Rame Back

Christer Rameback
ABB Automation Technology - 1 2003-09-16
Vice President
Process Automation
Process Automation History and Future
ABB Automation Technology - 2

2003-09-16
Facts about ABB
A leading power and automation technology company with broad

industry knowledge and geographic scope
About 150,000 employees in more than 100 countries
Leading position (1, 2 or 3) in each industry we serve and within our

product areas
Headquarters: Zurich, Switzerland

2003-09-16
Process Automation Systems
Listening to the users

Continuous improvements are customer driven

2003-09-16
Step changes are R&D driven

2003-09-16
Step changes are R&D driven
The BIG steps come

when R&D engineers
understand the users
Agenda
History of Industrial Automation
Current situation
Important aspects for the future

2003-09-16
Simplified business model

Process Control
Order Fulfillment
Time
Customer orders
Quality
Quantity
Raw material

2003-09-16
Energy
Energy waste
Environmental impact
Capital utilization
r
e
m
o
t
s
Cu
g
n
i
z
i
fit
o
r
P
Maxim
d
an
n
o
i
t
c
a
Satisf
Safety
Cost reduction
History
Control systems market

Users
Products
Large
System size
Automotive
Process
Industry,
Power Plants
DCS
PLC
Medium
Discrete
Manufact.
Hybrid systems

2003-09-16
Hybrid
Industries
Machine
Control
PLC
Small
Binary/Sequential
Analog
Functionality
Advanced
Binary/Sequential
Functionality
Analog
Advanced
History
PLC vs DCS
DCS History
Early 1900 electrification!
Rolling mills, paper mills, car

manufacturing
Early 1900 oil flow,

temperatures etc
Oil industry, pulp mills, (power

plants)
Contactors - Relays Electronic

relays with sequences etc
Programmable devices PLCs
Early 1970s - Microprocessor

based PLCs
Manual loops - Mechanical

controllers - Pneumatic controls Electronic controllers Single
Loop Controllers - DCSs
Simple MMCs (Man Machine

Communications)
Early 1970s - Microprocessor

based DCSs
More advanced MMCs
Somewhat more advanced

Information Management
Capabilities

2003-09-16
PLC History
Limited Information Management

Capabilities
Automation System
History
Evolution of digital control systems

Information
Management
ABC
ABC
IMS
ABC
Operator Stations
O/E/IM
CPU
Process Controllers
DDC
I/O
Centralized
Centralized

2003-09-16
60s and 70s
Process Controllers
Fieldbus
Fieldbus
Integrated
Integrated
Distributed
Distributed
70s, 80s and 90s
Improved functionality over time

Graphics, Alarms, Control, Information
Management, Batch, Communication
ty
i
x
le
p
90s and 00s
om
c
d
e
s
rea
c
In
PLC functions vs DCS functions

Binary, sequences, speed vs closed loops, alarms
etc
Integrated systems: PLC <-> DCS <-> IMS
Information
Technology (IT)
Industrial automation traditional

architecture model
History
Corporate
Business
Business Planning
Planning //
ERP
ERP
Other
Plant(s)
Manufacturing
Manufacturing Execution
Execution Systems
Systems
5
4
Plant
Industrial
Automation

2003-09-16
GAP
Process
Process Optimization
Optimization
Process
Process Automation
Automation
Area
Unit
Loop
Instrumentation
Instrumentation
Field
2
1
Today
Industrial automation new architecture model

Business
Business Planning
Planning //
ERP
ERP
Industrial
Automation
Other
Plant(s)
Corporate
Plant
Area
2003-09-16
Unit
Integrated
Systems
Loop
Field
Today
Market Forces

Process Control
Order Fulfillment
Time
Customer orders
Quality
Quantity
Raw material
Energy waste
Energy
Capital utilization
ATCE/CS- 9
er
Custom t
g
n
i
z
i
fi
Maxim
nd Pro
a
n
o
io
i
t
sfac
Satiis

2003-09-16
Safety
Cost reduction
Due to global competition combined

with slow market growth, process
industries forced to re-evaluate
business models and implement
continuous improvement initiatives
Cutting costs by consolidating, restructuring,

and downsizing
Today
Control systems market

Large
System size
Automotive
Medium
Process
Industry,
Power Plants
Discrete
Manufact.

