Introduction to Cloud Computing for Manufacturers: Demystifying the Cloud

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.

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Introduction to Cloud Computing Using Cloud Technology in Manufacturing to Drive Innovation & Insight

Connected Plant Connected Enterprise Connected Devices, Skids, Machines

Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved. 2

Agenda

RA Cloud Platform Demo

3 Customer Use Cases

Rockwell Automation’s Cloud Capabilities

The Value Proposition of Cloud Computing for Manufacturing

Microsoft Cloud Overview


Challenges in Manufacturing

Harnessing the power of data

Complying with complex regulations

Managing a mobile workforce

Collaborating in real-time


4 Megatrends We See For Our Growth


Cloud Design Principles

managed

automated usage based economics

elastic

always up. always on.


Computing Patterns

S M T W T F S

Capacity Needed (Max + 20%)

J F M A M J J A S O N D

Capacity Needed (Max + 20%)

t

Com

pute

Inactivity

Period

On and Off Growing Fast Unpredictable Bursting Predictable Bursting 24x7 Steady

Save 20-30%

Save 60-80%

On and Off (30%)

Growing Fast (15%)

Unpredictable Bursting (25%)

Predictable Bursting (20%)

24x7 Steady (10%)

Your Application Portfolio – What Does it Look Like..?


Microsoft Cloud OS vision

Providing a modern platform for the world’s apps

Customer

Service provider

Microsoft

1 CONSISTENT PLATFORM

Flexible development Unified management Common identity Integrated virtualization Complete data platform


Cloud Computing


Microsoft Differentiation

COMPUTE STORAGE NETWORKING BUSINESS INTELLIGENCE

DATA API

managed automated usage based

economics elastic

always up. always on.

hybrid open

flexible

New

Existing

+

hybrid

Other Service Providers

Your Data Center

Windows Azure


virtual machines web sites cloud services SQL database noSQL database blob storage connect virtual network traffic manager

. . .

Fra

mew

ork

s S

ervi

ces

Fab

ric

Infr

astr

uct

ure

N Central US, S Central US, N Europe, W Europe, E Asia, SE Asia + 24 Edge CDN Locations

. . . . . .

. . . . . .

. . .

Automated

Managed Resources

Elastic

Usage Based

Microsoft Azure – The Big Picture


The Value of Cloud for Manufacturing The Transformation of Manufacturing

Cloud Computing is a disruptive technology force in Manufacturing

Offers creativity, innovation & differentiation for our customers

Step change in simplicity & cost of ownership for Manufacturing IT assets

Enable new business models for every aspect of your value stream

Simplified integration with other Enterprise Systems (ERP, EAM, SCM, CRM…)

Big Data

Predictive Analytics

Analytics

Intelligence

Internet of Things

Machine to Machine

Access

Insight


The Evolution of Software Systems

12

Traditional IT

Storage

Servers

Networking

O/S

Middleware

Virtualization

Data

Applications

Runtime

Yo

u m

an

ag

e

Infrastructure

as a Service

Storage

Servers

Networking

O/S

Middleware

Virtualization

Data

Applications

Runtime

Man

ag

ed

by v

en

do

r

Yo

u m

an

ag

e

We m

an

ag

e

Platform

as a Service

Man

ag

ed

by M

icroso

ft

Storage

Servers

Networking

O/S

Middleware

Virtualization

Applications

Runtime

Data

Software

as a Service

Man

ag

ed

by R

A

Storage

Servers

Networking

O/S

Middleware

Virtualization

Applications

Runtime

Data

Our view… Customer’s view…


Cloud Value Prop for Manufacturing

Differentiated Solutions

Predictive Maintenance

Local deployments are difficult /

Assets are distributed across

broader geographies

Access to data to be shared across

corporations

Common requirements are shared

by many

Information Technology operating

costs are too high

There is a lack of technical

resources (Developing markets)

―Shadow IT‖ projects need to be

professionally managed

Enterprise data can be ―mashed-up‖

with public or syndicated data

Empower Your

Domain Experts

Scalable, Multi-Tenant Access for all Stakeholders

RA Accountable for Total

Lifecycle Mgmt (1BTK)

