Value of Asset Management Strategies

1. Value of Asset Management Strategies �I need to insure that my facility is operating the way I built it to run!�

2. When we talk to corporate management, these are the things that they tell us that they are concerned about in their plants. When we talk to corporate management, these are the things that they tell us that they are concerned about in their plants.

3. Water Supply & Water Treatment System Benefits Reduction in long term operating & maintenance costs and lowering the risks to the community served by� Improve maintenance staff effectiveness Root cause analysis & locked door device analysis automatically Monitor & protect systems Monitor devices on networks for abnormal operation including degradation or failure Automatic integrated condition monitoring including notification Automatic tracking of versions with security on all production intellectual property Messaging (email) appropriate personnel Facilitate more migration from reactive & preventive maintenance to predictive & reactive maintenance models Increase site security for device access Creating audit trails for asset configuration changes, detect unwanted changes Back up asset intellectual property to a secure system for disaster recovery Store every version of asset configurations in a secure system for archival and retrieval Automatic verification of some device configurations against controlled masters Extend service life of equipment through verification, condition monitoring & security

4. Assets and intellectual property are how companies make money. Without the proper investments in both, the plant or process does not work well and product suffers. An asset is everything that a company purchases through vendors or saleries. This is the way upper management looks at things. If an employee, no matter how nice a person, does not perform they will replace them. The employee is an asset that affects plant performance just like a PLC. Most of management does not realize that they have extremely vulnerable assets like their PLCs on the plant floor. Protecting those assets should be the most important thing in their life because it is how they make money and a company does not survive without money. I like to think about RSMACC like protecting my home and family much the same way. I consider my families safety to be one of the most important things in life. Yet, I only have locks on my house and a simple security system. I could have a perimeter fence and an armed security guard also. Why don't I pay for those also. I have made a risk management decision about my family based on the likelyhood of an invasion of my home. At the factory, it is important to help everyone realize that they are somewhat vulnerable and that RSMACC can provide a level of protection and recovery. At the factory they have backup systems to store critical business data even in offsite vaults to protect from disaster. Yet, they have left their PLCs and drives unprotected and without a disaster backup. They don't even know it. They assume that the people responsible for them, engineers and maintenance, are doing it. At my home I purchase insurance for disaster recovery. If someone breaks into my home and steals the TV, my insurace provides for recovery. At a plant, that usually has not been considered for the IP in a PLC or drive. We are trying to draw the same idea across to the plant about the programs in their assets. All the functions of RSMACC provide huge benefits in protection and disaster recovery. Let me give you some ideas: Change Management Archive Archive provides version control and security on those asset program versions so that no program is ever lost by mistake or worse. Your customer can recover an asset program from yesterday or last year if needed. Verification Maybe a worse case thing happens and someone changes the code a little or a lot, RSMACC will detect this even if the process does not. Security OK, I am going to assume that everyone gets this part. Network Health Altering a device, or a partial degradation of performance like the dirty photeye lense, may cause the process not to produce products correctly. Assets and intellectual property are how companies make money. Without the proper investments in both, the plant or process does not work well and product suffers. An asset is everything that a company purchases through vendors or saleries. This is the way upper management looks at things. If an employee, no matter how nice a person, does not perform they will replace them. The employee is an asset that affects plant performance just like a PLC. Most of management does not realize that they have extremely vulnerable assets like their PLCs on the plant floor. Protecting those assets should be the most important thing in their life because it is how they make money and a company does not survive without money. I like to think about RSMACC like protecting my home and family much the same way. I consider my families safety to be one of the most important things in life. Yet, I only have locks on my house and a simple security system. I could have a perimeter fence and an armed security guard also. Why don't I pay for those also. I have made a risk management decision about my family based on the likelyhood of an invasion of my home. At the factory, it is important to help everyone realize that they are somewhat vulnerable and that RSMACC can provide a level of protection and recovery. At the factory they have backup systems to store critical business data even in offsite vaults to protect from disaster. Yet, they have left their PLCs and drives unprotected and without a disaster backup. They don't even know it. They assume that the people responsible for them, engineers and maintenance, are doing it. At my home I purchase insurance for disaster recovery. If someone breaks into my home and steals the TV, my insurace provides for recovery. At a plant, that usually has not been considered for the IP in a PLC or drive. We are trying to draw the same idea across to the plant about the programs in their assets. All the functions of RSMACC provide huge benefits in protection and disaster recovery. Let me give you some ideas: Change Management Archive Archive provides version control and security on those asset program versions so that no program is ever lost by mistake or worse. Your customer can recover an asset program from yesterday or last year if needed. Verification Maybe a worse case thing happens and someone changes the code a little or a lot, RSMACC will detect this even if the process does not. Security OK, I am going to assume that everyone gets this part. Network Health Altering a device, or a partial degradation of performance like the dirty photeye lense, may cause the process not to produce products correctly.