2003-09-16
Hybrid
Industries
Machine
Control
Small
Binary/Sequential
Analog
Functionality
Advanced
Control systems market trends
Changes in the competitive structure
Consolidation
Too many suppliers and low profit levels
Mergers and acquisitions
Vertical integration
Merging market segments
PLC vendors enter the OCS market
The hybrid systems market is

common ground

2003-09-16
Siemens, Rockwell
ABB, Siemens, Rockwell, Fisher-Rosemount, Honeywell
Market exits due to increased development costs
Shake-out of smaller suppliers
Large end users with own control systems outsource
Today
Control systems market trends
Control systems become commodities
Commodity hardware
Decreasing differentiation at basic

product level

2003-09-16
Increasing competition on price
Competitive pressure on system components
PC, network components, I/O,
Unbundling
New product strategies
Broader scope of functionality
Unified systems: OCS + PLC + Safety + Scada
ABB, Siemens, Honeywell/Rockwell
Collaborative systems
Plant Automation, Asset Optimization, Business Systems
Today

Process Control
Order Fulfillment
Time
Customer orders
Quality
Quantity
Raw material

2003-09-16
Energy
Energy waste
Capital utilization
r
e
m
o
t
s
Cu
g
n
i
z
i
fit
o
r
P
Maxim
d
an
n
o
i
t
c
a
Satisf
Safety
Cost reduction
Trends
Important factors
oonn
ti
a
iz
m
ti
p
ti
o
a
t
e
e
iz
s
m
s
l
ti
A
oole
Asset op
r
r
s
rrs
o
t
o
a
rrat
e
p
e
EEnnggin
OOp
ineeeerrin
inggeefffficicie
iennccyy

2003-09-16
ll
o
r
t
n
o
c
o
r
t
d
n
e
c
o
AAddvvaannced c
En
ct
pact
impa
tallim
enta
men
onm
viron
Envir
eenntt
m
e
g
a
n
m
a
e
m
g
n
a
ion man
IInnffoorrm
maattio
In
Inte
teggra
rate
teddssaafe
fety
ty
tionnss
SSccaala
lutio
solu
leso
labble
Sy
Syste
stem
mmi
migra
gratio
tionn
Trends
The operators extended role

lele
o
r
o
r
s
r
s
o
r
aatto
r
e
r
OOppe
Process Control
Internet order
Maintenance order
Order Fulfillment
Time
Customer orders
Quality
Alarm
Quantity
Raw material
Energy
Energy waste
ATCE/CS- 19

2003-09-16
Capital utilization
er
Custom t
g
n
i
z
i
rofi
Maxim
n and P
o
io
i
t
c
a
f
s
Satiis
Safety
Mech Drawing
Cost reduction
Eng Spec
Live Video
Improved car worker efficiency

1.
2.
3.
4.
5.
Trends
Assembly robot stops

Operator calls maintenance
personnel
Wait 15 min
Maintenance person inspects
control program
Maintenance person fixes the
problem
50% utilization level of

manufacturing equipment

Process Control
Order Fulfillment
Time
Customer orders
Quality
ABB
Automation Technology - 20
ATCE/CS- 19
2003-09-16
Quantity
Raw material
Energy
lele
o
r
o
r
s
r
s
o
r
aatto
r
e
r
OOppe
er
Custom t
g
n
i
z
i
fi
Maxim
nd Pro
a
n
o
io
i
t
sfac
Satiis
Energy waste
1.
2.
3.
Capital utilization
Safety
Cost reduction
4.
Assembly robot stops

Operator checks with local PCn
The system is guiding the
operator to root cause
Operator fixes the problem
Trends
Asset Lifecycle and Engineering

Process Control
Quantity
Plant
Engineering
Energy waste
Asset
Optimization
Design
Energy
ATCE/CS- 19
Business
Systems
Quality
Customer orders
Raw material
Planning
&
Order Fulfillment
Scheduling
Time
Capital utilization
Process
Engineering er
m
g Custo fit
n
i
z
i
m
i
Max
and Pro
n
o
io
i
t
c
a
sf
Satiis
Safety
Plant Centric
Cost reduction Information

2003-09-16
Operations
Maintenance
EEnnggin
ineeeerrin
inggeefffficicie
iennccyy
Plant
Floor
mizizaatitioonn
AAsssseettoopptitim
Trends
Re-Use of solutions
Engineering Efficiency taken to the Next level:
Re-use of solutions with ALL Aspects included
Libraries of Typical Solutions with ALL Aspects
Copy & Paste of complete process areas
Inheritance -> Update type and all instances are updated!