Creative New

Business Models

Better Cash Flow Management

(CapEx - OpEx)


Analytics Process Insight

Predictive Maintenance Big Data

RA Cloud Solution

Security

Object Model

Data Storage

Event Detection

Alerts & Notification

Workflow

Portal

Dashboards & Reports

RA Cloud Solutions Moving from traditional software deployment to Software as a Service

14

Site 1 Site 2 Site n

Cloud

Gateway

Secure, smart

efficient transfer of

plant data to the

RA Cloud Platform

Wired Wireless

Cell Satellite

Control Systems

Clo

ud

Pla

tfo

rm

Data

Tra

nsp

ort

D

ata

So

urc

e

Performance Mgmt Performance Mgmt

Equipment & Process Behavior & Optimization


RA Cloud Gateway Capabilities

15

Data Sources

Connector Plug-In Connector Plug-In

Connector Plug-In

Data Conditioning

Filter / Event Detection

Transform

Aggregate

Cloud Adapter

Formatting

Compression

Authentication

Connection Mgmt

Transition to/from

Store & Forward

Local

Storage Buffer

Store & Forward

Data Pump

Thread

Communication Thread

Variety of Form Factors wired : wireless : cell : satellite : gps


Cloud Application Platform

16

Model for the application

Security associated with unified model

Common set of (web) services

Application services operating against the model

Time Series Services and history storage

Calculation

Scripting

Business Logic - Eventing & Notification

Common UI (property grids, namespace explorer, …)

Common clients (Manager, Trend, XY Plotter, Excel Integration)

Cross-platform Thin UI

Workflow execution


Cloud Security

18

Object level security

Role based ACL (Access Control List)

ACL can be inherited from the parent

Authentication via federated security

Live IDs

Google IDs

Yahoo IDs

Integration with Active Directory

Server-side users (managed by us)

Other providers can be added


Rockwell & Microsoft Infrastructure Security


B

A

Supplier A

OEM A

Support Org

Customer 1

RA Support

Utilities

Corporate Headquarters

OEM B OEM C

Supplier B

Prod/Proc Designers

RA Cloud Platform

Cloud

Gateway

Secure, smart


device data to the

RA Cloud Platform

Customer 2 Customer 3

Data Sources

Quality Org

Simple, Secure Access for Key Stakeholders


Model Driven UI Complex Object

21

21

Model driven thin UI has driven most of the improved efficiencies in project execution…


Model Drive UI Mobile Ad-hoc Reporting Application

22

select report properties

browse model hierarchy

view current values

view history trends


Cross-Platform Visualization

23

Simple Graphics



24

Dashboard



25

Trending



26

Basic Workflow


Powerful On-Premise Clients Ad Hoc Analytics

Trend, XY Plotter


Powerful On-Premise Clients Ad Hoc Reporting

Excel Add-in


Software as a Service Solution Components

Application Configuration Model Development

Dashboard Development Business Rule Configuration

Workflows

Non-Recurring-Eng Costs Per Site/Asset

Cloud Gateway Hardware

Optional Cellular svc contract

GPS capability

SaaS Subscription Fee*

All ‘Compute’ infrastructure All ‘Data Storage’ infrastructure

RA Cloud SW Platform (per Asset) Support SLA

Optional Cell or Satellite Connection Fee

* Invoiced quarterly, annually

(minimum 3 year contract)

Each of these components can be built into the subscription fee


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Use Case 1 High Volume, High Value, Highly Distributed Assets

Supermajor O&G Producer


Pump Motor Performance Monitoring

Note: This is one of many equipment types with specific performance techniques. There are dozens others. This

one is selected as a moderately complex example with well understood broadly applicable physical principles.