5. RSMACC Systems RSMACC Systems consist of an architecture that includes at least one core function. That RSMACC System can be added to, creating a much more comprehensive solution. The 4 core functions are: Change Management, CM Network Health, NH Enterprise Online, EOL Automated Asset Manager, AAM You can purchase CM alone and add AAM at anytime Or you can purchase a NH System and add EOL, etc�

6. Typical Device Configuration Scenario User starts RSLogix program User locates the RSLogix controller program User connects to the controller Downloads or makes online changes, saves program on local disk drive, floppy or somewhere else What version of the program is in your controller and where did the program come from & where did it go after the change? RSMACC is designed to eliminate these questions. RSMACC is designed to eliminate these questions.

7. Change Management The Value is greatest when applied proactively rather than after the fact! The stream of managing change starts with �Prevention� and flows through �Reconciliation�. Instead of waiting for a problem and providing only a method to hopefully correct that problem, RSMACC starts much earlier in the process where the mistake might occur by controlling access, archiving all versions and controlling access to them, auditing all actions on & offline that affect PLC code and as Factory Talk Audit gets deployed into more and more products, all of our systems. We also provide a method to Verify that the program in the PLC or on a HDD matches what we expect to be in the device and then record everything for audits, inquiries, training, troubleshooting and reporting. Instead of waiting for a problem and providing only a method to hopefully correct that problem, RSMACC starts much earlier in the process where the mistake might occur by controlling access, archiving all versions and controlling access to them, auditing all actions on & offline that affect PLC code and as Factory Talk Audit gets deployed into more and more products, all of our systems. We also provide a method to Verify that the program in the PLC or on a HDD matches what we expect to be in the device and then record everything for audits, inquiries, training, troubleshooting and reporting.

8. Change Management User starts RSLogix program RSMACC security system ask your domain controller to authenticate the user Regardless of results, RSMACC records workstation and user launching RSLogix RSMACC security applies the defined security permissions Note that the user experience for RSLogix 5 & 500 is very similar by using the File Open function the maintenance person can get or check out a file directly from the RSMACC Archive without much training. RSLogix 5000 requires the use of the RSMACC Client to check out the files from Archive. This is very easy to do and takes about 5 minutes to teach maintenance how to do it. Note that the user experience for RSLogix 5 & 500 is very similar by using the File Open function the maintenance person can get or check out a file directly from the RSMACC Archive without much training. RSLogix 5000 requires the use of the RSMACC Client to check out the files from Archive. This is very easy to do and takes about 5 minutes to teach maintenance how to do it.

9. Change Management User retrieves application program from RSMACC archive using RSLogix 5 or 500 file open or the RSMACC client using the RSMACC security system to verify permissions RSMACC records who retrieved the application program & where it went Note that the user experience for RSLogix 5 & 500 is very similar by using the File Open function the maintenance person can get or check out a file directly from the RSMACC Archive without much training. With RSLogix 5000, the controller is much more advanced so implementing a simple file open function is not as necessary. We may do it in the future, but for now you can get to all the files easily using the RSMACC Client. When a file is checked out, the system records who took the file and where. If it is lost, it can be recovered by an Administrator. You can get many view only copies for troubleshooting, but only one master copy at a time. This enforces the one master rule in version control and is critical to knowing what is going on moment to moment. When a file is checked back into the system, the system checks to see if the file is different. Upon detection of a difference, it increments the version and stores it as a new version automatically. This works for any type of file including even a procedural document or drawing as well as logic & configuration programs from any vendor. Note that the user experience for RSLogix 5 & 500 is very similar by using the File Open function the maintenance person can get or check out a file directly from the RSMACC Archive without much training. With RSLogix 5000, the controller is much more advanced so implementing a simple file open function is not as necessary. We may do it in the future, but for now you can get to all the files easily using the RSMACC Client. When a file is checked out, the system records who took the file and where. If it is lost, it can be recovered by an Administrator. You can get many view only copies for troubleshooting, but only one master copy at a time. This enforces the one master rule in version control and is critical to knowing what is going on moment to moment. When a file is checked back into the system, the system checks to see if the file is different. Upon detection of a difference, it increments the version and stores it as a new version automatically. This works for any type of file including even a procedural document or drawing as well as logic & configuration programs from any vendor.