Identify Solution

2003-09-16
Old
projects
Standard
libraries
Create
solution
Project
library
EEnnggin
ineeeerrin
inggeefffficicie
iennccyy
Implement
solution
Operation - Decommissioning
Trends
Plant Modeling - Object Hierarchies

2003-09-16
Valve
Heating System
EEnnggin
ineeeerrin
inggeefffficicie
iennccyy
Reactor
Trends
Highly Scalable Solutions
Modular design scaled on
Process Control
System size
Customer orders
Functionality
Order Fulfillment
Very Large
Time
Quality
Quantity
Raw material
Energy
Benefits
ATCE/CS- 19

2003-09-16
Energy waste
Required performance
Large
Capital utilization
Safety
Incremental
Capital
Investment
stomer
u
C
g
n
i
z
Maximi z n and Profit

io
sfactio
tiis
Sa
Cost reduction
Flexible Expansion
Pay for what you need.
Use the same software for

Engineering & Operations
irrespective of solution size.
Medium
Sy
Syste
stem
mmi
migra
gratio
tionn
Small
tionnss
SSccaala
lutio
solu
leso
labble
Very Small
Trends
Market Forces
Due to global competition, process

Order Fulfillment
Process Control
industries forced to re-evaluate
Time
Quality
Customer
orders
business
models and implement
Quantity
continuous
improvement
initiatives
Raw material
Energy waste

2003-09-16
Safety
er
tomcompanies
s
Traditionally,
view
u
C
g
zi n
i
t
i
m
f
i
o
x
r
a
P
M
d
Cost reduction
ion an
actio
f
s
i
is
t
a
S
maintenance as necessary evil and not
strategic opportunity
mizizaatitioonn
AAsssseettoopptitim
Cutting costs by consolidating,

restructuring,
and downsizing
Capital utilization
Energy
ATCE/CS- 19
Over $20 Billion USD, or

almost 5% of total North
American production is lost
each year due to
unscheduled downtime.
ARC Insights
Viewed as overhead, Maintenance is target

of managements cost cutting strategies
Yet, unexpected failures and poor

quality product can be devastating to
profit goals
Achieving Operational Excellence

2003-09-16
Plant Asset Management

systems providing real-time
asset performance
information to operations
and maintenance will
increase Return on Assets
(ROA) and lead to
operational excellence.
ARC Insights
Balancing act between high availability

and low cost demands requires a
proactive business strategy with clearly
defined metrics
Continuous Improvement programs

require real-time assessment of Key
Performance Indicators (KPI)
Measure asset performance and identify

performance gaps and opportunities
Unfortunately, traditional maintenance

systems lack real-time information
mizizaatitioonn
AAsssseettoopptitim
Trends
Provide schedule-based functions
Traditional Operation and Maintenance
Trends
OCS
CMMS

2003-09-16
Operations
Maintenance
In a typical day, maintenance will waste 40% of its time

determining root causes of problems
mizizaatitioonn
AAsssseettoopptitim
Trends
Real-Time Plant Asset Management (PAM) system
Asset Simplified business model

Condition
Process Control
Reporting
System
Customer orders
OCS
Order Fulfillment
Time
CMMS
Quality
Quantity
Raw material
Energy waste
Energy
Operations
Operations
ATCE/CS- 19
Capital utilization
Safety
stomer
u
C
g
n
i
z
fit
Maintenance
Maximi
Cost reduction
and Pro
n
o
io
i
t
c
a
sf
Satiis
Maintenance

2003-09-16
Modern automation systems
Field Devices
mizizaatitioonn
AAsssseettoopptitim
Asset
Health
Assessment
Advanced
Process
Performance
Assessment
Can you supply 2 tons in