Millions of Motor/Pump combinations in our customer base

Typically poorly monitored

Maintenance is usually reactive rather than proactive

Single customer estimates > $100M annual wastage

Calculate Motor Power from electrical inputs

Calculate Pump Power from fluid inputs

Compare dynamically

Notifications and alarms

Reporting and visualization


Motor Performance Calculations

Control System Inputs

Motor Speed (rpm): N

Motor Voltage (V)*: E

Motor Amps (Amps)*: I *Mean of 3 phases

Motor Power Factor: PF

Phase Angle: phi (if not measured lookup as Fn{L})

Constants

Nameplate rate current I_r

Nameplate rated voltage E_r

Calculated Outputs

Motor Load (%) L I*E/I_r*E_r*100

Efficiency, Motor eff_m 2D lookup table as Fn{L}

Motor Power (hp) mhp sqrt(3)*I*E*eff_m*(abs(cos(phi)))/746


Pump Performance Calculations

Control System Inputs

Pump Flow (gpm) Q

Pump Discharge press (PSI) Pd

Pump Suction press (PSI) Ps

Constants

Specific Gravity SG

Calculated Outputs

Efficiency, Pump, Expected eff_p_exp (Pd-Ps)*(2.31/SG)

Efficiency, Pump, Actual eff_p_act hhp/mhp

Head, Actual (ft) H_act 3D lookup table Fn{Q,N}

Head, Expected (ft) H_exp 3D lookup table Fn{Q,N}

Pump Hydraulic Power (hp) hhp Q*(Pd-Ps)/(1714)


Visualization Example


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Using Intelligence to Transform an Industry

Use Case 2


What is a L.A.C.T. Unit

The Lease Automatic Custody Transfer (L.A.C.T.) unit is a critical system

designed for the automatic transfer of ownership of liquid hydrocarbons

(crude oil and petroleum products) between the buyer and seller

On land – at every junction between production facilities, trucks,

railcars, pipelines or storage tanks

Offshore - into pipelines,

barges, and tanker loading

and offloading operations

The main objective of LACT unit

is to accurately measure, sample

and transfer the hydrocarbons

from between buyer and seller


The Value of a L.A.C.T. Unit

The greatest effect on volume is temperature — typical crude oil will

expand and contract at the rate of 2% per 40º F temperature change

The accumulation of errors present in the tank gauging may be as

high as 1%

The potential annual losses in revenue, based on daily lease

production and on $100 USD per barrel oil, would be as follows:

Daily Lease

Production Lost Revenue/Yr @ 1%

500 $182,500

1000 $365,000

2000 $730,000

3000 $1,095,000


Frustrations with the Current Approach

38

Visibility and access limited to site visits

Remote sites miles away

Operator errors go unnoticed

Delayed billings for Producers

No accountability for operations

Support/maintenance is difficult


RA Cloud Platform

Security

Object Model

Data Storage

Event Detection

Alerts & Notification

Workflow

Portal

Dashboards & Reports

A Perfect Solution - Asset Performance Management from Rockwell Automation

39

Remote Monitoring & Support

Real Time System Alarms/ Faults Event/Notification Mgmt

Predictive & Preventive Maint

Asset Performance Management Performance Mgmt

Improve LACT Efficiency Improve Profitability

Cloud

Gateway

Secure, smart


plant data to the

RA Cloud Platform


High Level Asset Status

40

USA Locations North Dakota

- Bakken S1120

- Bakken S1290

- Bakken N2415

- Bakken N2416

- Bakken N2417

- Bakken S3305

South Dakota

- Harding W4451

- Harding N2225

- Harding N2115

- Harding W1175

Oklahoma

- Hunton W7664

- Morrow S8874

Texas

- WT.W115

- WT.N9971


L.A.C.T. Unit: Key Performance Indicators

41


Real Time Alarm/Event View

42


Key Process Variables

43


Transaction Overview & Summary

44


Conclusions

45

Savings in supporting their installed base

Significant new revenue because of accountability for custody transfer

New levels of access to their equipment to:

Improve the performance of their equipment in the field

Improves the profitability of their supply chain

Reduce their support costs

Exciting new business/services opportunities

Differentiated capabilities & business model


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Competitive Differentiation; Building a New Services Offering

Use Case 3


Looking Forward…


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Zdenek Kodejs

RA Cloud Platform Application Demo


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Any Questions?