10. Change Management File management system Holds any kind of document Manage user folder rights Supports Pinning/ mastering Sharing Branching The Archive system will report all activities and can apply security to folders to facilitate better access control for different parts of a plant. We also support �pinning� a version of the master file. When someone gets a view only copy, they are automatically given the �pinned� version. This enables continued work and troubleshooting especially during startup and commissioning. Also, when the Verification system runs a compare, it will compare the code from the device to the �pinned� master creating a comparison report against the �pinned� version. This can be very useful for a variety of situations. If �pinning� is not enabled for a master, then the system uses the latest version automatically. The Archive system will report all activities and can apply security to folders to facilitate better access control for different parts of a plant. We also support �pinning� a version of the master file. When someone gets a view only copy, they are automatically given the �pinned� version. This enables continued work and troubleshooting especially during startup and commissioning. Also, when the Verification system runs a compare, it will compare the code from the device to the �pinned� master creating a comparison report against the �pinned� version. This can be very useful for a variety of situations. If �pinning� is not enabled for a master, then the system uses the latest version automatically.

11. Change Management User connects to the controller RSMACC records device connection User makes online modifications to control program RSMACC records each user change as it occurs RSMACC records everything the user is doing even if they are not connected to the network at the moment. When disconnected, the system stores data locally on the laptop until the computer reconnects to the network. Then RSMACC gets an automatic update from the laptop. RSMACC records everything the user is doing even if they are not connected to the network at the moment. When disconnected, the system stores data locally on the laptop until the computer reconnects to the network. Then RSMACC gets an automatic update from the laptop.

12. Change Management Note that we record two different times. �Occurred� time for when it happened on the laptop and �Logged� time for when it is inserted into the RSMACC server. You may note also that the data recorded includes real-time changes like the Timer Preset indicated in the image. Note that we record two different times. �Occurred� time for when it happened on the laptop and �Logged� time for when it is inserted into the RSMACC server. You may note also that the data recorded includes real-time changes like the Timer Preset indicated in the image.

13. Change Management Secure operator changes from RSView SE or PanelView Plus during production Set-point change (Tag write) Command Alarm acknowledgement Recipe download Signature required before operation occurs Generates compliance enabling 21 CFR Part 11 audit trail Our RSView SE or PV+ products can create local Audit trails including no signature, a signature, or the originator�s and their supervisor or approvers signature. Ina RSMACC system this record can be combined into the RSMACC Audit log using FactoryTalk without any effort for a unified reporting system. Our RSView SE or PV+ products can create local Audit trails including no signature, a signature, or the originator�s and their supervisor or approvers signature. Ina RSMACC system this record can be combined into the RSMACC Audit log using FactoryTalk without any effort for a unified reporting system.

14. Change Management Documenting Configuration Changes Supports self-documenting Change Management procedure Ability to prove scope of change is limited to approved change Contains information necessary to enable FDA 21 CFR Part 11 compliance Date/Time of audit event Source (Application) Location (Workstation) Username (Domain ID, and Full Name from Domain Id) Automatically generated description of change with old and new value You facility probably utilizes a manual procedure base change management system for implementing planned changes to your manufacturing configuration. RSMACC Audit trail captures the users actions performed from RSMACC-enabled workstations. This enables you to generate a report of all changes made to the specific resource being altered and demonstrate that only the authorized changes were performed.You facility probably utilizes a manual procedure base change management system for implementing planned changes to your manufacturing configuration. RSMACC Audit trail captures the users actions performed from RSMACC-enabled workstations. This enables you to generate a report of all changes made to the specific resource being altered and demonstrate that only the authorized changes were performed.

15. Change Management User returns the application program to the RSMACC archive system RSMACC archive compares the files and increments the version if it is different regardless of the type of program RSMACC even records when the program is returned. An indefinite amount of versions can be stored. There is an algorithm to control the number that are kept also. Remember, if the system detects a changed program, it automatically increments the version and stores the new version. RSMACC even records when the program is returned. An indefinite amount of versions can be stored. There is an algorithm to control the number that are kept also. Remember, if the system detects a changed program, it automatically increments the version and stores the new version.

