Cisco presentation in RAOTM 2012, HCMC Vietnam

Cisco Smart+Connected Manufacturing
Operations Excellence
Phan Thanh Son
CTO, Cisco Vietnam

Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential 1

My IT, Communication, Industrial Convergence

Communications IT Industrial

1988 1989 1994


Achieving Operations Excellence
for more Flexibility and Productivity

 Make more informed business decisions using
improved collaboration with real-time production
visibility linked to business context
 Enhance event response, with immediate collaboration
for faster resolution to downtime and production issues
 Improve productivity—quality, performance, cost—of
production and people with unified communications and
control infrastructure


Complex Manufacturing Environment
Globalized Operations Need Efficiency, Agility
Machine Raw
Power Plant Materials/
Builder
Exploration

Manufacturing
Plant Headquarters Supplier

Distributor
Supplier
Retailer

 Rising energy costs  Flat world competition
Pain  Aging and remote workforce  Product proliferation
 Globally distributed operations  Asset optimization
Points
 Customer support time zones  Rapidly changing demand

Manufacturing Operations
Business Pressures and Priorities

Reduce Production
Reduce Costs
Variability

Optimize Asset
Ensure Quality
Utilization

Competitive Improve
Advantage Collaboration

Synchronize Plant
Profitability and Corporate
Targets Objectives

Globalization Visibility for
Decision Making

0 10 20 30 40 50 60 0 10 20 30 40 50 60

All Others All Others Best in Class

Source: Manufacturing Performance Management, Aberdeen Group, May 2009

Top Business Priorities for Top Strategic Actions to
Manufacturing Operations? Achieve Business Objectives?


“This is about a business change,
to make our manufacturing
facilities more flexible, more
agile and more lean.”

Kirk Gutmann,
Global Information Officer,
Manufacturing and Quality, General
Motors Corporation


Operations Excellence

What If Production Issues Could Be Identified
and Collaboratively Resolved Immediately?

Industrial Automation 3.0:
Converged Plant Architecture

Integrated Real-Time Enhanced IT and
Collaborative Mobile and Sensor
Business and Asset Security and Control
Tools and Remote Enabled
Plant Data Tracking & Personnel System
Processes Workers Manufacturing
…Multi-Site Monitoring Tracking Flexibility

Traditional Plant
Plant of the Future
Restricted and Real Dynamic, Integrated
Isolated Mobile, Real-Time
Static Environment
Time Connected
Environment
“Solid State”
“Liquid State”

Source: AMR, Industry Week, Cisco Analysis

Challenges in
Achieving Operations Excellence

 Communication and collaboration across the value
chain and down to the factory floor
 Integrating innovation processes with operations
 Converging plant floor automation with business
networks and systems
 Real-Time access to information and knowledge
 Security

“Manufacturers must integrate product innovation with operations excellence
to deliver complete customer value. An improper balance often leads to new
products that are unprofitable to deliver or high-margin products that lack
differentiation or strategic market impact.”
Source: AMR Research

Manufacturing Excellence
Availability Training Communications

Safety Automation Energy

Risk
Delivery
Asset
Sales
Procurement Smart +
Connected
Manufacturing Service
Visibility
Satisfaction
Warehousing

Collaboration Communication

Intellectual Property

What Is Smart+Connected Manufacturing?
“Intelligent, timely information and collaboration in
Definition context for superior business results”

Benefits Solutions Portfolio

 Accelerate time to market for new  Continuous Innovation
products
 Create a consistent, differentiated  Customer Intimacy
customer experience
 Adapt your supply chain to changing  Supply Chain Agility
markets
 Improved operations efficiency  Operations Excellence


Portfolio of Solutions to Enable Converged
Plant Architecture
Ethernet to SAFE for Secure Context Aware
the Factory Process Control Wireless Plant Solution

