How OT Context Can Simplify Your

Digital Transformation Journey

June • 2020
Andrew Ellis • Director, Global Technical Consultants

PUBLIC
 Definition of context
Dictionary meaning 1: the parts of a discourse that surround a word or passage and can
throw light on its meaning
2: the interrelated conditions in which something exists or occurs
https://www.merriam-webster.com/dictionary/context

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 • You are going to a hockey game
How to think about • Boston Bruins vs Toronto Maple Leafs
context • Who will win?

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Agenda

1 2 3 4
Importance Of Factory of the What is driving How some
context Future this change companies are
benefiting

5 6 7
Keys to success How Rockwell is Wrap-up and
driving innovation take aways

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 Past and
Future,

Decision Making Ability

Broadly
Alarms
Performance Security Scoped

Sustainability At the
Product Control
Layer
Limited

Operator Diagnostics
Context Provided

What is the status of our machine?

Why is context Who is the operator on the line?

important? When is it next scheduled for maintenance?

What order are we running?
When will we need to replace the reels?
Are we meeting our OEE targets?
Are we on schedule?

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DESIGN
Engineering
• CAD – 2D and 3D designs
• PLM – BOM & configuration management,
change, bill of process
• ALM – Software lifecycle, requirements
• CAE – Simulation, behavioral modeling
• MBSE – Model-based requirements
and product structures
• Tech Pubs – service procedures
and parts catalogs
• Retail – Product line, seasons, supply chain
Corporate/CXO
• ERP – Item master, Inventory
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D I G I TA L T H R E A D
OPERATE MAINTAIN
Customer Service
• CRM/ERP/DMS/FSM – Service orders
• Warranty and service contract claims
• Product Cloud – fielded product telemetry
Customer Operations
• EAM/MRO – As-maintained configurations and history
• Product Cloud – fleet telemetry
Manufacturing & Supply Chain
• MES/MOM – Factory invoice and assembly detail, OEE…
• Sensor Gateway – Production process telemetry
• Historian – Production process event timeline
• SCADA – Gathering and analyzing real-time data
• WAGES – Sustainable Operations data
Sales & Marketing
• CRM – Sales invoices for products
• Enterprise Product Costing – BOM costs
6
 Factory of the
future, today
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The Factory of the Future requires a modern solution
Meeting the needs of internal and external consumers

Regulatory
Equipment Plant Director Sales
Affairs CEO
Operator Engineer Manufacturing Executive
Officer

Flexible
Data Driven
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Secure
Understanding the drivers
Convergence of Adherence to New commercial
business drivers regulations technologies

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Business
factors
New business demands are
encouraging manufacturers
to review their processes
Capturing and using data
• Integrated environment
• Put data into context
• We used to contextualize high in the
Arch, now we need to add context as
low in the stack as possible

Integrating the factory floor with

ERP systems
• Mature ERP systems
• Inflexible custom systems

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 Adherence to standards and regulations
Environmental regulations, quality • Transportation Recall Enhancement,
standards and tracking and tracing Accountability and Documentation (TREAD) Act
requirements, from industry and • 21 CFR Part 11
government, are creating a sense of • Information on demand (WEEE, RoHS and
urgency for more and better company-specific)
manufacturing information. • Sarbanes Oxley

Antiquated and paper systems cannot

satisfy the intricacies of these demands

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 Real-time information on demand
Off-the-shelf technologies Using automation Decentralized
in manufacturing to innovate manufacturing

Microsoft® Windows®, Data generated on factory Connecting “islands of

commercial network floor can provide significant factories” together into a
processors, more robust, insight that helps create single integrated
versatile databases, new products. manufacturing enterprise.
Web services, service-
oriented architectures Data collected as
(SOA) and robust products are built or
protocols for EtherNet manufactured also can be
such as EtherNet/IP. used to both reduce cost
and time-to-market as well
as increase innovation.

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 Traditional Approach
Customer Requirements
Compute

Execute
ERP

Historize

Control The Goal

Data Access Visualize

Typical Control & Automation

System
Data Access
Device Analytics Collaborate
Device Analytics & Compute
Historize Data
Manage Orders – MES/MOM (Execute)
Visualize and Collaborate
Traditional Approach
How it really gets done

ERP

Raw For Each Map to Data Access

Material Machine /
Tag Auto Discover of Assets

Map to Historian

Map consumption in MES

Map tag to IIOT

Each system creates

their own model!
Traditional Approach

Now do it for your Line,

your Plants, your Enterprise!
Time consuming Maintenance of No real master No leveraging of pre- Error-prone
to develop many models existing engineering

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Demand for an
integrated control and
information system
• Convergence of business drivers
• Adherence to regulations
• New commercial technologies

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Identifying the opportunities
The perfect order

What is the BUSINESS BENEFITS

Source: 2005 AMR Research study.

perfect order? 35%

30%
30%
1 No inventory
25%

2 No work in progress (WIP) 20%

15% 17%
3 Impeccable quality 15%

10%
10%
4 Optimum delivery 5%

5 Immediate payment 0%
Reduced OOS Inventory Fulfillment Improved C2C
improvement improvement times

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 Integrated systems and departments

Batch automation Automatic Improved efficiency

system + accounting + ordering and cost
finance effectiveness

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 Customer involvement
Manufacturers are including the customer more than ever.

