T83 - Lifecycle Extension and Migrations - Rockwell … · PMA’s are stored centrally at a Rockwell Automation facility. Generally, PMA’s require that Generally, PMA’s require

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T83 - Lifecycle Extension and MigrationsMinimizing Obsolescence Risk on the Journey to The Connected Enterprise

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC

Agenda

Help Eliminate Risk

Mitigate Risk

Identifying Risk

Defining Risk

Global Manufacturing Outlook

Getting Started


EMERGING MARKET

CONSUMERISM

RESOURCE PRODUCTIVITY

INVESTMENT

$1T50%More Energy

More Water

30% 100%More Vehicles

GLOBAL POPULATION TRENDS

INCREASE DEMAND FOR

Manufacturing

80%More Steel

Resources

Infrastructure Annually

By 20201 billion new middle class consumers will add

$8 trillion to consumer spending

GLOBAL MANUFACTURINGTomorrow’s Scenario

Source: McKinsey

3


OT

IT

CONVERGENCE

…

Transactional data: orders, supply network, product design …

MATERIALS & TRANSPORT

CONTROLLERS SENSORS, ACTUATORS

MACHINES & EQUIPMENT

FINANCIALS HR LOGISTICS QUALITY CRMERP

Real-time data: control, safety, security…

How Industry Meets the Challenge…

The Connected Enterprise has become a business imperative


Contextualizing and analyzing data

Reliability, support and disaster recovery

Access to actionable information

Work force is Mobileduring typical work day

Shift from CapEx to Flexible & Scalable OpEx

Smart devices create more

‘things’ to be analyzed

DATA

ANALYTICS

CLOUD &

VIRTUALIZATION MOBILITY

Connected Enterprise

The Industrial Internet of Things at work for Industrial Applications

Enabled by Integrated Control and Information

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.PUBLIC 6

Industry Status

What is your Status and what is your Plan?


Limited Parts

Availability

Increasing

Support Costs

Regulatory

Compliance

Subject Matter

Expert Attrition

Safety &

Sustainability

Automation Obsolescence Risks

Modernization of legacy automation helps eliminate obsolescence risk and helps accelerate progress to The Connected Enterprise


Defining Automation Obsolescence Risk

88

What is Automation Obsolescence Risk? The extended downtime risk automation users take (knowingly or unknowingly)

using products that are no longer available for sale and have limited to no serviceability remaining

The goal is simple:

Help you maintain awareness of automation obsolescence and

develop a strategy to mitigate and ultimately help eliminate this risk


Product Lifecycle Category Definitions

Product Launch

A Newer Product in that Category is Launched

Announcement that Product will be Discontinued

Discontinued Date


What We Want You to Know

10

A number of popular Rockwell Automation products are no longer produced or are nearing the end of their production life

Discontinued

Powerflex 700H ICS® Triplex® Regent

Automax DCS 1394 Servo Drives

1326 Motors 1305 AC Drives

PanelView™ Std 1336 AC Drives

1557 MV 1395 DC Drives


PLC5 End of Life – Current State

PLC-5® has been sold for nearly 30

years

End of Life for PLC-5 and 1771 I/O

is near

PLC5 and 1771 I/O sales are

currently restricted

Parts availability will become more

restricted for installed base support

PLC-5 and 1771 customers need a

migration plan


Strategy


Strategy


Step 1 - Identify

Safe collection and attention to detail are necessary for success

Identify

14


Research

Step 2 - Research

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http://www.google.com/imgres?imgurl=http://dauleriochristopherfbgp.files.wordpress.com/2010/01/research-writing.jpg&imgrefurl=http://dauleriochristopherfbgp.wordpress.com/2010/01/26/blog-entry-1-what-is-research-writing-what-does-it-mean-to-be-a-research-writer-how-are-research-questions-developed/&usg=__tJrCFG_F79y9O7qpLbmhQAjOd2g=&h=399&w=600&sz=28&hl=en&start=101&zoom=1&itbs=1&tbnid=Zz7ojHPhcb-M7M:&tbnh=90&tbnw=135&prev=/search?q=research&start=100&hl=en&sa=N&biw=1259&bih=633&gbv=2&ndsp=20&tbm=isch&ei=rQ8mTrmOB4-gsQOPq-yQCQ


Prioritize

Step 3 - Prioritize

16


Online Lifecycle Lookup Tool

17


Additional Self-Help Tools


Migration Brochure

19


Migration Solutions Notifications

Initial Releases Powerflex® 700H

PanelView™ Standard

PLC-5®

1394 Servo Drives

AutoMax®

Reliance Drives

1336 AC Drives

1305 AC Drives

1395 / 1397 DC Drives

1557 MV Drives


Assessment Option

21

Assessment Service Includes:

MRO analysis including location & optimization recommendations

Identification of automation obsolescence risks

Identification of product lifecycle status via plant hierarchy

Benefit

Provides clear understanding of MRO stocking and obsolescence risks and opportunities for better storeroom and migration planning


Strategy


Once the Risks are Identified… Then What?

How long do you intend to operate equipment?

Is support readily available?

Is capital funding available?

Is there applicable new technology available?

What are the migration implications (training, support, etc)?

After the risk has been quantified, you have to make some critical decisions…

Mitigate Risk?

Eliminate Risk?

Mitigating obsolescence risk until scheduling and/or capital

funding becomes available

Eliminating obsolescence risk through product migration

23


Risk Mitigation – Being Prepared

24


Obsolescence Risk Mitigation

1. Preventive Maintenance “Critical Actions”

2. Access to Legacy Technical Support

3. Spare Replacement & Legacy Repair Support

4. On-Going Management of

Obsolescence Status

Mitigating risk of irreplaceable, obsolete equipment requires a

renewed level of attention...Intensive-Care Support 8143

25


Preventive Maintenance for Discontinued Products

Are filters replaced regularly?

Legacy products DEMAND adherence to consistent preventive maintenance activities when maximum product life is desired

Are programs/parameters backed-up? When was battery last

replaced?When was power last checked?

Was there a product notification on

equipment?

Is current operating environment within OEM specifications?

Are cooling fans operational and clear of obstructions?

When is the last time grounding was checked?Does the equipment possess the last firmware update?

How often are PM actions performed?

Do you have an updated logbook documenting inspections of obsolete equipment?

81403

26


Access to Legacy Remote Support

Are newer technicians skilled at maintaining all legacy

products? • Can they:

– Install or re-install. . .

– Configure. . .

– Maintain. . .

– Diagnose operating problems for. . .

– Fix operating problems associated with. . .

– Perform basic programming tasks for. . .

All Legacy Products?

Have the “legacy experts” been promoted, moved to different departments,

employers or retired?

(source: ARC Advisory Group – 6/10)

58% of companies surveyed have faced issues with training young engineers and technicians to operate and maintain older control systems

27


Access to Legacy Spares and Repair Support

Do you carry MRO automation spares inventory?

• If yes:

– How was it calculated?

Has it been effective? By what measure?

Is it too much? Is it too little?

What is your carrying cost?

Is it in operating condition? How do you know?

Did you purchase, consign or leverage supplier?

– Do you know what is active, excess-active and inactive?

– Do you know what is legacy vs. active inventory?

– How have you re-calculated for your legacy installed base?

• If no:

– How are you going to support legacy products when you can no longer acquire new?

MarcusEvans Maintenance conferences 2010

An ineffective spares management process can result in at least 15% - 35% of machine down time

28


On-Going Management of Obsolescence Status

Are you prepared to make the investment to maintain an obsolescence database?

• If yes:

– Who has the expertise to maintain it? What makes them qualified?

Do they have the bandwidth?

What tools are at their disposal?

• If no:

– How do you avoid future problems regarding obsolescence?

The key to success for better obsolescence management is committing to a continuous program... Are You Committed?

29


A “Bridge” to New Technology

30

A single, comprehensive agreement created to maximize the life of your automation investment and minimize downtime events


Elements of the Extension Agreement

31

Solutions to buy you TIME to implement your migration strategy!

Lifecycle Extension Agreement: options designed to minimize the risk of operating discontinued Rockwell Automation® hardware as you migrate to newer technology!


Key Contract Services for End of Life and Discontinued Products

32

Installed Base Evaluation™ – On-site collection and consulting service that pinpoints

automation obsolescence risk by enterprise, facility, line, machine, panel and identifies

MRO inventory risks and optimization opportunities.

Legacy TechConnect℠ – Remote Support to sustain availability to product updates and

access to knowledgeable “legacy product” engineers. Supplements customer engineer staff.

Reserved Repair – Provides guaranteed repair-ability of discontinued products. Secured

component parts, technicians, test stands, etc. for customers who cannot immediately

migrate, but must keep legacy automation up and running.

Parts Management Agreements (PMA) – Rockwell Automation owned inventory dedicated

to one (P1) or multiple (P2) customers. P1 PMA’s are located on customer’s site, while P2

PMA’s are stored centrally at a Rockwell Automation facility. Generally, PMA’s require that

the contract is secured prior to the discontinue date.

Last Time Buy Agreements – Provides continued access to finished goods after the

product has been discontinued. Contract must be secured prior to discontinuation (unless

inventory remains) and customer agrees to a predetermined minimum quantities and

consumption rate.

On-Site Engineering – Preventive Maintenance (PM) contracts to support legacy products.

Embedded Lifecycle Engineers can be contracted as well to develop a modernization

roadmap and execute migration services under contract.


Can Be Combined into Tailored Options

33




Elements of the Extension Agreement

34




Strategy


Benefits of Replacing Technology

Functionality

Cost

“Low” Offering

“Middle” Offering

“High” Offering

“Low” Offering

“Middle” Offering

“High” Offering

36


Technology Advancements

More Memory: Fewer Processors Required for Same Applications

Performance: Improved Scan Times = Increased Production & Quality

Safety: Designed Into Product

Reliability: Redundancy Without Relays

Compliance: RoHS Certification

Sustainable: No More Batteries

Reduced Size: Less Panel Space

37

PLC-5® ControlLogix®


IBE Migration Planning Application

Develop a migration plan

Prioritize work processes and machines based on their reliability, priority to the facility, and expected life. Also prioritize the types of equipment that are most important i.e. Drives vs. PLCs vs. HMIs.

Outcome

Risk based scoring model shines the light on the most critical pieces of equipment based on collected information as well as customer inputs.

This score can be used to know where to start a migration discussion!


Obsolescence Risk Elimination –Managed Migration

Installed(Legacy)Control System

Considerations:

• Downtime for new install• New application code development• Employee training on new systems• Network compatibility• Retain field wiring investment• Disposal of legacy products• Managing spares

New(Rockwell Automation®)Control System

Rockwell Automation® Products & Services

New products:• Integrate with existing systems

(Drop-in replacement)

Migration of legacy products:• Migration tools

(Adaptors, Code Conversion, IAB, etc.)• Commercial programs• Services (Installed Base Evaluation™)

Simplify the plant maintenance effort by making automation

“Common & Current”39


Migration planning & execution options to meet all needs

40

Rockwell Automation® Solutions


Phased Migration & Extensive Migrations Toolkit

41


I/O Wiring Conversion System

42

An I/O Conversion System consists of three

components:

1492 Mounting Assy (Cover

Plate and Base Plate)

1492 Conversion Modules

1492 Cables

Base-Plate(Houses Conversion Modules)

ConversionModules

Cover-Plate(1756 Chassis Mounts on Top)

1756 Chassis & I/O

D-shell Connectorsfor Cables


I/O Conversion System

43


A Scalable, Phased Migration Option

44

We systematically prioritize your migration requirements by

migrating only one PLC-5 rack, leaving any connected devices,

slave controllers and I/O racks in place

By migrating the core controller and chassis, you lay the foundation

for future modernization

The PLC-5 migration package is ideal for discrete, straightforward

applications communicating to devices and remote I/O racks on

existing networks such as DH+ and remote I/O

Rockwell Automation can help you cost-effectively migrate to

the latest ControlLogix® technology:

A whole new meaning to migration – Easy, Fast, Affordable


What Can Be Expected Post Migration

Reduced maintenance

Less downtime

Enhanced data collection and

analysis capabilities

Ability to integrate other

control/information systems

Integrated Motion

Integrated Safety

Quicker product changeovers

Fewer manual operations

required

Improved quality

Less energy required

Increased throughput

Advanced process control

capability

Built-in cyber security features


For More Information

46

Visit the Literature Library:

Rockwell Automation® Migration Solutions Brochure

PLC-5® > ControlLogix® Phased Migration Solution Profile

1756-RIO Product Profile

1492 I/O Wiring Conversion System Selection Guide

Visit the E-tools website:

Install Integrated Architecture® Builder

Install ProposalWorks™

Visit the Product Lifecycle Status website

Visit the Migration Solutions website

Visit the Integrated Architecture Tools website

Visit the Lifecycle Extension & Migrations website

http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/migrat-pp003_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/1756-pp012_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1492-sg121_-en-p.pdf

http://www.rockwellautomation.com/en/e-tools/configuration.html

http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/overview.page

http://www.rockwellautomation.com/solutions/migration/

http://www.rockwellautomation.com/solutions/integratedarchitecture/resources.html

http://www.rockwellautomation.com/rockwellautomation/solutions-services/capabilities/migration-solutions/lifestyle-extensions.page