 Integrated plant and  Protect critical control  Integrated sensor and  Visibility into material
business networks system assets WLAN networks and asset status
 Secure visibility and  Secure visibility and  Improved productivity  Accurately locate
remote access remote access through mobility people and assets
 Control system  Enable new applications
flexibility

Video-Enabled
Industrial Wireless Unified
Plant VoWLAN Collaborative
Video Surveillance Communications
Production Management

 Intelligent video  Access experts in  Improve productivity  Collaborate and share
monitoring and security real-time and issue information, video, and
response time voice to solve issues on
 Collaborate with design the plant floor
teams and suppliers  Enable effective mobile
communications  Extend remote SME
across the globe
 Share knowledge and
best practices

Architecture for Manufacturing
Communications and Controls
Network Architecture for Manufacturing Convergence
Stand-Alone Networks, Information Silos,
Go From
Single Purpose, Proprietary

Corporate Network
Of f ice Applications,
Back-Of f ice Internetworking,
Mainf rames Data Servers,
and Servers and Storage
Control Network
Gateway
Human
Machine Programmable
PC-Based
Interf ace Logic Controllers
Controllers

Motors,
Drives, and
Actuators
Robotics

Control Network
Device-Level Network Sensors and Other
Ethernet Input/Output Devices


Integrated Platform, Standard Architecture
…To
Enabling Real-Time Visibility and Collaboration

Corporate Network
Of f ice Applications,
Back-Of f ice Internetworking,
Mainf rames Data Servers,
and Servers and Storage

Industrial
Video

Human PC-Based Programmable
Machine Controllers
Robotics Interf ace Logic
Sensors Controllers
and Other
Input/Output
Devices



Reduced Standard Remote
Manufacturing Global Support for
Downtime Architecture Faster MTTR


Ethernet to the Factory
“How-it-Works” Example

1 2 3 4
 Visibility into  Log into automation  Check network  Access automation
production system with secure status through system and devices
performance issue remote access FactoryTalk to identify and
at one plant capability integration resolve issue

 Improves visibility into production systems for faster issue identification
Business  Reduced travel time and cost
 Faster response and resolution to issues reduces downtime
Value  Prevents security incidents and unauthorized access

Improve Operations Efficiency Connecting
a World Wide Manufacturing Operation

Standardize
operating model
Network is a key part
globally
of the infrastructure to
build and deliver
vehicles

All devices in the
plant are connected
to the central
system, including
robots and PLCs

 Single system to see what’s going on in all the plants
 Reinvent how GM makes cars and trucks
Business  Get access to the right people at the right time to fix issues quickly
Value  Reduced network downtime 95%
 Moved from chaos and firefighting to innovation

SAFE for Process Control
Disparate Networks, Limited Visibility,
Go From
Control Network Security Issues

 Limited real-time
information visibility
 Multiple networks
 Downtime and
productivity issues due
to security incidents
 Poor asset utilization
and performance


Secure Connectivity Between Plant and Business
…To
Systems, Visibility Into Production Systems

 Secure connectivity
between plant and
business systems
 Real-time information
visibility
 Secure architecture
 Remote access



Quicker Better Plant
Improved
Response to Reduced Performance
Asset
Production Downtime with Real-
Utilization
Issues time Visibility


Drivers for Manufacturing Wireless Applications
More Points of Visibility and Control

 Eliminating Wires and Cables
Increase reliability
Reduce installation cost
 Remote Device Monitoring
Troubleshooting/maintenance
Instrumenting existing machinery
 Tracking Assets
RFID
Real-Time location services
 Enabling Portability and Mobility
Mobile HMI (People)
AGVs (Equipment)
Communications (VoWLAN)
 Video Surveillance
Security and process monitoring
 Guest Access


Secure Wireless Plant
Secure Wireless Network for Sensors and Advanced Solutions

Expensive Sensor Deployments, Multiple Isolated
Go From
Networks, Limited Worker Mobility and Asset Tracking



Integrated Wireless Sensor and Information
…To
Network, Plant Wide Mobility and Access



Efficient
Deployment of
Improved Enhanced
Increased Plant Wide
Asset Worker
Visibility Wireless
Utilization Productivity
Applications
(Location, etc.)