Customer track from entry Web portal information CRM systems connected Improve warranty
through shipment exchange to manufacturing management and
catch recalls
(TREAD Act compliance)

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Compliance support

Improved products Better use of capital Superior workforce

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Helping suppliers
work together better

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The keys to success
 CRITICAL FACTORS
1 2 3

The right tools Commitment from End-to-end

and technologies senior management problem definition

There needs to be a mutual understanding of roles, business pressures, metrics used to

evaluate, functions, and most of all, the types of information needed for success.

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 Key attributes

Integrated Providing context Support for open Integrated suite Automation- Strategic
multidisciplined as low in tech IT networking of plant-wide and Information- alliances
control platform stack as possible standards information software enabled

Control Context is key; the lower EtherNet/IP Maximize ROI Scope of delivery No single entity can
in the tech stack, the provide everything
Visualization better Message Queues Automation layer Scalability/Modularity
information feed Leverage the strengths
Motion Leverage existing Beyond OPC and SQL Real-time information of your partners
engineering effort Relevant, real-time
Safety Context-enabled information Faster ROI 1+1=3
Consistent structure
Power
Available for higher-level
Analytics systems

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Acquisitions, inorganic investments and partnerships
Together with key partners, we help our customers bring the Connected Enterprise to life

DIGITAL
TRANSFORMATION

PROCESS

MODELING AND
ɅNSYS
VISUALIZATION

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 Kalypso is a
professional Consumer Industrial
High Tech
Life
Sciences

services firm. Strategy

We help our clients

Process
Consulting Operational Improvement
Organizational Change Management

discover, create, make Digital Product Creation

and sell better Digital

IoT
Extended Reality (AR, VR, MR)

products with digital. Advanced Analytics & Machine Learning

Product Lifecycle Management (PLM)

Enterprise Technology Master Data Management (MDM)

Product Portfolio Management (PPM)

Established in 2004 260+ Professionals

Acquired by Rockwell 400+ Clients Served Business Process Management Application Support & Hosting
Staff Augmentation
Automation in 2020 & Managed Services Project Support & DevOps

3 Innovation Centers
and Studios
30
C ONFI DENTIAL | Unauthorized use and disclosure prohibited Co p y right ©2020 Kalypso: A Rockwell Automation Comp any
How is Rockwell helping…
 How are we leveraging
Context to simplify the
solution?

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Smart Objects
aka “Context”
Analytics
Alarms

An automation
system built with
information in mind Smart
Object-based data model
• Common data across the system
Object
• Re-use and library management
at the automation layer
• Automatic discovery by the
information layer
Real-time
• Modern foundation for application
Recipe & historical
development data
Context at the source – the controller
Studio 5000 – developing models at the source

Instance of UDT - Wrapper

Wrapper

Machine

Speed

Order

UDT

Machine

Speed

Order

UDT – User Defined Type

Leveraging context for device analytics
FactoryTalk® Analytics for Devices – sharing context with ThingWorx

Benefits Pre-built Profiles

Leverage Existing Models

Auto Discovered and Mapped

OOTB Analytics and Visualization

Shared Model with ThingWorx

Pre-configured Mashups

Context and Data Shared with DataView

Leveraging context for FactoryTalk® Historian
FactoryTalk® Historian – consuming the UDT and sharing context with ThingWorx

Benefits Develop Asset Model (AF) from UDTs

Contextualize Time Events (EF)

FactoryTalk Historian to ThingWorx Connector

Shared Model with ThingWorx

Context and Data Shared with DataView

Leveraging context for ThingWorx
ThingWorx – using the UDT to develop Thing Templates and Things

Benefits Configured solution (not developed)

Create Thing Templates from UDTs
Create Things from UDT Instances
Leveraging Context for MES
FactoryTalk® ProductionCentre – using a UDT for MES context

Benefits Consistent way of providing context to the PLC

Auto-wiring of new pieces of equipment using the UDT

Configured solution (not developed)

Create Thing Templates from UDTs

Create Things from UDT Instances

Share context with IOT and AR

•Retrieve complex data structures such as the Batch Record

•Ensures Data Integrity

 The Evolution of Models and Context
Distributed New Context can be
The basis of the Digital Thread Models Added

IOT Build Upon

layers
below and
above
MES ERP

Systems
Each layer decides
will Adorn
Virtual Model their Model what context to use

Each layer can “own”

Control
their content Functional
Maintain at the Ownership
Appropriate Layer

Analytics
It will
Evolve
Coming Soon!
 Connecting OT to IT Systems Summer 2020!
Made even easier…

Collects and preserves the context of the data

in the controller through Smart Objects (and
other data structures)

Discovers Smart Objects and allows context to

be edited or created on the edge for 3rd Party, Configuration UI
legacy or controllers that can’t be changed

Security Service
Usability targeted for the OT practitioner
Device
Benefits

Management
Service
Time
UI / workflow / security aligned with our Series
Data
Automation tools
Ingress Data Process / Local Egress
Model analyze Store
May be sold standalone – or as an enabler to
an information solution – reducing the work
required to organize and label data

Designed to run packaged applications on the

edge, which include data collection,
calculations, even visualization of data (future,
sold separately)
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Wrap Up
 Reduced Minimal model Each system “owns’ Ability to leverage Reduced errors as a result
development time maintenance their context existing engineering of automation

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Integrated control and • Understand what we mean by context in an OT / IT infrastructure
• The driving factors our customers are experiencing
information systems: • How customers are reaching their goals today

today •
•
How Rockwell Automation is making it easier – today!
Some insights into the future…

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Thank you
www.rockwellautomation.com