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Savings and Expertise for your plant

ALL IN ONE SOLUTION FOR THE PROCESS INDUSTRY. Savings and Expertise for your plant. Discover a new level of Data Safety for Automation Technology. Discover a new level of Data Safety for Automation Technology. Version Control Smart Compare History Audit-Trail Archiving Check-In/Out

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Savings and Expertise for your plant

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  1. ALL IN ONE SOLUTION FOR THE PROCESS INDUSTRY Savings and Expertise for your plant

  2. Discover a new level of Data Safety for Automation Technology Discover a new level of Data Safety for Automation Technology Version Control Smart Compare History Audit-Trail Archiving Check-In/Out Access Controle-SignatureAutom.Backupsemail ReportReporting in line with ISO 900x and FDA 21 CFR 11

  3. Problem Consistent data management Consistent data management - was never as important as it is today Problem It doesn‘t matter whether you produce cars, drinks or pharmaceutical products The problem Planning, maintenance production: vital data is changing all the time! Reasonsfor changes: Product mods., bug fixes cycle time optim., safety measures, “botched mods.“...

  4. Risks Risk assessment for data management Risk assessment for data management: • How likely is it that something will go wrong?(FMEA = Failure Mode and Effect Analysis) • How serious would the consequences be? • How often does the risk arise? • How many people could be affected? • How much product could be affected? • What are the financial implications? • Are the effects immediate or chronic (long term)? • What does the law require? Risks

  5. Risks Risks to be controlled and prevented Risks to be controlled and prevented: • Are the correct software releases operating the production? • Do software changes effect quality and safety? • Can unauthorised software modifications be detected? • Are all systems software secured and accessible? • Is there control over data access and handling? • Can a replaced device be restored in acceptable time? Risks and, and ......

  6. Reality Which measures have been taken? Which measures have been taken? • Filing on HDs and server • Backup on CD, DVD (monthly, weekly)? • LAN integration of PCs and workstations • LAN enabled (SoftnetTM) programming software • Formal work instructions and procedures • .... and your actions? Reality

  7. Reality Have you gained control? Reality Have you gained control?...

  8. Reality Or does this seem familiar? .... or does this seem familiar? • Where is the correct version? • What exactly has been changed and why? • Who has overwritten my changes on the server? • What software version is our system really using at present? • Why is it that nobody knows the answer...!!! Reality …. and now?

  9. Reality The current situation? The current situation? Enormous efforts, poor quality, lots of risks! Reality Action must be taken!

  10. Requirements The requirements The requirements: • Server based, central project data storage withuser and access management • Copy management between workstationsand server • Automated program editor operations • Version control and archiving • Change management & documentation • Change history, reporting and audit trail Requirements

  11. Requirements The requirements The requirements: • Scheduled automatic backup of controller and device programs, including change detection • Automatic change notification via e-mail • Efficient and speedy “disaster recovery” • Documented change process in line with ISO 900x and FDA 21 CFR 11 • Proven solution with reference sites Requirements

  12. Requirements The type of data to be managed? The type of data to be managed: PLC / PC SCADA / HMI / ROBOTS • WinCC, ProTool, PCS 7 • InTouch • Citect • Ghost Images • ABB, KUKA • FANUC, ADEPT • usw. Requirements • Siemens • Rockwell • Schneider (Concept, Unity*) • 3S CoDeSys • TwinCAT • NC, CNC, DNC (840D…) • usw. • .bin, .xls, • .exe, .ppt, • .txt, .mdb, • .doc • E-CAD • Specifications • etc. • Indramat • SEW • Lenze • Leutze • Datalogic • etc. FIELD DEVICES AND DRIVES FILES / DOCUMENTS „A well designed concept can manage the data of any application“

  13. Solution Vital data totally under control! Vital data under total control! Version Control Smart Compare History Audit-Trail Archiving Check-In/Out Access Controle-SignatureAutom.Backupsemail ReportReporting

