Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Bausch & Lomb Leverages PlantPAx to “See Better, Live Better” on Its Journey to The Connected Enterprise
Steve Schneebeli Manager – Director of Engineering / ITMalisko Engineering
Matthew Roberts Business Development ManagerMalisko Engineering
AGENDA• Introduction
• Project Goals
• Selecting a PlantPAx® Solution
• System Overview
• Results
• Lessons Learned and Recommendations
• Next Steps
• Questions
INTRODUCING BAUSCH + LOMB AND
MALISKO ENGINEERING, INC.
WHO IS BAUSCH + LOMB?• Founded in 1853 in Rochester, NY
• Three Core Business Units:• Vision Care: Contact Lenses and Eye-Care products• Pharmaceuticals: Rx and OTC Medicines for various Eye Diseases and Irritations• Surgical: Medical Devices, Instruments
• Global company with key US Manufacturing sites:• Rochester, NY• Clearwater and Tampa, FL• St. Louis, MO• Greenville, SC
• Acquired by Valeant Pharmaceuticals Aug. 2013 (VRX)
B+L LENS CARE SOLUTIONS FACILITY – GREENVILLE, SC
• Aseptic Lens Care Solutions Manufacturing Facility• Pharmacy, Compounding, Mixing, Filling, Packaging and
Palletizing• Plant and Process Utilities• Warehouse / DC off-site
• Originally built early 1980’s
• Volume growth of approx. 9.5% per year
• Products: Biotrue, Renu, PeroxiClear, Sensitive Eyes….• ~ 25 Package formats and ~8 Package sizes
• 2012 Master Plan – identified DCS replacement for Risk Mitigation – controls Process Utilities and Bulk Manufacturing
WHO IS MALISKO ENGINEERING?• Experts in manufacturing automation and validation
• Founded in 1994
• Headquartered in St. Louis, Missouri USA
• Regional Offices in Denver, Colorado USA and Eau Claire, Wisconsin USA
• Rockwell Automation® Solution Partner for Control, Process, Information, Industrial IT and Power Quality & Energy Management.
• CSIA Certified Member
Historic Laclede’s LandingSt. Louis, MO
Malisko Western Regional Office Denver, CO
Phoenix Park AreaEau Claire, WI
Control | Process | InformationIndustrial IT | Power Quality &
Energy Management
MALISKO’S PAST PRESENTATIONS
PROJECT GOALS
PROJECT GOALS• Legacy DCS Migration / Risk Mitigation
– Main goal of new Process Control System (PCS) was to provide functionality similar to the existing DCS system– Two Fisher Porter System Six DCS systems - Utilities and Mixing– System cut-over done on a tank-by-tank, system-by-system basis – not ‘rip and replace’
• Provide an interface in the new PCS for future plant-level MES system– Production Schedule Interface– Electronic Batch Records
• Expose process (continuous) and batch data outside of the process network– Existing DCS was an ‘island of automation’ – No direct ties to the corporate network– All existing reports and historian data had to be printed out– No visibility of the process outside of the DCS network
CHOOSING A PLANTPAX SOLUTION
“TRADITIONAL” DCS VS. PLANTPAX
Criteria Traditional DCS
Local Support Single Local Solutions Provider
Local Eco-System consisting of dozens of local
Integrators and Solution Partners
ScalabilityHardware + Additional
License required for additional I/O
No additional licensing required
TopologyDedicated Servers.
Software and Hardware Upgrades Expensive
Virtualization Fully Supported – Decoupling Hardware from Software
BASIS OF DESIGN PHASE• Basis of Design (BOD) was performed to provide enough technical and financial detail to
determine the best course toward implementation.
• BOD deliverables included:– Proposed System Architecture and Bill of Material with options for redundancy– Preliminary Design Drawings, including preliminary CAD drawings for Network, I/O and Power Distribution– Detailed Analysis against current URS– Initial design engineering (FRS 30% – 50% complete, initial DDS draft)– Technical options or considerations (i.e. Simulation System, FactoryTalk® AssetCentre)– Preliminary schedule– Validation Strategy– Cost Estimate
SYSTEM OVERVIEW
DOCUMENT EXISTING SYSTEM FUNCTIONALITY
• No formal Functional Requirement Specification (FRS) or Detailed Design Specification (DDS) existed for the Fisher Porter DCS.
• Malisko Engineers generated the FRS and DDS using DCS code exports and interviews with B&L production and engineering groups.
• S-88 Modeling - Define Control Modules, Equipment Modules, Phases and Units.
• Optimized Existing Sterilization Procedure. DCS had multiple phases. PCS has a single Sterilization phase with multiple steps.
• Several review meetings with key B&L production and engineering resources to finalize system design.
PLAN FOR STAGED CUT-OVER
• Production scheduling eliminated the idea of ‘rip and replace’
• Malisko had to devise a plan to stage cut over of tanks and Utilities systems
• IFM modules were placed over the DCS termination boards, prior to tank cutover. This allowed for a tank-by-tank cutover when a tank came available, thus minimizing the downtime occurred by the tank.
• Tank cutover time – 2.5 days.
STAGED CUTOVER I/O PANEL PICTURES
PLANTPAX SYSTEM CHARACTERIZATIONCharacterization verifies that the system provides the required performance.
