Учебники CALS(SE) / Enterprise Control Systems Unify Manufacturing and Business Systems to Provide Operational Excellence
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ARC WHITE PAPER
By ARC Advisory Group
APRIL 2007
Enterprise Control Systems Unify |
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Manufacturing and Business Systems to |
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Provide Operational Excellence |
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Executive Overview .................................................................... |
3 |
Customer Requirements Are Business Requirements........................ |
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ECS Is a Unified Environment for Collaborative |
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Operations Management.............................................................. |
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What Is InFusion Enterprise Control System? ................................. |
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The Business Value Proposition of InFusion ECS............................. |
12 |
Recent Successes and the Road Ahead ......................................... |
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THOUGHT LEADERS FOR MANUFACTURING & SUPPLY CHAIN
ARC White Paper • April 2007
InFusion ECS Bridges the Gap between Automation Systems and Enterprise Systems
InFusion ECS Supports ARC’s Vision for a Collaborative Operations Management Environment
2 • Copyright © ARC Advisory Group • ARCweb.com
ARC White Paper • April 2007
Executive Overview
The process automation system is the manufacturing industry convention for controlling continuous and batch processes for all of the process industries from refining and petrochemical to pharmaceuticals, food & beverage, and power generation. Taking measurements from the field, the system uses this information along with previously established setpoints to control the process stream or production line in an prescribed manner. At the same time, the process automation system provides connectivity with production management systems, plant level asset management systems, and other
systems in the plant to create a unified platform for engineering, operations, and maintenance that ARC refers to as the Collaborative Process Automation System (CPAS).
What if you could take the concept of a Collaborative Process Automation System and elevate it to the level of the manufacturing
enterprise? Instead of controlling one plant or location, you would have a single view of the performance of all of your supply chain. This view would show not only how each individual plant or location is performing, but also how this performance affects all the other plants and elements of the supply chain, from raw materials through manufacturing and distribution. In addition to visibility into the performance of the enterprise, you would also of course have a means to close the loop and control the performance. Since this “Enterprise Control System” or ECS essentially operates at a business level, the system would also provide a real time view into the economic impact of manufacturing and its contribution to overall profitability.
Of course, this ECS would have to work in an environment with disparate applications and platforms from multiple suppliers. The ECS would be a collaborative framework where all the key applications in the enterprise would converge and the wealth of information from these applications could be turned into useful data that could drive business decisions to increase competitiveness and reach optimum performance.
This is what Invensys has done with the introduction of the InFusion Enterprise Control System (ECS). Released in 2006, InFusion ECS fulfills the vision of an enterprise level control system and conforms to ARC’s vision
Copyright © ARC Advisory Group • ARCweb.com • 3
ARC White Paper • April 2007
for a Collaborative Operations Management platform. The full impact of what InFusion ECS really means to the overall marketplace is yet to be realized. This paper will examine just what InFusion ECS is and what it really means for the process manufacturing industries.
Customer Requirements Are Business
Requirements
The business environment surrounding the world of manufacturing has changed to embrace global competition, agility, lean manufacturing practices, and maximizing return on investment. End users are finding it increasingly difficult to justify automation purchases based solely on technology. Automation must provide solid business value benefits based on a combination of metrics, such as enhanced asset availability, return on as-
sets, reduced lifecycle cost, and many other strategic and financial objectives. The enterprise control system (ECS) addresses these requirements and provides end users with a real business value proposition.
Superior |
Maintenance |
Reduction |
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A Large and Diverse Legacy
Installed Base
The legacy installed base of disparate systems and data is another challenge facing end users today. The landscape is cluttered with a variety
of disparate legacy systems, most of which are not really integrated with one another and are reaching the end of their useful life. ARC estimates there is an installed base of process automation systems worth roughly $65 billion that are at or near the end of their useful life. This in turn presents a migration challenge for end users, who must balance the preservation of installed assets with the need to respond to new business opportunities.
4 • Copyright © ARC Advisory Group • ARCweb.com
ARC White Paper • April 2007
SKILL LEVEL
Data Abounds, but Not Useful Information
Technology has created proliferation of data throughout automation systems and enterprise level systems. This issue is only compounded with the introduction of wireless sensors and lower cost measuring points, and process fieldbus technologies. Unfortunately, turning all of this data into useful information is more of a challenge. Many applications facilitate the presentation of data as useful information, but few do this in a manner that is easy to use and implement.