  14. Solution A closed loop control for data flow A closed loop control for data flow: - developed from practical experience - Archive Server Work process Workstations Devices

  15. Solution Eindeutige Datenablage Direct overview: • Easy to use with the Commander Easy Mode • Project components, including all versions • Instant access to change history • Filing order and structure as required Work bench: Commander Easy-Mode

  16. Solution Eindeutige Datenablage Transparency and functionality: • Search function for the project tree and master data • Overview of all components which are „under construction“ • Indication of the PG- and AG- Actuality • Backup- and Restoring on push of a button Work bench: Commander Power Mode

  17. Solution Detailed changes - S7 Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  18. Solution Detailed changes - S7 Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  19. Solution Detaillierte Unterschiede - S7 Eindeutige Versionierung: • Detaillierte Darstellung • aller Änderungen • Zusätzliche Kommentierung Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  20. Solution Detailed changes - WinCC Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  21. Solution Detaillierte Unterschiede – PCS 7 Complete version control: • Locating all changes by using • „Smart Compare“ • (SFC Smart Compare) Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  22. Solution Detaillierte Unterschiede – PCS 7 Complete version control: • Locating all changes by using • „Smart Compare“ • (CFC Smart Compare) Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  23. Solution Detailed changes - InTouch Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  24. Solution Detaillierte Unterschiede - Schneider Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  25. Solution Detaillierte Unterschiede - Citect Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  26. Solution Detailed changes - Word Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  27. Solution Detailed changes - KUKA Complete version control: • Locating all changes by using • „Smart Compare“ • Additional commenting features Version control S7 Rockwell Codesys TwinCat WinCC PCS 7 InTouch Schneider Citect Word KUKA ... and more

  28. Solution Components history Component history • Electronic change records – audit trail • „Smart Compare“between any two versions History Audit-Trail

  29. Solution Central data vault Central data vault • User administration with account policies • Automated file and directory management of all copying procedures (check-in/ -out) Archiving

  30. Solution User security policy User security policy • Unique user administration and management • Electronic signature of specific actions Access controle-signature

  31. Solution Sicherheitsrichtlinien für Benutzer Release procedure - Workflow • Release procedure according to the four-eye-principle for new versions: • Electronic Signature • Escalation Management • Deputy Regulation • Email Notification • Audit Trail for all actions Release Procedure

  32. Solution Automated Backups Automated, scheduled device data backupvia LAN (device upload via PLC-Saver) • Backup of PLC programs (including Soft-PLC), SCADA or HMI, robot controllers, NC, etc. • Backup of recipes, setpoint values and parameters (for S7: according to selected words or variables) • Backup of any files via shared network resource or FTP • Change detection between backup and archived version • Backup and change report via email • Support of manual program backups for non LAN accessible devices Automatedbackups

  33. Solution Automated change report Automated change report: • Email report • “Smart Compare” of any change Change report via email

  34. Solution Project State and reporting ProjectState and Reporting • Audit trail of all activities • Predefined and user defined selections and filtering • Time-stamped to local- and UTC time • Print functions and export to CSV-file Audit-TrailReporting

  35. Highlights Highlights of VersionWorks® Highlights of VersionWorks® • Archiving of program- and data files on a server with secure user-, access- and copy management • Support of all PC based data types • Version control and archiving • Change history and audit trail • Scheduled automated backup of controller and device programs including change detection • Automated change notification via e-mail • Efficient and speedy “Disaster recovery” • Documented change process and audit trailin line with ISO 900x and FDA 21 CFR 11 • Proven solution with reference sites: • 170 companies approximately 2000 user administer approximately 20.000 devices Highlights