16. Change Management RSMACC verifies automatically at the prescribed periodicity that the controller program matches the master program and version in archive A message can notify that the function ran correctly or not, and differences were found or not. A report of the differences found is saved. RSMACC can automatically check a program in the PLC to see if it matches the one in the RSMACC Archive. It will generate a message and save the file as a version if you want also. Reports can be emailed, printed, etc and are saved in the message system in RSMACC indefinitely for later inquiries for validation or regulation reports or troubleshooting. RSMACC can automatically check a program in the PLC to see if it matches the one in the RSMACC Archive. It will generate a message and save the file as a version if you want also. Reports can be emailed, printed, etc and are saved in the message system in RSMACC indefinitely for later inquiries for validation or regulation reports or troubleshooting.

17. Brief Overview, Managing Device Configuration

18. RSMACC Systems RSMACC Systems consist of an architecture that includes at least one core function. That RSMACC System can be added to, creating a much more comprehensive solution. The 4 core functions are: Change Management, CM Network Health, NH Enterprise Online, EOL Automated Asset Manager, AAM You can purchase CM alone and add AAM at anytime Or you can purchase a NH System and add EOL, etc�

19. Typical Device Status Events Event Radio message or alarm

20. Automatic Device Health Status Periodically the Diagnostic Scheduler Service, running on a local computer, scans the health of DeviceNet, ControlNet, and Ethernet/IP network devices and reports on their status to the RSMACC system. Smart devices, when prompted, will identify their health status by responding with a coded number Comparing that number to the type of device using the network configuration file allows us to automatically generate information about the failure In a RSMACC NH system we install Diagnostic Scheduler Services on local machines to query each device periodically to see if it is OK. This can be installed on a local HMI computer. If a problem is detected, we alarm through RSMACC automatically. We also provide the troubleshooting information specific for the problem code discovered by the DSS inquiry. All without anyone going to and looking at the device, in fact we can detect it prior to it failing and operations calling in a lot of cases. In a RSMACC NH system we install Diagnostic Scheduler Services on local machines to query each device periodically to see if it is OK. This can be installed on a local HMI computer. If a problem is detected, we alarm through RSMACC automatically. We also provide the troubleshooting information specific for the problem code discovered by the DSS inquiry. All without anyone going to and looking at the device, in fact we can detect it prior to it failing and operations calling in a lot of cases.

21. Automatic Device Health Status That number corresponds to a real problem for the device at that node. These are automatically logged to the centralized RSMACC Diagnostics and Health log database In a RSMACC NH system we install Diagnostic Scheduler Services on local machines to query each device periodically to see if it is OK. This can be installed on a local HMI computer. If a problem is detected, we alarm through RSMACC automatically. We also provide the troubleshooting information specific for the problem code discovered by the DSS inquiry. All without anyone going to and looking at the device, in fact we can detect it prior to it failing and operations calling in a lot of cases. In a RSMACC NH system we install Diagnostic Scheduler Services on local machines to query each device periodically to see if it is OK. This can be installed on a local HMI computer. If a problem is detected, we alarm through RSMACC automatically. We also provide the troubleshooting information specific for the problem code discovered by the DSS inquiry. All without anyone going to and looking at the device, in fact we can detect it prior to it failing and operations calling in a lot of cases.

22. Automatic Device Health Status RSMACC log message includes a link to root cause and solution information from distributed RSMACC Clients RSMACC requires no additional code or configuration to recognize a device code and communicate the device status to the system and subsequently the appropriate personnel �explanation and possible solutions for the problem. No more looking for the manual! PLEASE MENTION THAT NOT ONLY CAN WE DETECT DEVICES LIKE THE PHOTOEYE ON DNET, BUT WE CAN DETECT THE PROCESSORS ALSO. THEREFORE WE CAN NOTIFY OF A BATTERY FAILURE IN A LOCKED CABINET SOMEWHERE INSTEAD OF DOING A PM AND TAGOUT TO OPEN THE CABINET TO SEE IF IT HAS FAILED. �explanation and possible solutions for the problem. No more looking for the manual! PLEASE MENTION THAT NOT ONLY CAN WE DETECT DEVICES LIKE THE PHOTOEYE ON DNET, BUT WE CAN DETECT THE PROCESSORS ALSO. THEREFORE WE CAN NOTIFY OF A BATTERY FAILURE IN A LOCKED CABINET SOMEWHERE INSTEAD OF DOING A PM AND TAGOUT TO OPEN THE CABINET TO SEE IF IT HAS FAILED.