The Labor Challenge: Avoiding the Brain Drain
The manufacturing industries continue to be faced with a shrinking workforce, and along with it a shrinking pool of knowledge and experience. Organizations have been planning for the change in worker demographics for years, however, the ensuing step change in the work force domain
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knowledge and associated loss in |
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Productivity |
competency has been wholly un- |
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anticipated. The |
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of |
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Quality |
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Process Engineers |
Labor Statistics claims that by |
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2010, more than 25 percent of the |
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working population |
will reach |
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age. |
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statistic |
is |
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even more |
alarming |
for the |
oil |
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and gas industry, which could |
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lose more than 50 percent of its |
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by 2010. |
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Exacerbating the problem is the |
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fact that finding younger re- |
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Quality and Productivity Is Dependent upon |
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becoming |
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Knowledge Capture of Skilled Workers |
extremely difficult. |
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A Common Actionable Context Empowers the
Knowledge Workforce
Overall, the loss of skilled workers reduces an organization’s ability to identify production problems and take corrective actions that eliminates or mitigates any detrimental affects. In addition, the loss of intrinsic process knowledge and production knowledge from the retirement of production personnel significantly erodes their ability to sustain operational excellence initiatives and implement continuous improvement programs. Companies
Copyright © ARC Advisory Group • ARCweb.com • 5
ARC White Paper • April 2007
Performance Model
Performance
Metrics,
Targets, operational & costing data
are in dire need of ways to capture and retain the knowledge of their existing workforce and transfer that knowledge to a collective information system that can be leveraged throughout a global manufacturing operation. Collective knowledge is an information reservoir that will effectively enable organizations to improve productivity beyond any econometric projections. Companies must look to replace intellectual capital with automated intelligent solutions.
ECS Is a Unified Environment for Collaborative Operations Management
The territory occupied by what most people think of as the traditional DCS is represented in ARC’s model for collaborative process automation systems (CPAS). While CPAS focuses on control of the plant and related functions, the ECS occupies the space 
that ARC calls Operations Manage-
ment, which incorporates many of the
same principles as CPAS but operates
at a much wider level across multiple
plants and the manufacturing enterprise.
ECS overlaps with ARC’s mode for
Collaborative Operations Management in several respects. Today’s supply networks are distributed around the globe. Manufacturers need a single approach that can sup-
port all of their globally distributed operational activities. ARC’s Collaborative Operations Management model is the management of those activities that coordinate personnel, equipment, material, energy, and information in the conversion of raw materials or parts into products, and the management of those activities across multiple facilities.
In some cases, this can extend to coordinating manufacturing and logistics operations within a network that extends around the globe and across multiple businesses. Business systems need manufacturing information about product, materials, operators, equipment, and more for financial, planning,
6 • Copyright © ARC Advisory Group • ARCweb.com
ARC White Paper • April 2007
materials, and human capital management. Process automation systems, production management applications, and ERP systems need consistent information from each stage of production in order to be effective and to enable continuous improvement.
The variety of applications found throughout manufacturing operations need to be better coordinated in order to improve overall performance. The COM model calls for a solution that can be created, deployed, and managed at an enterprise level, while supporting individual plant requirements for receiving, storing, and shipping material, allocating and tracking labor, deploying capital equipment and tools to manipulate or move the work, and all the other activities that keep a manufacturing enterprise running.
Collaborative Operations Management enables distributed manufacturing operations to gather and analyze the data needed to make effective decisions. COM goes beyond providing visibility and corporate decision support. In principle, it services all operational functions of a distributed manufacturing company, unifying the various convergent dimensions of manufacturing, including business processes and enterprise level functions, manufacturing processes and operations, management of resources, and most importantly performance management that encompasses the entire manufacturing enterprise. The Enterprise Control System does a good job at eliminating the barriers to provide a unified, common environment for the management of all three of these manufacturing dimensions.
What Is InFusion Enterprise Control
System?
Primary InFusion Components
•InFusion Application Environment
•InFusion Access
•InFusion Historian
•InFusion Collaboration Wall
•InFusion View
•InFusion Remote View
•InFusion System Manager
•InFusion Engineering Environment
•InFusion Field Device Manager
What is InFusion and what makes it unique? This discussion is probably best prefaced by describing what InFusion is not. InFusion is not a “new DCS” from Invensys and is not designed to replace the I/A Series system, A2 system, or any other DCS offering supported by Invensys Process Systems. InFusion is designed to operate at a level above where the traditional DCS operates, providing a single information space throughout the enterprise and across multiple process control domains. InFusion can retrieve and
Copyright © ARC Advisory Group • ARCweb.com • 7
ARC White Paper • April 2007
incorporate data and information from any element of the control system at any time. In fact, InFusion is designed to aggregate the data and information provided by DCSs, safety systems, production management applications, and enterprise level systems into a unified environment.
