P RE -MES A SSESSMENT

Indias Largest Cigarette Manufacturer

Green~Wave Solutions partnered with Indias largest cigarette manufacturer to deliver a blueprint for MES adoption at their largest factory. The study included IT-OT integration readiness assessment from both infrastructure and operational perspectives

Green~Wave Solutions December 2011

Green~Wave Confidential

1/1/2011

PRE-MES ASSESSMENT
Indias Largest Cigarette Manufacturer Scope:
To Assess IT-OT integration readiness of Indias largest cigarette manufacturer and ensure that the shop floor infrastructure and operations are ready for the adoption of Manufacturing Intelligence Applications

Challenge:
The Control and Automation Infrastructure of the client was complex and heterogeneous and was isolated from their corporate IT set-up. The challenges faced by the client were: PLCs were from numerous OEMs and some of them did not support OPC The plant network was not seamless and there was an unsecured PC based connectivity with corporate IT network No security measures including anti-virus and patch updates for HMIs There was no password policy for the HMIs Lack of asset, configuration and change management guidelines The incidence and problem management processes were manual Lack of clarity about must have and nice to have reports

The Solution:
Green~Wave Solutions deployed a team consultants comprising of Manufacturing experts, Automation Professionals and IT experts to assess the environment and applied a Green~View 360 methodology to recommend the following Seamless Data Extraction strategy from the level 2 devices. For few non-OPC devices custom script was devised and for the rest an upgrade or refresh path was suggested The plant network blueprint along with secured firewall and DMZ based connectivity was submitted to the stakeholders and was approved Implemented schedule based and push based virus protection Password policy for all shop floor workstations and HMIs was enforced ITIL based incidence, change and problem management strategy was devised and trainings conducted Asset Management software blueprint was tabled ABC analysis for MI reports was conducted and a modular approach was tabled for their MES roadmap

Green~Wave Confidential