  36. Benefits What do we gain by this? What do we gain by this? Benefits

  37. Benefits Quality improvement due to VersionWorks® Quality improvement due to VersionWorks® • Complete version control and archiving of all data and software releases as a foundation for “disaster recovery” • Exact reproducable production conditions • Association and traceability of software releases and product batches • Secure user and access administration • Electronic signature for all relevant actions • Documented change process and audit trail in line with ISO 900x and FDA 21 CFR 11 • Automated change check and e-mail reporting Benefits

  38. Benefits Cost reduction due to VersionWorks® Cost reduction due to VersionWorks® • Reduction of production down time • Prevention of down time and bad product, due to accidentally activated old software • Prevention of financial loss, due to loss of vital data • Prevention of loss of know-how, due to personnel changes/movement • Quick training of new personnel • Time saving for the searching of valid Software releases • Extreme improvement of daily procedures and routines • Short amortization time (ROI) Benefits

  39. References Referenzen - Automobilindustrie Automotive Industry DaimlerChrysler Rastatt, Wörth, Mannheim Audi Ingolstadt DaimlerChrysler Sindelfingen BMW Dingolfing References BMW Landshut, Leipzig DaimlerChrysler Berlin, Bremen Ford Köln BMW Regensburg BMW München Volkswagen Brüssel (BELGIEN) Shanghai GM Shanghai (China) Volkswagen Hannover, Braunschweig DaimlerChrysler Germersheim Volkswagen Wolfsburg DaimlerChrysler Mettingen FAW-VW Changchun (CHINA) Automotive Associated Industries Behr Mühlacker Continental Teves Morganton (USA) Brose Coburg Corning Kaiserslautern Continental Teves Frankfurt KS Aluminium Neckarsulm Continental Teves Mechelen (BELGIEN) LuK Bühl Continental Teves Culpeper (USA) Mann + Hummel Marklkofen

  40. References References – Food Beverage/Parma Food and Beverage Industry Nestlé Hamburg-Wandsbek Bavaria Lieshout (HOLLAND) Nestlé Biessenhofen Beck’s Bremen References Nordwest Getränke Soest Carlsberg Northampton (UK) TetraPak Glinde Danone Ochsenfurt Indag Eppelheim Veltins Meschede Krombacher Kreuztal Wagner Nonnweiler-Braunshausen Langnese-Iglo Reken Warsteiner Warstein Molkerei Alois Müller Fischach Pharmaceutical and Chemical Industry BASF Minden Roche Mannheim Boehringer Ingelheim Ingelheim Roche Penzberg Fresenius St. Wendel Salutas Pharma Magdeburg Merck Gernsheim Wacker Chemie Burghausen Novartis Basle (SWITZERLAND) Wella Weiterstadt

  41. References References - Various Steel and Metallurgy Industry, Machine builder and various Industries Salzgitter Flachstahl Salzgitter AluNorf Neuss SAP St. Leon-Rot Alstom Birr (SWITZERLAND) References Sekurit Saint-Gobain Herzogenrath Datev Nuremberg Schott Rohrglas Mitterteich Eckart-Werke Velden EKO Stahl Eisenhüttenstadt Schweizer Electronic Schramberg Forbo Linoleum Assendelft (HOLLAND) Stihl Waiblingen Franz Viegener II Großheringen VA Tech Elin Linz (AUSTRIA) Gebr. Heller Nürtingen Knauf Immingham (UK) Kocher-Plastik Sulzbach-Laufen Miele Gütersloh NECSA Pelindaba (SOUTH AFRICA) Neumag Saurer Neumünster

  42. Contact Information BIConsulting Inc.Miami, USA 9050 Pines Blvd. Suite 480 Pembroke Pines, FL 33024 Tel.:  +1 (954) 272-6120Fax.: +1 (954) 885-6503E-mail:  sales@biconsulting.com BIConsulting C.A. Valencia, Venezuela Centro Comercial Paseo Tarbes Planta Alta, Oficina PA-4 Valencia, Venezuela Tel.:  +58 (241) 8242139 Fax.: + 58 (241) 8242139 E-mail:  ventas@biconsulting.com

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