Context Aware Manufacturing
Lack of Information, Lost WIP Assets,
Go From
Unresponsive Supply Chain, Regulatory Challenges

High Scrap Rate Lost Inventory

Safety Challenges Labor
Inefficiencies


Holistic View of Assets, WIP, Inventory and People with
…To
Interactive Real-Time Responsiveness
In-Use
Status

Location

Over Cisco
Unified Wi-Fi
Network

Condition


Use Case

“AeroScout eliminated the manual scanning
process and removed human error.” says Matt
Miesner, Six Sigma Blackbelt at Viracon, “We went
from between several hours to several minutes to
find a carrier, down to less than a minute.”

* Matt Miesner is a Six Sigma Blackbelt at Viracon

“How-it-works” Supply Chain (WIP) Example

1 2 3
 MES system provides  System provides rack  Visual blinking indication
next Job number and lot location on tag speeds up
is displayed on map detection

 Reduces several minutes per each operation, over hundreds of process
Business steps over previous manual operator search process
Value  Significant improvement in production throughput over manual system


Improve Operations Efficiency
Cisco Context Aware Solution
1700 critical parts,
plus tools and
machines in the
factory have RFID Advanced wireless
tags and can be technology from Cisco
located instantly used to overcome
dead spots in the
building

Because each
component has a
unique tag, items
can be better
identified to resolve
service issues

 Improved productivity due to ability to quickly locate parts and tools
Business  Enhance parts traceability and reduce cycle time to solve in-service issues
Value  Reduced production delays and government fines

Source: Cisco® Customer Systems, Inc. Transformation Group
Presentation_ID © 2009 Cisco Business All rights reserved. Cisco Confidential 29

Industrial Wireless Video Surveillance
Limited Plant Wide Security Visibility, Disparate
Go From
Security Networks, Expensive Deployments

 New security and
compliance requirements
 Difficult remote
equipment and process
monitoring
 Expensive, disparate
video systems
 No plant wide visibility


Integrated Video Surveillance Systems,
…To
Efficient Deployment, Improved Security

 Industrial video surveillance
 Efficient deployment on Cisco wireless architecture



Open Industrial
Improved Integrate
Architecture Grade
Plant Safety Into Plant
for Efficient Security and
and Security Applications
Deployment Monitoring


UC for Manufacturing
Provides Collaboration Across the Value Chain
for Improved Shop Floor Communications
Real-Time Emergency Contacting Production Performance Tracking

MES Interfacing; Equipment ERP Interfacing; Inventory/Supply
Downtime Alerts to Phone Chain Alerts to Phone

Plant Voice over Wireless
Multiple Communication Devices and Networks,
Go From
Limited Access and Communication on the Plant Floor

 Limited communications
outside of control rooms
 Separate networks for
“walkie talkies”
 Multiple devices and
missed communications
 Limited access to
applications and data


Plant Voice Over Wireless
Real-Time Collaboration Across the Plant,
…To
Mobile Application Access, Integrated Networks

 Effective communication
across the plant
 Single device for desk
and mobile
communication
 Access to data and
applications on IP phone
or other mobile device
 Support for Cisco and
partner devices


Plant Voice Over Wireless

Efficient
Reduce Improved
deployment
unplanned communication Eliminate
on Cisco
stoppage for issue silos of
Unified
times by up notification communication
Wireless
to 50% and resolution
Network


Increasing Productivity and Cost Metals and Mining

Savings on the Plant Floor Using UC Major Use Case

1 2 3
 Smelter operator needs  Pulls up critical  Makes process change
to check process data to production data on PDA accurately and rapidly
make adjustments via PDA
 Calls operator in another
location to discuss
change using soft-phone
on PDA

