Creating the Modernization Plan that Works for You


Agenda

Risk Elimination

Risk Identification

Industry Status


Solving Critical Manufacturing Issues

People & AssetSafety

ROCKWELL AUTOMATION SERVICES

Product & Application Lifecycle Support

Minimizing Risk. Maximizing Productivity.

WorkforceSupport & Training

Asset & Plant Optimization

Information Infrastructure & Security


$65BAutomation systems reaching end of life

~75%U.S. plants are more than 20 years old

2 Exabytes Big data generated in manufacturing

$20B cost of unscheduled downtime

<14 % US Plants completely integrated

21% Suffered a loss of IP in the past year

SOURCE: Industry Week SOURCE: Kapersky (2014)SOURCE: McKinseySOURCE: ARC SOURCE: Industry WeekSOURCE: ARC

Business Risks & DriversRealizing Smart Manufacturing has become a business imperative


IMPROVED TIME TO MARKET

REDUCTION IN EXPENDITURES

30% 10%REDUCTION IN INVENTORY

IMPROVED PRODUCTIVITY

30% 4%

5

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 6Rockwell Automation TechED 2017 @ROKTechED #ROKTechED 6

Limited Parts Availability

Increasing Support Costs

Regulatory Compliance

Subject Matter Expert Attrition

Safety Sustainability


MODERNIZATION

STRATEGY

Risk Identification

Risk Elimination

Risk Mitigation


RISK IDENTIFICATION

Product Lifecycle

On-Line Tools

Migration Brochure and Profiles

Assessment

8


Product

Launch

A Newer

Product in that

Category is

Launched

Announcement

that Product

will be

Discontinued

Product Lifecycle Categories

Discontinued

Date

PUBLIC Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 10Rockwell Automation TechED 2017 @ROKTechED #ROKTechED 10

Online Lifecycle Lookup Tool

www.rockwellautomation.com/support

“Modernization Support”


Addition Tools Available

Migration Solutions Brochure

Migration Profiles


Assessment OptionInstalled Base Evaluation

Providing actionable intelligence thorough analysis of your critical plant assets and condition, so that you

can make data-driven decisions regarding their support and obsolescence management


COLLECTION PROCESSING

Delivery of reporting

using a consultative

approach

DELIVERY

On-Site data collected by a

Rockwell Automation Field

Service Professional

Off-site processing and analysis

determines lifecycle risks and

overall MRO inventory status

13


What did we collect?What are your Inventory Positions?Do you have the right spares?What is your lifecycle risk?What lines are most at risk?Do you have condition problems?

EXECUTIVE

SUMMARY


LIFECYCLE

REPORTS

What is your obsolescence risk Overall?What is your obsolescence risk by Line?What is your obsolescence risk by Machine?


INVENTORY

REPORTS

What parts do you have?What are the recommended spares?


LOCATION

REPORTS

What is the BOM of each panel?What is the location of each asset?


CONDITION

REPORTS

Do you have plant floor conditions

That may impact uptime?

What condition is your storeroom in?

Are all of your spares useful?


LIFECYCLE

PLANNING

TOOL

Great Reports, Where do I start?

• Product obsolescence?

• Proper spares inventory level?

• Product migration?

• Vendor consolidation?

• Inventory reduction?

• Machine BOM accuracy?

The Lifecycle Planning

Application helps you

develop a “Risk-Score”

based on inputs only you

would know about your

facility. These inputs can

be fine tuned to most

effectively create a

lifecycle plan.

These fields are used to

determine which part

categories are of most

concern to the customer. If a

customer is experiencing

particular pain around

“Drives” as an example, set

the priority to High or Critical.

Keeping the priority as “Low”

will have a null impact to the

risk scoring.

Part CategoriesLifecycle Planning ApplicationLine Level Scoring

Location (Line) Scores:• Reliability Rating – Is the line

generally reliable unreliable

• Priority Rating – Not all lines are created equal, assign lines of more importance a higher priority ranking

• Customer Expected Life –How long do you expect this line to stay around? If a line is going away in <5 years, we likely shouldn’t build a long-term lifecycle plan for it.

