected]