Simulation. "A Quality Assurance Tool at The Plant Floor Level"

1. Simulation. "A Quality Assurance Tool at The Plant Floor Level" Marco Echeverria International Counsil of Systems Engineering Society of Hispanic Professional Engineers

2. Agenda: • Role Definition • Planning Phase • Development and Testing Phase • Process Validation • Deliverables • Simulation Overview • Simulation in Training Process • Q & A

3. Trainer After 10 years and $ 230,000, Guy makes his own Boeing 747 Flight Simulator

4. Process Management and Data acquisition Systems After 6 months and 1000 lh, guy and gal have a plant floor simulator Virtual Controllers Control Room HMI Simulation Development Tool & Trainer

5. Role Definition Controls Engineering leads Process Engineering qualifies Simulation supports Defines controls platform Identifies Controls components Establish Controls Standards. Process Knowledge Process parameters Tuning parameters Project limits. Device Behavior Library Unit Behavior Library Identify custom process requirements Process knowledge.

6. Contractor imbedded Project Responsibilities • Simulation Phase Definition • Simulation Configuration • Tests Definition • Process Validation • Ongoing Tests • Factory Acceptance Test • Deliverables. Scope of Work FAT + Automatic Device Tests Custom Process Tests Validation Phase Development Phase Fine tuning Simulation imbedded in Project Process Validation Controls Programming & HMI configuration Change Management Unit Simulation Configuration Test Definition Device Simulation Configuration

7. Process Validation Controls Programming & HMI configuration CIP + Change Management Unit Simulation Configuration Test Definition Device Simulation Configuration Automatic Device Tests Custom Process Tests Validation Phase Development Phase Fine tuning Continuous Improvement and training simulation environment Deliverables Partial simulation blocks with small projects Or Complete simulation environment in grass roots project

8. CIP + Validation Phase Development Phase Custom Process Tests Fine tuning Continuous Improvement Process Automatic Device Tests Build Quality in Prevent Defects Risk Management Defects found and fixed Root cause analysis

9. Remote Location Webex (Internet / Intranet) HMI Server Process Management Systems Central Engineering Lab Remote Location Soft and Hard Logic Controllers Simulation as a Project Development Tool Recognized as simple to configure and utilize Recognized in bringing people together to solve functional problems clearly and effectively Recognized as a “Unique testing platform for Information systems that depend on a running, data generating system” . Startups begin earlier, in a simulated fashion. Start-up Punch lists are created earlier and contractors are held in closer control to minimize startup delays. Simulations created in one project have been used as the basis for another. Simulation, builds assets: Testing and Training Assets.

10. HMI Server Process Management Systems Simulation in Training Complete Systems Remote Location Webex (Internet / Intranet) Central Engineering Training sessions may be held anywhere it is most desirable. Complete Systems utilizing core components. Engineering equipment is fully utilized . Soft and Hard Logic Controllers

11. Remote Location Remote Location BOT Engineering BOT Engineering HMI Server HMI Server Engineering Lab BOT Engineering Remote Location Remote Location Soft and Hard PLCs Soft and Hard PLCs Simulation Consolidation Strategy Spend more time in simulation and testing Simulation as a Q A Tool Development Training …Reduce Startup …Build Simulation Asset

12. Q & A