• Reliability Rating – Is the Machine

generally reliable unreliable

• Priority Rating – Not all machines

are created equal, assign machines

of more importance a higher priority

ranking

• Customer Expected Life – How

long do you expect this machine to

stay around? If a machine is going

away in <5 years, we likely shouldn’t

build a long-term lifecycle plan for it.

• Support Type – When this machine

needs repair / support, is this

managed in house out of house.

• MTTR (Mean time to repair) –

Longer times to repair a machine

adds risk to the machine score

• Downtime Cost – The more

downtime costs, the higher the risk

score

Machine Level Scoring


RISK ELIMINATION

Do it Yourself

Packaged Solutions

Custom Projects

Modernization Service Agreements

20


Current Situation

Aging automation technology

Reduced reliability and shorter mean time between

failures

Limited or declining support capabilities

Skilled employees not replaced or replaced with

limited knowledge and experience

Shortage of available replacement parts

Producers are continually faced with the daunting task of how to

balance current goals and objectives with the limited capital

funding available to update an aging automation infrastructure

Increase production output

Improve employee productivity

Lower support inventories

Reduce downtime events/

duration

Reduce maintenance costs

Improve employee safety

Go

als

/Ob

jective

s

Ch

alle

ng

es


Modernization Benefits

Connectivity

Safety

Flexibility

Reliability

Performance

Security

Modernizing aging automation

technology has far reaching benefits

which can help…

Improve productivity with better asset

utilization and system performance

Promote globalization with easy access

to actionable, plant-wide information

Supporting sustainability with extended

product lifecycles and better asset

utilization

Cultivate innovation with increased

system flexibility and technical risk

mitigation


Migrating from PLC-5® to ControlLogixA Phased Approach

By targeting the main processor you are able to keep your existing devices/networks

Getting started: Analyzing your automation system

Know the current lifecycle status of your hardware

Evaluate your migration options (Do-It-Yourself, Packaged, or Custom)

Complete the code conversion using RSLogix™ Project Migrator

Convert 80 to 100% of code

May need to manually convert messages and special instructions such as PID

Replace PLC-5® system

Either use the wiring system or rewire

Your ControlLogix® system is now ready for startup


Rockwell Automation offers:

• Superior product longevity and communication throughout the

lifecycle

• Phased Migration Strategy and Extensive Migrations Toolkit

• Global Solutions and Services

PLC-5 and 1771 I/O Migration Strategy from Rockwell

Automation offers unmatched value:

• Typically saves 10 hours per rack of ten, 40-point I/O

modules

• Lowers engineering and labor costs

• Reduces production downtime

• Reduces risk by eliminating potential wiring errors

(preservation of existing field wiring)

Migrating from PLC-5® to ControlLogixA Phased Approach


Your migration requirements are systematically prioritized by

migrating only one PLC-5 rack and up to four remote I/O racks,

leaving any connected devices and slave controllers in place

By migrating the core controller and chassis, you lay the foundation

for future modernization

The PLC-5 packaged migration is ideal for discrete, straightforward

applications communicating to devices and remote I/O racks on

existing networks such as DH+ and remote I/O

Rockwell Automation can help you cost-effectively migrate to the

latest ControlLogix® technology:

A whole new meaning to migration – Easy, Fast, Affordable

PLC-5 Packaged Migration:A Scalable, Phased Migration Option


10 Steps to Migrate RSLogix™ project1. Launch RSLogix Project Migrator (RPM) and select project type to migrate. Follow directions under

selection…

2. Launch RSLogix software and open project to be migrated.

3. Save project to RSLogix library format (.PC5 for PLC-5, .SLC™ for others).

4. Perform an ASCII export of project to CSV format.

5. Return to RPM, browse to RSLogix project folder and select exported project file. Select Next button and on

next RPM screen, then select Migrate.

6. Migration Results are shown and logged. Optionally, examine the migration log. See RPM help for details

7. Choose the target controller project type and version and select Next.

8. Next you may be prompted to chose your I/O migration strategy. Follow instructions shown and select Next.

The I/O migration progress and status will be shown. Select Launch Studio 5000®.

9. Follow the Studio 5000® prompts to import your project to Logix Design and open Routine 2_MAIN_LADDER.

10. Congratulations you have completed the automated migration process! You should verify the controller project

and consult the controller migration guide if needed.


Selecting Your ControlLogix® System

Integrated Architecture® Builder is

used to help generate your BOM for

hardware

Simple project creation,

configurations, and hardware

generated

You can download IAB from the

Rockwell Automation® website http://www.rockwellautomation.com/global/e-

tools/product-selection-toolbox.page?#tab3


Integrated Architecture® Builder

Select your Chassis

size

Select ControlLogix®

size from the options

provided

Select the PLC-5®

Power Supply

Select ControlLogix®

PS from the options

provided


Key Takeaways

• RSLogix™ Project Migrator can make RSLogix project migrations faster

• Tools like IAB are important planning tool to use BEFORE you try to convert your RSLogix project

• RPM converts up to 80-100% of code, but may need to manually convert messages, special instructions (like PID) and potential timing/scan differences

• Logix has powerful new constructs and features (like structures and integrated motion) that you may want to leverage when migrating your project

• If you need migration help, contact your local Rockwell Automation Representative


Do it Yourself

Tools to plan and execute the migration

Product Lifecycle Status Link: Product Lifecycle Status

Integrated Architecture Builder Link: IAB Download

RSLogix™ Project Builder Link: RSLogix Project Migrator Download

Wiring Conversion System (Chassis, Controller, and I/O) Link: Selection Guide

Network Interface Modules Link: ControlLogix System Selection Guide

Migration Profile Link: Literature Migration Profile

Reference Manual for Converting Link: Converting PLC-5 to ControlLogix

http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/overview.page?

http://www.rockwellautomation.com/global/support/configuration.page

http://compatibility.rockwellautomation.com/Pages/MultiProductDownload.aspx?crumb=112

http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1492-sg121_-en-p.pdfhttp:/literature.rockwellautomation.com/idc/groups/literature/documents/sg/1492-sg121_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1756-sg001_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/migrat-pp003_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/rm/1756-rm085_-en-p.pdf


PLC-5 Packaged Migration Product

Base Package - The in-kind migration includes:

Up to 1,000 rungs of application code conversion

Up to 5,000 tags updated Rockwell Automation®

HMI tag database

PLC to PLC Communications NEW

1756 ControlLogix Chassis

1756-L72 ControlLogix Controller

1756-PA72 or 1756 PA75 Power Supply

1756 ControlLogix Communication Module

Replacement Digital I/O

Wiring Conversion System

Assurance™ Integrated Support Phone support within 10 minutes, parts and on-site assistance as fast

as a 24-hour response

Added Options Additional rungs of code conversion

Additional HMI tags retagging

Indirect Addressing NEW

Replacement Analog I/O

Additional communications modules

Remote Racks NEW

On-site start-up assistance

ControlLogix System Fundamentals

Training class NEW

PUBLIC

Copyright © 2016 Rockwell Automation, Inc. All Rights Reserved. 32

Custom SolutionsHow to reduce costs and migration time


List of Modernization Services

PanelView 550 to PanelView 1000

MPR Upgrade

Classic to Forge Control

UPS: Internal or External

Dialog to Flex

140U to 140M Breakers

1336 to PowerFlex 750

Eutectic & E3 Overloads to E300s

Non-network/Dnet to Ethernet

PowerFlex 4/40 to PowerFlex 520

Air-Break to Vacuum Contactor

Motor Protection System

Now is the time to update outdated optional hardware


Power Control Modernization Services

MPR Upgrade



Dialog to Flex SMC




Eutectic & E3 Overloads to E300

Circuit Breaker and Starters


Static Exciter Air-Break to Vacuum Contactor


Benefits of Newer MCC or Drive Platform

Increase integration for plant-wide control, meet global standards, and gain

a competitive advantage

Greater production visibility, for quicker response to customer demand

Higher profit margins through improved inventory management, cycle times

and quality control

Improved capacity and asset utilization, leading to greater Overall

Equipment Effectiveness (OEE)

Regulatory compliance and reduced exposure to security risks


Benefits to Migrating Components on Existing MCCs

Reduced procurement time - components can be shipped 50% faster than new cabinets

Reduced downtime

MCC cabinet is not removed

Depending on version of the old component, most components can be converted without a main power buss outage

Can continue to run adjoining MCC buckets during migration

No change to MCC infrastructure

Keep the same MCC infrastructure without having to purchase NEW MCC cabinets


Benefits to Migrating Components on Existing MCCs (cont’d)

Cost savings and extension of MCC Lifecycle

Only required hardware within the existing prepared space is updated

Existing enclosure, incoming power cables, motor feeder cables, and

motor control cables can be re-used

Re-use of many controls

Reduced risk with component upgrade

All new components including lockable disconnect switch, starter,

overloads, CPTs, soft starters, drives etc.