 Eliminated three to four wasted hours walking to control room per shift
per operator
Business
 >80% faster operator decision making
Value  50% reduction of physical control rooms
Presentation_ID © 2009 Cisco Systems, Inc. All rights reserved. Cisco Confidential
Source: Cisco® Customer Business Transformation Group
38

UC Can Help Reduce US Refining

the Response Time in Crises Major

Case Example: Responding to Equipment Failure in the Refinery

1 2 3 4 5
 Equipment failure  Partner extension to  Enter the meeting  Meeting Room  Conduct meeting
in the refinery that MeetingPlace to through touch- appears on your PC with ‘show and tell’
can cause quickly initiate a screen on IP bringing together all of equipment set-up
production loss and blast dial for phone key participants in and action plan
safety issues emergency minutes
personnel with up to
3 pre-populated
phone numbers per
individuals

 Improved employee safety
Business
 Faster incident response and resolution
Value
 Higher refinery uptime and production

Video Enable Collaborative
Limited Visibility and Collaboration with Plant Floor,
Go From
Inefficient Resolution of Production Issues

 Globally distributed operations
 Limited remote access and collaboration across global production sites and suppliers
 Slow, expensive issue resolution


Real-Time Collaboration Using Voice, Video, and Web
…To Conferencing Across Global Plants, Enterprise, and Suppliers

 Streaming mobile voice and video from the plant floor
 Share video across company and with partners using WebEx
 Find experts using TelePresence
 Integrated with Unified Communications & Cisco WLAN for efficient interoperability


Improve
Capture and
Quickly Productivity
Share Videos
Resolve and Reduce Extend SME
for Best
Issues to Costs Across the
Practice and
Reduce Due to Globe
Knowledge
Downtime Reduced
Sharing
Travel


Enabling Faster and More Effective
Response to Plant Floor Issues

Alert Connect with
Plant Floor Issue Engage
Employee central support
Camera
Onsite

Remote Expert
Onsite Expert Need to Find
Resources/ and/or CUPC An Expert
Central Technical audio/video Internally
Support call

Share via Need to connect
Internal TelePresence* with Supplier
Experts and WebEx Externally

External IM and WebEx Publish on Portal
Suppliers with Supplier Show and Share

*TP/WebEx integration and multi-conferencing need testing and validation

TelePresence for Manufacturing

Accurate planning can be Use TelePresence for Improved business agility,
hampered by inefficient more efficient, effective reduced supply chain
communications communication and costs and improved
collaboration forecast accuracy

 Distributed participants
 Short timeframe to act
TelePresence Value  Collaborative decision has high business impact
 Complex information to share
 Multicultural participants

Plant Floor Safely and Securely Connected with the Enterprise
 Integrated key expertise through voice, video and access to applications improving operational efficiency
 Increased information on plant process and assets by extending sensor network and adding location determination
 Reduced cost by relying on standard network
Security and Network Administration
Wide Area
Plant Wi-Fi Network Plant DMZ Plant IT Network Network

Wireless Location
Controller Engine
Industrial Wi-Fi Mesh and Location Receivers Core
Video Routers
Plant Floor Si Si

Managers,
Terminal Engineers
Server Distribution
Manufacturing Routers Si Si

Router
Location
Chokepoint Access
Location Switches
Tags ERP, etc.

Automation and Enterprise
Wi-Fi Voice Control Applications

Industrial Switch Internet
Wireless Sensor Cell/Area IT Servers
Network Automation and
Control Devices

Wireless, Video
and Voice Servers
Sensor Mesh Teleworkers/
Network Video Customers
and Partners
Voice
Ethernet
Remote


Plant Floor Safely and Securely Connected with the Enterprise
 Integrated key expertise through voice, video and access to applications improving operational efficiency
 Increased information on plant
Safe and Secure Plant Integration process and assets by extending sensor network Response location determination
Improve Operational and adding
 Reduced cost by relying on systems
 Tightly manage access to plant standard network  Key experts respond to issues with access to plant
 Control flow of traffic and data between key zones Security and Network Administration access to voice and video
applications and
 Mobile technicians stay in touch and have accessWide Area
Plant Wi-Fi Network Plant DMZ to key data Plant IT Network Network

