Making it possible to use the IT department to support Manufacturing

1
Integrating IT and Manufacturing

• Making it possible to use the IT department to
  support Manufacturing
• November 2007

2
Presenter

•  Erik Goode
• 14 years in the IT industry.
• Chief Architect for Cargill Plant Controls Group
• Chair of Microsoft Manufacturing Users Group
• Cargill is an international provider of food,
  agricultural and risk management products and
  services. With 149,000 employees in 63 countries,
  the company is committed to using its knowledge
  and experience to collaborate with customers to
  help them succeed.

3

• www.omac.orc/msmug
• The Microsoft Manufacturing User Group was formed
  in 1999 to address issues that arise when
  applying Microsoft technology in manufacturing.
• Our mission is to define and resolve these
  issues, such as version management, system
  integration, maintenance, and supplier
  responsibility.

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Data flow is important

• Manufacturing systems need to be tightly
  integrated into business systems so that
  manufacturers can operate cost efficient
  operations that are agile and can adapt quickly
  to changing market needs

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Perspective
IT
6
Perspective
Plant
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Integrating Applications
Business Logistics Systems (ERP)
Level 4
4 - Establishing the basic plant schedule -
production, material use, delivery, and shipping.
Determining inventory levels. Time
Frame Months, weeks, days, shifts
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Manufacturing Operations Systems (MES, Batch,
LIMS, AM, )
Level 3
Manufacturing Operations Management Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
3 - Work flow / recipe control to produce the
desired end products. Maintaining records and
optimizing the production process. Time
Frame Shifts, hours, minutes, seconds
Control Systems (PLC, DCS, OCS, )
Level 2
Manufacturing Control Basic Control, Supervisory
Control, Process Sensing, Process Manipulation,
2 - Monitoring, supervisory control and
automated control of the production process
Intelligent devices (Vision, Flow,
Level 1
1 - Sensing the production process, manipulating
the production process
Level 0
0 - The physical production process
Source Dennis Brandl, BRL Consulting
8
Technical Recommendations

• Architectural design standards have some.
• Formulate a zero-day patching strategy and
  practice it.
• Review your single-points of failure seriously
  consider eliminating them.
• Reboots happen, do more than plan for them,
  design around them.
• Firewalls are not a silver bullet. (There is no
  silver bullet)
• Design solutions to fail available rather than
  secure
• Dont forget the importance of physical security

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Organizational Recommendations

• Set and agree on SLAs (Service Level Agreements)
• Define a project board (governance)
• Define escalation of issues
• Set clear responsibilities
• Focus on managing customer and vendor perception
• Put effort in real collaboration
• Designate a BRM who understands the different
  terminology used by Plant and IT
• Ensure controls (metrics) are in place to monitor
  service levels for outsourced activities
• Consider use of RACI matrix charts to track
  accountability.

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Freeze-dried tips

• One reboot of an MS based device should NEVER
  stop production.
• One NIC failure in a client/server should NEVER
  stop production. 
• Dont add complexity that doesnt add value.
• Remove single points of failure. Design for
  availability.
• Design so that people dont matter then go make
  sure people do matter.
• Watch the data flow between systems.

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Integrating What ?
Level 4
4 - Establishing the basic plant schedule -
production, material use, delivery, and shipping.
Determining inventory levels. Time
Frame Months, weeks, days, shifts
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Level 3
Manufacturing Operations Management Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
3 - Work flow / recipe control to produce the
desired end products. Maintaining records and
optimizing the production process. Time
Frame Shifts, hours, minutes, seconds
Level 2
Manufacturing Control Basic Control, Supervisory
Control, Process Sensing, Process Manipulation,
2 - Monitoring, supervisory control and
automated control of the production process
Level 1
1 - Sensing the production process, manipulating
the production process
Level 0
0 - The physical production process
Source Dennis Brandl, BRL Consulting
12

• OMAC Information
• Contact Bruno Kisala, OMAC Executive Director
• bkisala_at_omac.org
• www.omac.org/joinomac
• Microsoft Manufacturing Users Group (MsMUG)
• www.omac.org/msmug
• Some lists of tools and training
• www.sans.org/whatworks/