23. Automatic Device Health Status

24. RSMACC Systems RSMACC Systems consist of an architecture that includes at least one core function. That RSMACC System can be added to, creating a much more comprehensive solution. The 4 core functions are: Change Management, CM Network Health, NH Enterprise Online, EOL Automated Asset Manager, AAM You can purchase CM alone and add AAM at anytime Or you can purchase a NH System and add EOL, etc�

25. Traditional Condition Monitoring Machinery in the plant might malfunction so we must do our preventive maintenance periodically regardless of real indicators like cycles, revolutions, temperature, vibration, level or viscosity. This requires a person to take local readings and then analyze those readings typically back at their desk. In several industries this may even require travel In all, it is extremely time consuming Regular Preventive Maintenance to determine the condition of a bearing on a machine in the plant. First someone reads the PM and then has to decide where the machine is and what equipment he will need to perform the analysis. When they finally get to the machine, they collect the readings and come back to the office. After transferring the readings to a computer for analysis they realize that the bearing is having a little trouble and should need work. They are not sure how long the problem has been going on (so it is assumed that it began after the last set of readings). Eventually someone notifies the appropriate people of the problem and a schedule is created to service the motor. Since the data is collected sporadically, the data is inconsistent and may not be analyzed until after a problem has begun and could have been prevented from becoming worse. Regular Preventive Maintenance to determine the condition of a bearing on a machine in the plant. First someone reads the PM and then has to decide where the machine is and what equipment he will need to perform the analysis. When they finally get to the machine, they collect the readings and come back to the office. After transferring the readings to a computer for analysis they realize that the bearing is having a little trouble and should need work. They are not sure how long the problem has been going on (so it is assumed that it began after the last set of readings). Eventually someone notifies the appropriate people of the problem and a schedule is created to service the motor. Since the data is collected sporadically, the data is inconsistent and may not be analyzed until after a problem has begun and could have been prevented from becoming worse.

26. Automatic/Integrated Condition Monitoring Our integrated and automatic protection systems are designed to provide continuous monitoring and protection to machinery RSMACC system provides a live connection to sensor data from the XM modules Vibration Analysis Process Parameters Temperature, Pressure, and Flow Turbine Supervisory Instrumentation (TSI) Thrust, Differential and Case Expansion, Valve position, and Eccentricity No more traveling to the location or climbing on machines to take readings! By using the XM Ethernet Gateway, we can hook up all of the remote sensors to RSMACC EOL for� Entek's revolutionary XM� series is the world's first integrated machinery monitoring and protection system, comprised of individual modules and related software. The XM� series is a family of intelligent DIN rail mounted Measurement, Relay and Gateway modules deployed on a common industrial DeviceNet� bus. A total of 64 modules may be installed locally, connected end-to-end using their integral connectors, or distributed anywhere on the DeviceNet� bus up to 500 meters in length.XM� series modules may be applied as a stand-alone system, or integrated with existing plant information and control systems and provide diagnostic information to key individuals throughout the organization. XM Configuration Softtware is: Single User Local configuration Provided free with every configurable XM module Individual module setup capability Snapshot data viewing capability during setup for commissioning By using the XM Ethernet Gateway, we can hook up all of the remote sensors to RSMACC EOL for� Entek's revolutionary XM� series is the world's first integrated machinery monitoring and protection system, comprised of individual modules and related software.

27. Automatic/Integrated Condition Monitoring RSMACC Client combines digital images of your plant equipment with monitored data for simple asset monitoring and alarm annunciation EnWatch data can be combined with the XM data on the live monitor �online monitoring. In a RSMACC EOL system, Henry doesn�t leave his desk. In fact Henry does not even have to look at the bearing because he set it up to warn him automatically if there is a problem detected. Henry now can analyze more machines and make much faster decisions based on real-time data collected constantly versus a PM once in a while. Henry can get his job done well now and does not let PMs slip because of lack of manpower. Henry gets an intuitive visual display of the plant status at a glance The system now transfers data over existing Ethernet LAN for sequential monitoring of machines distributed throughout the plant Connectivity to online hardware modules XM family of monitors Enwatch family of monitors FTLiveData connectivity with other Automation systems Configuration XM device setup and commissioning Enwatch hardware setup and commissioning FTLiveData Client configuration Correlation and Analysis Overalls, Spectrum, Time waveform, 2 channel, orbits and transient data� �online monitoring. In a RSMACC EOL system, Henry doesn�t leave his desk. In fact Henry does not even have to look at the bearing because he set it up to warn him automatically if there is a problem detected. Henry now can analyze more machines and make much faster decisions based on real-time data collected constantly versus a PM once in a while. Henry can get his job done well now and does not let PMs slip because of lack of manpower. Henry gets an intuitive visual display of the plant status at a glance The system now transfers data over existing Ethernet LAN for sequential monitoring of machines distributed throughout the plant Connectivity to online hardware modules XM family of monitors Enwatch family of monitors FTLiveData connectivity with other Automation systems Configuration XM device setup and commissioning Enwatch hardware setup and commissioning FTLiveData Client configuration Correlation and Analysis Overalls, Spectrum, Time waveform, 2 channel, orbits and transient data�

28. Automatic/Integrated Condition Monitoring Online remote configuration capability In a RSMACC EOL system, Henry doesn�t leave his desk even to configure the devices that might be hundreds of miles away. Henry gets an intuitive visual display of the plant status at a glance The system now transfers data over existing Ethernet LAN for sequential monitoring of machines distributed throughout the plant Connectivity to online hardware modules XM family of monitors Enwatch family of monitors FTLiveData connectivity with other Automation systems Configuration XM device setup and commissioning Enwatch hardware setup and commissioning FTLiveData Client configuration Correlation and Analysis Overalls, Spectrum, Time waveform, 2 channel, orbits and transient data� In a RSMACC EOL system, Henry doesn�t leave his desk even to configure the devices that might be hundreds of miles away. Henry gets an intuitive visual display of the plant status at a glance The system now transfers data over existing Ethernet LAN for sequential monitoring of machines distributed throughout the plant Connectivity to online hardware modules XM family of monitors Enwatch family of monitors FTLiveData connectivity with other Automation systems Configuration XM device setup and commissioning Enwatch hardware setup and commissioning FTLiveData Client configuration Correlation and Analysis Overalls, Spectrum, Time waveform, 2 channel, orbits and transient data�

29. Automatic/Integrated Condition Monitoring Live Time data display from any XM channel Trend, Spectrum, Waveform, Waterfall, Polar, Orbit, Shaft-Centerline Henry can even look at the spectral analysis of accelerometer in real-time from the comfort of his or her desk. No more trucking to the machine to get readings. It is only the most recent data coming off of the accelerometer though. EOL talks directly with the device (either XM or Enwatch) and requests the current data for the channel in question. To view historical data, Emonitor must be used. EOL does not have a database to store any data. Henry is not exposed to dangerous situations Henry can concentrate on problem-solving instead of manual data collection Henry enables data acquisition to be scheduled more frequently for earlier fault diagnosis Henry, a �non-PdM experts� gets a snapshot overview of the plant machinery health, allowing him to respond quickly to machine problems to minimize costly downtime Henry can even look at the spectral analysis of accelerometer in real-time from the comfort of his or her desk. No more trucking to the machine to get readings. It is only the most recent data coming off of the accelerometer though. EOL talks directly with the device (either XM or Enwatch) and requests the current data for the channel in question. To view historical data, Emonitor must be used. EOL does not have a database to store any data. Henry is not exposed to dangerous situations Henry can concentrate on problem-solving instead of manual data collection Henry enables data acquisition to be scheduled more frequently for earlier fault diagnosis Henry, a �non-PdM experts� gets a snapshot overview of the plant machinery health, allowing him to respond quickly to machine problems to minimize costly downtime

30. Automatic/Integrated Condition Monitoring Historical data can be added to real-time using our Emonitor systems Emonitor Enshare Data Storage, Alarming, Frequency Analysis, & Connectivity Emonitor Odyssey Deluxe Data Storage, Alarming, & Frequency Analysis Emonitor Odyssey Data Storage & Alarming Using an Emonitor system, Henry can even look at historical spectral analysis data compared to real-time from the comfort of his or her desk. To view historical data, an Emonitor system (Odyssey, Odyssey Deluxe, or Enshare) must be used. EOL does not have a database to store any data. Emonitor systems approximate pricing: Odyssey ~$8,000 USD Odyssey Deluxe ~$18,000 USD Enshare ~$45,000 USD (not usually required with a RSMACC EOL solution because it is redundant in it�s communication ability) Using an Emonitor system, Henry can even look at historical spectral analysis data compared to real-time from the comfort of his or her desk. To view historical data, an Emonitor system (Odyssey, Odyssey Deluxe, or Enshare) must be used. EOL does not have a database to store any data. Emonitor systems approximate pricing: Odyssey ~$8,000 USD Odyssey Deluxe ~$18,000 USD Enshare ~$45,000 USD (not usually required with a RSMACC EOL solution because it is redundant in it�s communication ability)