Options for both Allen-Bradley and 3rd Party MCCs


Advantages of Full MCC Migration

Reduced cost and downtime

Existing enclosure, incoming power cables, motor feeder cables and motor control cables

can be re-used

Downtime reduced as MCC cabinet is not removed

Re-use of many controls

Reduced risk with component upgrade All new components including lockable disconnect switch,

starter, overloads, CPTs, softstarters, drives etc.

Options for both Allen-Bradley® Motor Control Centers and

third-party MCCs


Migrated MCC

Features

All new components such as

Starters, SMCs, Drives,

Overloads

Commonality of equipment

Typically plug and play

New doors

Supplied on panel or field

retrofitted

Ethernet connectivity PowerFlex® 750 series on same roll-out cart

1336 Drive on roll-out cart



MPR Upgrade



Dialog to Flex SMC









Benefits of Converting Existing MV Drive™ Components

Reduced downtime

Conversion takes only 8 days

5 days for the field modification

3 days for complete recommissioning of the drive after the conversion

Conversion uses same footprint/cabinet space in most applications

Replacement of the obsolete PanelView™ 550 found in early ForGe drives with

PanelView™ 1000

PanelView™ 1000 available with touch screen for ease of use

PanelView™ 1000 mounting can be local or remote, offering flexibility of access by the

operator



MPR Upgrade



Dialog to Flex SMC









Migrating to PV1000 in your Existing PF7000

This field retrofit upgrades PowerFlex® 7000 Medium Voltage drives to the latest technology using

the PanelView™ 1000 and PowerFlex® Human Machine Interface board

Replacing the obsolete PanelView™ 550 with the current PanelView™ 1000 HMI reduces the risk of

unplanned down time

Remotely mounted

Gives the user the flexibility to mount where required e.g. in the control room or at

the driven machine

No requirement for PPE when accessing HMI, depending on where it is located

The HMI connects to the VFD via a hardwired Ethernet cable; there is no functional

distance limitation

Locally mounted

Direct replacement for the PanelView™ 550 offering in a ForGe MV drive


Capital Investment Reality

Extremely slow economic growth

Pain of 2008 recession still

lingers, creating a pessimistic

outlook

Inconsistent market data and

trends

Process industries struggle with

energy and other commodity

prices

Capital investment growth is beginning to turn positive, however it will remain very slow and will

not reach 2014 levels until 2021*

* ARC Capital Expenditure Report 7/16

Capital Expenditures


Changing the Paradigm

How do you change the long

standing paradigm of maximizing

productivity with an installed

base of legacy production

automation and limited access to

capital funding needed to

modernize?


The Solution…

Engineering Pre-engineering of systems scheduled for

upgrade

Includes drawings, bills of material, and

modernization schedule

Hardware and software All required hardware for the system

All software and program conversion for the

system

Configuration and startup Qualified field service engineer will provide any

configuration need for the installed system and

will provided startup and testing

Extended Parts Warranty Site wide warranty on existing legacy Rockwell

assets and modernized technology

Any failed units will be remanufactured or

replaced at no additional charge

Remote Technical Support Product level phone support, Knowledgebase

access, email support, and chat support

Provides assistance with troubleshooting,

diagnosis, configuration, maintenance and

issue resolution

Additional Options On-site parts, on-site field service

Support ModernizationProgram

Management

…a Modernization Service Agreement which minimizes the risk of operating aging automation assets and provides a

mechanism to upgrade to the latest technology on a pre-determined time schedule during the agreement. This

agreement includes support, modernization, and program management for a fixed monthly fee.