Wireless Location 1
Controller Engine
Industrial Wi-Fi Mesh and Location Receivers Core
Video Routers
Plant Floor Si Si

1
Reduce Terminal
Support Costs 3
Managers,
Engineers
Server Distribution
Manufacturing  Rely on IT for support on standard networks
Routers Si Si

Extend Visibility into Plant Processes
Location
Router
Chokepoint 2  Reduce the number Access
of technologies supported
 Location
Improve operational efficiency with more Switches
Tags
information by cheaply deploying additional 3
ERP, etc.

sensors and devices Automation and Enterprise
Wi-Fi Voice Control Applications
 Reduce loss and search time with location context
of mobile assets and product Improve Support Industrial Switch
and Decision Making Internet
Wireless Sensor Cell/Area IT Servers
Network  Enterprise-based users access up to date
Automation and
Control Devices
operational status
 Enterprise applications integrate real-time
2
with plant floor applications Wireless, Video
and Voice Servers
Sensor Mesh Teleworkers/
Network Video Customers
and Partners
Voice
Ethernet
Remote


Roadmap to Operations Excellence
SAFE for Context-Aware Secure Wireless Industrial Wireless
Process Control Solutions Plant Video Surveillance
WebEx

Achieve real-
Efficiently Boost efficiency Communicate in
time visibility Locate and track
expand plant- and security of real-time,
and integration valuable assets
monitoring manufacturing regardless of
with business and resources
capabilities assets location
systems

Deploy rapidly
Protect and Integrate data, Optimize the Improve
and cost-
secure voice, video, movement of efficiency and
effectively in
production and sensor material and mobility of
harsh
assets networks people communications
locations

Ethernet to the Secure Wireless Location-Based Industrial Wireless
Plant VoWLAN
Factory Plant Services Video Surveillance


Smart+Connected Manufacturing
Operations Excellence Benefits
Business Results Operations Excellence

 Create flexibility to react to  Provide real-time
changes in demand and market communications to factory
needs floor personnel
 Improve efficiency, reduce cost  Manage operational risk and
and decrease idle time improve compliance
 Identify and respond
collaboratively to process
exceptions in ERP workflow

48

Additional Material
Cisco and Rockwell Automation Alliance

 Website
http://www.ab.com/networks/architectures.html

 Design Guides
CPwE DIG 2.0

 Education Series
 Whitepapers
• Securing Manufacturing Computer and
Controller Assets
• Production Software within Manufacturing
Reference Architectures
• Achieving Secure Remote Access to Plant Floor
Applications and Data


Cisco & Rockwell
http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html


Reference materials


Cisco Vietnam
 Opened office in Vietnam since 1999
 60 people in HCMC and Hanoi offices:
Hanoi office is moving to VN tallest building by end of July 2012
HCMC office: 9th floor Saigon Trade Center, 37 Ton Duc Thang, HCMC
 Web site: http://www.cisco.com/VN/
 Toll free: 1800 585807, vn-support@external.cisco.com
 Distributors: Ingram, FPT Distribution
 Partners and resellers: more than 300
 Segments: Service Provider, Public Sector, Enterprise, Mid-market, SMB and Consumer
 IT: 45 Mbps HCMC-Singapore, 20 Mbps Hanoi-Singapore, TP, VC, etc.
 Cisco & Rockwell:
http://www.cisco.com/web/strategy/manufacturing/cisco-rockwell_automation.html


Connected Manufacturing Book
http://www.cisco.com/web/about/ac79/docs/wp/ctd/ConnectedManufacturingFINAL.pdf


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Cisco presentation in RAOTM 2012, HCMC Vietnam

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