31. RSMACC Systems RSMACC Systems consist of an architecture that includes at least one core function. That RSMACC System can be added to, creating a much more comprehensive solution. The 4 core functions are: Change Management, CM Network Health, NH Enterprise Online, EOL Automated Asset Manager, AAM You can purchase CM alone and add AAM at anytime Or you can purchase a NH System and add EOL, etc�

32. Automatic Messaging RSMACC binds process information from intelligent assets and RSMACC internal systems & messaging to MAXIMO to facilitate WORK ORDER generation and tracking Predictive Interaction Process data like� N:7:0 > desired level A work order for checking/calibrating the thermocouples should be issued Operator interface sends signal requesting maintenance on machinery based on a reading or operator input Reactive Interaction An intelligent sensor or device is malfunctioning Photo eye signal is degrading, work order issued to clean RSMACC detects that an assets configuration does not match the master on file Work order created to asses the situation a RSMACC detects a security violation Message sent to IT or Security to investigate issue Process data B120/12 not 0 A work order for fixing a leaking valve should be issued RSView SE Interface for Work Order generation/messaging Track status of work orders & data Plan for work based on status & changes Adjust schedules and priorities of planned work By using the AAM module, an OPC value can be sent to the MAXIMO computer maintenance management system, CMMS, to generate a work order automatically. Even a value from screen in an HMI or SCADA can be sent to MAXIMO. This system does require that you use MAXIMO from MRO. Our interface is not generic because there is not a standard yet for interfacing to CMMS. Mimosa and the OPC Foundation are considering a standard currently (2004). Currently we use a custom JAVA interface to MAXIMO. It is possible to design an interface to other CMMS systems including SAP PM, but there is substantial cost involved. We are considering moving to a more generic interface so that we will work with more systems soon. By using the AAM module, an OPC value can be sent to the MAXIMO computer maintenance management system, CMMS, to generate a work order automatically. Even a value from screen in an HMI or SCADA can be sent to MAXIMO. This system does require that you use MAXIMO from MRO. Our interface is not generic because there is not a standard yet for interfacing to CMMS. Mimosa and the OPC Foundation are considering a standard currently (2004). Currently we use a custom JAVA interface to MAXIMO. It is possible to design an interface to other CMMS systems including SAP PM, but there is substantial cost involved. We are considering moving to a more generic interface so that we will work with more systems soon.

33. Automatic Messaging A lot of plants are struggling with the increased work load including increased complexity of systems. Consequently plants have moved to more of a run-to-failure, RTF, mode for some maintenance This is as expensive in some cases as hiring more people and doing preventive maintenance A balanced approach is more appropriate based on individual requirements This type of system is deigned to help in the balance between RTF and total PMS Moving some appropriate systems to Reactive models Compensates for not having time to do PMS Facilitates better time management Facilitates a more appropriate cost model for maintenance

34. RSMACC Systems RSMACC Systems architecture includes some basic functions like Reporting Both manual ad-hoc and automatic Security Service Monitoring Archive

35. Manual & Automatic Reporting RSMACC can be configured to generate automatic reports for changes to machines and their respective assets. For instance, a maintenance manager might want a report for changes that occurred over the weekend or during the past evening.

36. Manual & Automatic Reporting Other Uses For Reporting Generate a morning report for Maintenance/ Engineering Manager review showing ALL changes to PLC programs during 2nd and 3rd shift Forces Empty branches Changes to rungs, ignoring value modifications All employees that made modifications Generate a weekly report for the Plant Manager showing all programmable assets that have been modified by name Generate a report monitoring critical applications (e.g., pasteurization process) that have not been changed Reports give you the power to analyze changes that have been made in your system; the ability to review, consult, and demonstrate the scope of change.Reports give you the power to analyze changes that have been made in your system; the ability to review, consult, and demonstrate the scope of change.

37. System Planning & Architecture Common Architecture with Plug-In Functions RSMACC Server & RSMACC Client common to all applications Plug-In Functions RSMACC Network Health Monitor, report, and diagnose device and network health RSMACC Automated Asset Manager Automate preventive, predictive, and reactive maintenance RSMACC Enterprise Online Condition Monitor Integrated automation condition monitoring RSMACC Change Management Authenticate, audit, archive, and verify device configuration

38. System Planning & Architecture RSMACC Server(s) Windows 2003 Server Windows 2000 Server w/SP4 Pentium 4, 2GHz or more 1GB RAM 1.5GB free on system volume 20GB shared volume, RAID-5 capable Only if hosting Microsoft SQL 2000 Server RSMACC Client Windows 2000 w/SP4 or XP Pro SP1 DO NOT USE XP SP2 Pentium III, 500MHz 256MB RAM 1GB free on system volume Today, our server and client requirements are these. You can not install the RSMACC Server and modules on a domain controller, it must be installed on an application server in the domain. It does have to be installed on a server class machine and operating system. As you�ll see in the next few slides, it can scale to do a lot of work. Today, our server and client requirements are these. You can not install the RSMACC Server and modules on a domain controller, it must be installed on an application server in the domain. It does have to be installed on a server class machine and operating system. As you�ll see in the next few slides, it can scale to do a lot of work.