Modernization Service Agreement Value

Reduced

Production

Risk

Improved

Asset

Productivity

Enhanced

Financial

Performance

Ensuring technical support and repair capability of legacy assets to

maintain production

Reduction in downtime events and duration with legacy support

services

Leverage the benefits of new technology: speed, performance,

supportability, safety, energy consumption, connectivity

Support for operation and maintenance on new technology to ease

the learning curve

Fixed, predictable support and upgrade costs for improved

operational planning and more accurate budgeting

No large capital outlay, minimizes the impact on working capital and

creates the ability to fund other critical activities


How the Agreement Works

Time

Co

st

Fixed monthly payments

Remote support and extended warranty for both legacy and new technology

$

Fixed monthly payment for support and modernization activities over the agreement period

Support covers both legacy and the new technology as it is upgraded

Modernization activities are pre-engineered and performed on a mutually agreed time schedule as production allows

Phased modernizations on a

predetermined time schedule


Program Elements/Details

Scope

Legacy Rockwell Automation equipment in the End of Life and

Discontinued lifecycle status

Ownership of modernized assets transfers to customer upon

completion of each migration

− Legacy assets removed from service become the property of

Rockwell Automation

Agreement Terms

3 and 5 year terms are standard

Longer options may be available based on customer situation

Pricing

Pricing is determined base on installed base needing

migration, the term of the agreement, and the support

coverage selected

End of agreement

Upon completion of the agreement, the customer has

the option to extend support elements for additional

terms

Multisite

Agreements can be designed to cover multiple sites

and enterprise wide as required


Case Study

Rockwell Automation Services delivers Asset Optimization solution at Polyester Plant

• Lowered total cost of ownership

• Delivered predictable maintenance spending

• Accurate management of obsolescence risk

• Improved equipment reliability

• Significant reduction in unplanned down time

• High risk due to aging assets

• 1336 drives, GV 3000, SLC, PLC5

• Limited Availability of CAPEX budget for

upgrades

• Unpredictable maintenance budget

• Unacceptable unplanned downtimeRESULTS

DELIVERED SOLUTIONCHALLENGES

• Rockwell Automation Services delivered a 7 year

Lifecycle Extension and Modernization Solution:• Installed Base Evaluation

• Extended warranty

• Fixed price reserve repair

• Phased upgrades using embedded engineers

• 24x7 Tech Connectsm Agreement (Legacy Support)


Taking the first step…

Numerous tools are available to assist in the

identification of legacy equipment

Product Lifecycle Status Search Click

Migration Solutions Publication Click

A critical element in any Asset Optimization strategy is to identify and understand the existing legacy equipment risk and its potential impact on production.

Self Assessment Installed Base Evaluation

MRO analysis including location & optimization

recommendations

Identification of automation obsolescence risks

Identification of product lifecycle status via production

hierarchy

On-Site Assessment

http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/overview.page?

http://literature.rockwellautomation.com/idc/groups/literature/documents/br/migrat-br002_-en-p.pdf


For More Information

Visit the Literature Library:

Rockwell Automation® Migration Solutions Brochure

PLC-5® to ControlLogix® Phased Migration Solution Profile

1492 I/O Wiring Conversion System Selection Guide

Visit the E-tools website:

Install Integrated Architecture® Builder

Install ProposalWorks™

Visit the Process Solutions website

Visit the Product Lifecycle Status website

Visit the Modernization website

http://literature.rockwellautomation.com/idc/groups/literature/documents/br/migrat-br002_-en-p.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/pp/migrat-pp003_-en-e.pdf

http://literature.rockwellautomation.com/idc/groups/literature/documents/sg/1492-sg121_-en-p.pdf

http://www.rockwellautomation.com/en/e-tools/configuration.html

http://www.rockwellautomation.com/global/solutions-services/capabilities/process-solutions/overview.page

http://www.rockwellautomation.com/global/solutions-services/capabilities/migration-solutions/product-search/overview.page

http://www.rockwellautomation.com/global/capabilities/industrial-maintenance-support/overview.page?pagetitle=Modernization&docid=4577964e48bcb918747a354e7f92c738


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Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 55Rockwell Automation TechED 2017 @ROKTechED #ROKTechED

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Creating the Modernization Plan that Works for You

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