10 days for 945 dollars?
Answer in ten minutes.
Today
Industrial automation new architecture model
Industrial
Automation
Other
Plant(s)
Corporate
Plant
Area
eenntt
m
e
g
a
n
m
a
e
m
g
n
a
ion man
IInnffoorrm
maattio
Unit
Integrated
Systems
ATCE/CS- 14

2003-09-16
Business
Business Planning
Planning //
ERP
ERP
Loop
Field
Trends
Safety first!
Safety
Safetyisisplaying
playingan
an
increasingly
increasinglyimportant
importantrole
role
both
bothfor
forProcess
ProcessIndustries
Industries
and
andManufacturing
ManufacturingIndustries
Industries
Avoiding
AvoidingHuman
HumanAND
AND
2003-09-16
Environmantal
Environmantalimpact
impact
Integrated
Integratedin
incontrol
controlsystems
systems
Moving
Movingaway
awayfrom
fromhard
hard
ty
fe
a
s
d
te
ty
a
r
fe
g
a
s
te
d
In
te
a
r
Integ
wired
wiredsolutions
solutions
Environmental regulations
Trends
Environment
Environmentisisnot
notfree
free
anymore!
anymore!
Environmental
Environmentalfees
feesare
are
2003-09-16
being
beingcharged
chargedto
tocompanies
companies
Tracking,
Tracking,reporting
reportingand
and
REDUCING!
REDUCING!
En
ct
pact
impa
tallim
enta
men
onm
viron
Envir
Summary
Integrated systems

2003-09-16
Process Control
DCS PLC IMS ERP
Increased complexity
Increased competition
Users
Suppliers
Operators extended role
Information Management
Asset Management
Scalable Solutions
Order Fulfillment
Time
Customer orders
Quality
Quantity
Raw material
Energy
Energy waste
Capital utilization
ATCE/CS- 19
stomer
u
C
g
n
i
z
fit
Maximi
and Pro
n
o
io
i
t
c
a
sf
Satiis
Safety
Cost reduction
Christer Rameback
ABB Automation Technology - 33 2003-09-16
Vice President
Process Automation
Process Automation History and Future

Rame Back

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Rame Back

Uploaded by

Copyright:

Available Formats

Christer Rameback

ABB Automation Technology - 1 2003-09-16

Process Automation History and Future

ABB Automation Technology - 2

Facts about ABB

A leading power and automation technology company with broad

About 150,000 employees in more than 100 countries

Leading position (1, 2 or 3) in each industry we serve and within our

Headquarters: Zurich, Switzerland

ABB Automation Technology - 3

Process Automation Systems

Listening to the users

ABB Automation Technology - 4

Step changes are R&D driven

ABB Automation Technology - 5

Step changes are R&D driven

The BIG steps come

Important aspects for the future

ABB Automation Technology - 6

Simplified business model

ABB Automation Technology - 7

Control systems market

ABB Automation Technology - 8

Early 1900 electrification!

Rolling mills, paper mills, car

Early 1900 oil flow,

Oil industry, pulp mills, (power

Contactors - Relays Electronic

Early 1970s - Microprocessor

Manual loops - Mechanical

Simple MMCs (Man Machine

Early 1970s - Microprocessor

More advanced MMCs

Somewhat more advanced

ABB Automation Technology - 9

Limited Information Management

Evolution of digital control systems

ABB Automation Technology - 10

60s and 70s

Improved functionality over time

PLC functions vs DCS functions

Integrated systems: PLC <-> DCS <-> IMS

Industrial automation traditional

ABB Automation Technology - 11

Industrial automation new architecture model

Simplified business model

ABB Automation Technology - 13

Due to global competition combined

Cutting costs by consolidating, restructuring,

Control systems market

ABB Automation Technology - 14

Control systems market trends

Changes in the competitive structure

Too many suppliers and low profit levels

Mergers and acquisitions

Merging market segments

PLC vendors enter the OCS market

The hybrid systems market is

ABB Automation Technology - 15

ABB, Siemens, Rockwell, Fisher-Rosemount, Honeywell

Market exits due to increased development costs

Shake-out of smaller suppliers

Large end users with own control systems outsource

Control systems market trends