39. System Planning & Architecture This is what a typical system might look like. The pdc operates on a separate computer. RSMACC can be installed on an application server in the domain with SQL Server on the same machine, or (CLICK) SQL Server can be installed on a separate machine or even a cluster. The controllers and computers have to be accessible to the RSMACC Server via Ethernet or a Gateway using sub-networks like DH+ or ControlNet. It is possible, rarely practical, to put ControlNet, DeviceNet, DH+ type communications cards directly in the RSMACC Server computer. We would suggest a CLX Gateway to be more practical. This is what a typical system might look like. The pdc operates on a separate computer. RSMACC can be installed on an application server in the domain with SQL Server on the same machine, or (CLICK) SQL Server can be installed on a separate machine or even a cluster. The controllers and computers have to be accessible to the RSMACC Server via Ethernet or a Gateway using sub-networks like DH+ or ControlNet. It is possible, rarely practical, to put ControlNet, DeviceNet, DH+ type communications cards directly in the RSMACC Server computer. We would suggest a CLX Gateway to be more practical.

40. System Planning & Architecture This is what a typical system might look like. The pdc operates on a separate computer. RSMACC can be installed on an application server in the domain with SQL Server on the same machine, or (CLICK) SQL Server can be installed on a separate machine or even a cluster. The controllers and computers have to be accessible to the RSMACC Server via Ethernet or a Gateway using sub-networks like DH+ or ControlNet. It is possible, rarely practical, to put ControlNet, DeviceNet, DH+ type communications cards directly in the RSMACC Server computer. We would suggest a CLX Gateway to be more practical. This is what a typical system might look like. The pdc operates on a separate computer. RSMACC can be installed on an application server in the domain with SQL Server on the same machine, or (CLICK) SQL Server can be installed on a separate machine or even a cluster. The controllers and computers have to be accessible to the RSMACC Server via Ethernet or a Gateway using sub-networks like DH+ or ControlNet. It is possible, rarely practical, to put ControlNet, DeviceNet, DH+ type communications cards directly in the RSMACC Server computer. We would suggest a CLX Gateway to be more practical.

41. System Planning & Architecture So, we said it could scale up to do a lot of work, here is an idea of how far it might go in a system using all of the modules. Ass RSMACC provides more and more benefit to maintenance, you will want to add modules to automate more of the maintenance tasks. All of these reduce MTTR and increase MTTF. So, we said it could scale up to do a lot of work, here is an idea of how far it might go in a system using all of the modules. Ass RSMACC provides more and more benefit to maintenance, you will want to add modules to automate more of the maintenance tasks. All of these reduce MTTR and increase MTTF.

42. We have seen how all of these assets can be affected and how an RSMACC System can help to mitigate some of the risks involved everyday to manufacturing� We have seen how all of these assets can be affected and how an RSMACC System can help to mitigate some of the risks involved everyday to manufacturing�

43. We also have seen how a RSMACC System can help with these objectives�We also have seen how a RSMACC System can help with these objectives�

44. Water Supply & Water Treatment System Benefits Reduction in long term operating & maintenance costs and lowering the risks to the community served by� Improve maintenance staff effectiveness Root cause analysis & locked door device analysis automatically Monitor & protect systems Monitor devices on networks for abnormal operation including degradation or failure Automatic integrated condition monitoring including notification Automatic tracking of versions with security on all production intellectual property Messaging (email) appropriate personnel Facilitate more migration from reactive & preventive maintenance to predictive & reactive maintenance models Increase site security for device access Creating audit trails for asset configuration changes, detect unwanted changes Back up asset intellectual property to a secure system for disaster recovery Store every version of asset configurations in a secure system for archival and retrieval Automatic verification of some device configurations against controlled masters Extend service life of equipment through verification, condition monitoring & security And how an RSMACC System can� And how an RSMACC System can�

45. What�s next� Action� How can we help you?How can we help you?