Getting Started

COLLECT ANALYZE COLLABORATE

Parts Repair Recycle Remote On-site

SU

PP

OR

T

MIG

RA

TE

STEP 1 STEP 2 STEP 3

SOLUTIONS

Train


Summary

Effective management of automation obsolescence risk can be accomplished without sacrificing profitability, quality, and production rates

Quantifying Obsolescence should be looked at as a three-step process:

1. Identify

2. Research

3. Prioritize

Constantly monitor product availability and serviceability

Provide “Intensive Care” Support for legacy installed base

Minimize surprises through Managed Migration Planning

Successful implementation of these initiatives will significantly minimize obsolescence risks and drive improvements in plant uptime as well as improve

corporate financial performance.

48

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Installed Base Evaluation™

50

Assessment Service Includes:

MRO analysis including location & optimization recommendations

Identification of automation discontinuation risks (RYG)

Identification of product lifecycle status via plant hierarchy

Benefit

Provides clear understanding of MRO stocking and discontinuation risks and opportunities for better storeroom and migration planning

Assessment of Customer’s Installed Base and Spare Parts Inventory


Reserved Repair

51

When repair capabilities become constrained or finite… only customers with Reserved Repair can be assured of

repair access

Guaranteed access to a repair, not a repair itself

Components secured in Rockwell Automation repair center

Testing equipment maintained

Technicians trained on old products

Documentation and systems

The Rockwell Automation reserved repair obligation ends when all reserved repairs are consumed OR when the contractual time period ends, whichever comes first

Quarterly reports are included


Extended Warranty (Assurance™ Integrated Support)

52

All support is provided for one fixed price

Repairs

Remote Support

On-Site Support

Holistic support that covers legacy equipment while your migration is taking place.


Legacy TechConnect℠

53

Benefits include:

Unlimited web support

One business day response

Technical assistance for

Installation

Configuration

Troubleshooting

Diagnosis

Basic programming

Access to Knowledgebase

Possible upgrade to phone support

“Self-Assist” Tech Support for Rockwell Automation discontinued and End of Life hardware


On-Site Support

54

Annual Scheduled Maintenance services and Migration/Conversion planning support

On-Site Support includes:

Assessment to

Record pertinent system/component data

Conduct environmental observations

Determine overall equipment condition

Standard inspections and tests to help verify equipment is operating to

specifications

Collected information and discussions with facility managers will be

used to construct migration plan

Benefits:

Provide visibility to changes in customer’s plant floor

Custom plan to support and migrate plant assets according to

customer’s needs

*Additional on-site services available


Parts

55

Parts Management Agreements confirm

ready access to critical spares by providing

Rockwell Automation owned inventory at

your site or a Rockwell Automation location.

• Fixed monthly/quarterly pricing

• Flexible over time

• In-service warranty on agreement stock

• Extended warranty option may be purchased


Last-Time Buy Contract

56

Rockwell Automation will

Manufacture/acquire requested quantity of product

Hold product in its own facilities

Deliver product in pre-determined schedule over contractual period

Benefits

Cash flow improvement

Buys extra time for your migration plan

Support of Rockwell Automation® products in the End of Life phase by providing a specified quantity of parts to be delivered over a specified

period of time


Embedded Lifecycle Engineer

57

A great option for customers:

With a large and diverse installed base of Rockwell Automation End of Life and Discontinued products

Who do not have enough time or personnel to maintain migration planning

A Lifecycle Engineer’s responsibilities include collaborating with the

customer to:

Identify and prioritize highest risk equipment

Provide solution recommendations through Hardware Engineering

Software Engineering

Commissioning Services

Develop comprehensive schedule for implementation of migration solutions

An engineer who is dedicated solely to the identification, mitigation, and migration of a specific customer’s discontinued RA assets


Migration Contract

58

Contract that provides product migration support through planning and execution

Migration that includes other services such as

Pre-Engineering

On-Site Support

Extended Warranty

Repair Support

Benefits

Multiple migration options

Phased

Complete Turnkey

Upon Failure

Opportunity for diverse product migrations

*Works well with Embedded Lifecycle Engineer

Documents

T83 - Lifecycle Extension and Migrations - Rockwell … · PMA’s are stored centrally at a Rockwell Automation facility. Generally, PMA’s require that Generally, PMA’s require