SYSTEM ARCHITECTURE• Three Physical Servers with eight virtualized images
– FactoryTalk® View Servers (Primary and Secondary)– ACP ThinManager Remote Desktop Services (RDS) Servers (Primary and Secondary)– FactoryTalk® Batch Servers (Primary and Warm Backup)– FactoryTalk® Historian – Microsoft SQL Server– Seven FactoryTalk® View SE Thin Clients
• Two Engineering Workstations
• Cisco Stackwise Switches between Data Center and DCS I/O Room
• Device-level Ethernet Ring– Utilized for all I/O Chassis
• Separate network cards for connection to B&L business network for domain authentication.– Controlled by access rules on B&L corporate switches
• VPN Connection into system for Remote Support
LIBRARY OF PROCESS OBJECTS• V3.0 process objects • “Out of the Box” PlantPAx AOIs • “Enhanced” Global Objects (Valves, Pumps, etc)
HMI SCREEN SAMPLE (EXISTING DCS)
• 19” 4:3 Monitors• 1024 x 768 resolution• Ability to move main process screens
utilizing Windows pop-up functionality
HMI SCREEN LAYOUT (PLANTPAX)• 24” 16:9 Monitors
• 1920 x 1080 resolution
• Ability to move main process screensutilizing Windowspop-up functionality
FACTORYTALK BATCH• Primary and Warm Backup Servers• 30 Unit License – 19 units used• 33 Phases across two processors• Validated default recipes• Using ‘off the shelf’ Rockwell Batch Overview
screen for viewing and controlling batches• Developed custom screen for starting orders read in
from future B&L MES system
REPORTING• Reporting done through SQL Server
Reporting Services allowing Web-based access to reports
• Data taken from SQL tables and FactoryTalk® Historian SE
Confidential
DATA HISTORIAN AND SQL SERVER• 1,000 tag FactoryTalk® Historian SE server with
redundant FactoryTalk® Live Data interface nodes
• Historian data gathered from both PCS ControlLogix® processors and stand-alone skids
• Ability to import Historian data into Excel using DataLink add-in
• SQL database used to store FactoryTalk® Batch data, FactoryTalk® Alarms and Events, and FactoryTalk® Diagnostics data utilized for reporting
• Future connectivity of SQL and FactoryTalk® Historian to upcoming FactoryTalk® VantagePoint® installation
BIOMETRICS FOR USER AUTHENTICATION• DigitalPersona U.are.U 4500 Readers• Utilizes U.are.U Software Development Kit• VB .Net application used to detect and log-in users into FactoryTalk View SE• Users can enroll up to two fingerprints• Challenge of getting reader to work with ACP ThinManger Thin Clients
VB.Net App Interprets data
from Reader and sends FT Login
Credentials
Fingerprint Read from Reader
FT User is Logged into
System
RESULTS
IMMEDIATE RESULTS
• Robust, redundant system including servers, PLCs, application software, and networking (I/O Ring and Server to Client utilizing Stackwise switches)
• Local Rockwell support and readily available replacement parts
• Remote access for troubleshooting support if needed
• Built on a standardized set of process objects (PlantPAx)
• Easier for maintenance and engineering to learn and troubleshoot the system
LONG TERM BENEFITS• PCS system provides the framework to get data exposed to the corporate level
• Roll-out of VantagePoint to display and analyze data on the desktop (process users or engineers)
• Provide standardized programming environment following site standards
• S-88 model utilizing Phase Manager opens up options for further automation of the Mixing System
• Ability to interface with future B+L MES system to pass production orders down to the batching system, and feed critical production data for Electronic Batch Records
LESSONS LEARNEDAND
RECOMMENDATIONS
LESSONS LEARNED AND RECOMMENDATIONS• DCS replacements require planning and communications if not ‘rip and replace’
• At the mercy of Production, so scheduling needs to be flexible
• During initial design, factor-in framework for new enhancements, even if replacing with similar functionality.
• While laying your framework for the Connected Enterprise, have early and often conversations with plant IT groups. Make them part of the design process.
• Spend time with operators on the existing system. Don’t just ‘reverse engineer’ the old DCS code.
B&L LESSONS LEARNED AND RECOMMENDATIONS• Create a comprehensive URS – approved by key stakeholders; incorporate inputs from SME’s
• Include and fund a BOD phase if appropriate
• Follow a formal vendor selection process; evaluate proposals against critical criteria
• Align vendor capabilities with business needs
• Create and follow a detailed Project Plan in partnership with your vendor(s)
• Include SME’s in Design Reviews
• Understand Change Order process
• Include Contingency Plans
NEXT STEPS• Work towards bringing other isolated systems into the new Process Control Network
• Determine data to be collected via Historian (continuous) and SQL (events)
• Roll-out ‘Data to the Desktop’ initiative. Utilize FactoryTalk® VantagePoint and Historian DataLink.
• Look for ways to automate existing manual processes
Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
THANK YOU
Steve SchneebeliMalisko Engineering Inc.Director of Engineering / IT – St. Louis, [email protected]
Matthew RobertsMalisko Engineering Inc.Business Development [email protected]