By using a common actionable context, every person in the company can be empowered to access the information they need at the right time. InFusion also has the ability to capture the knowledge of workers so that knowledge can be reused and distributed throughout the enterprise. All of this is done in an environment that incorporates the same determinism and high availability that is found in the process automation system.
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Business
Performance
Management
Secure Control InFormation Network
InFusion View
Asset Set
Optimization
Fault-Tolerant 1 GB Mesh Control Network
I/A Series
Mobile Operation
Station
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Internet
Suite Voyager
Collaboration Wall
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InFusion Historian |
IEE & Galaxy Server |
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Engineering |
Base Asset Management |
Environment |
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DIN |
Installed DCS |
Rail Mounted |
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Distributd Control |
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Safety System
InFusion Logical View
How Does It Work? The ECS Infrastructure
How does InFusion accomplish this task? InFusion is a combination of a framework that binds everything together and executes necessary tasks combined with a set of applications and tools. The glue that provides the integration of all these systems and applications is the ArchestrA technology developed by Invensys several years ago, which is already installed in
8 • Copyright © ARC Advisory Group • ARCweb.com
ARC White Paper • April 2007
over a thousand plants around the world, and which Invensys has dubbed an Industrial Service Oriented Architecture. InFusion also relies heavily on Microsoft technology and offers close integration with SAP and other ERP systems. The following is a description of the InFusion components and applications that are available today, but the future development path calls for more extensions to be added to InFusion in the near future, from Triconex safety applications to SCADA applications and more. InFusion will be a constantly and consistently evolving offering that will eventually incorporate all of the automation expertise of IPS.
InFusion Application Environment
Two of the most important basic components of InFusion include the Application Environment and the Historian. The InFusion Application Environment is a plant information and automation software environment that brings together all aspects of the plant in real time. Application objects are the core component of the InFusion Application Environment and represent various functional elements that can contain data, execute programs, or transact information in real time.
Inside the Application Environment, users and developers can engineer application objects that can represent anything in the plant, not just control elements. For example, an application object can be created that modifies alarm states in controllers, or an object that monitors runtime of a pump, it
can be considered a compound. Application objects can be widely varied in function and are fully available to the users, allowing Invensys, end users, or other engineers to create application objects that are instantiated and then mass deployed throughout the system. This is a powerful capability, providing a foundation for the distribution of best practices. Any template that is created in the system can be modified and the redeployed throughout the system. This ability to build object templates can greatly reduce engineering time. Objects can have a number of facets and metadata associated with them, such as alarming, visualization, and so on.
InFusion Provides a Single Version of the Truth
InFusion Access offers a library of communication interfaces that allow users to connect to practically all legacy control systems and other common third party subsystems that have the ability to communicate digitally. These interfaces are called Data Access Servers (DAServers), and allow for
Copyright © ARC Advisory Group • ARCweb.com • 9
ARC White Paper • April 2007
standardizing how information is presented to other InFusion components, such as visualization or historian applications. The driver library features support of over 300 third party device protocols. InFusion Access enables various specialized systems to speak a common language. It also provides a level of common data aggregation, promoting security and effective data management.
InFusion Historian
The InFusion Historian is a high-performance data management tool based on Microsoft SQL Server. Having an historian based on SQL Server also means that the historian can serve as a relational database. The advantage of relational database technology is that snapshots of data can be taken in context and then stored in standard data tables from which the data can be retrieved by applications for future analysis and integration.
InFusion Collaboration Environment
The InFusion Collaboration Environment offers a convenient way to present all information views required to run a business in a single collaborative environment. The Collaboration Environment really operates on the same principle as the NASA mission control wall, which allowed all aspects of a mission to be visible to all the appropriate personnel. The expanded view of the enterprise means that personnel are no longer limited to viewing compartmentalized data related only related to their specific functions. This expanded, mission control style view, however, also re-
quires a different way of thinking and working than may be the norm at many plants today. Invensys built the Collaboration Environment with the idea that it must not only aggre-
gate data, but should also
aggregate views from mul-
tiple applications, multiple operating systems, rendering them securely to audiences anywhere in the world.