ap02: amgen, inc.: the no-impact migration – upgrades in a validated environment
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Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
PUBLIC INFORMATION
Amgen, Inc.: The No-Impact Migration -Upgrades in a Validated Environment
Innovative Strategies in Migrating Legacy PLC5 Control Systems
Tom Lopez, Amgen
Richard Kleinfeld, M+W Automation
Agenda
• Company Background
• CEMS Implementation
• UCS Implementation
• Q & A
Amgen Today
World’s largest independent biotechnology company
~ 20,000 employees
> 75 countries
Reached millions of patients
For additional information about Amgen products, including important safety information, please visit amgen.com; Kyprolis® (carfilzomib) is developed and marketed (except in Japan) by Onyx Pharmaceuticals, an Amgen subsidiary; NEXAVAR® (sorafenib) is developed and marketed under collaboration and co‐promotion agreements between Bayer Healthcare and Onyx Pharmaceuticals
M+W Automation (MWA) Competence Network
AMERICAS EUROPE ASIA/PACIFIC
270 Employees
Headquarters:• Danbury, CT, USA
630 Employees
Headquarters:• Ludwigshafen, Germany
60 Employees
Headquarters:• Shanghai, China
• Austria• Belgium• Czech Republic• Germany• Ireland• Poland
• Russia• Switzerland• Slovakia• The Netherlands• Turkey
• Canada• Puerto Rico• USA
Chemicals Pharma & Biotech Food & Nutrition
Automotive Semiconductor Oil & Gas, Mining
Industries
Background:
• Critical Equipment Monitoring System (CEMS)
• Windows 2000 Upgrades initiated discussions for strategic review/replacement of obsolete hardware/software
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CEMS Implementation
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CEMS ImplementationBackground:
• Main Buildings in scope (I/O count):
• BA (120)• BB (45)• BC (80)• BD (240)• BE (720)• BF (180)• BG (200)• BH (690)
Total Buildings Upgraded: 11Total I/O: 2615
• Other Buildings/Sites:• BI (300)• SiteJ (45)
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CEMS Implementation
Business Case Detailed Design
Implementation/Testing
Commissioning
Traditional New Design BenefitsStand-Alone Installations Rockwell Client-Server-
architectureFully integrated design, Centralized software,Ease of maintenance/ change management
iFix HMI – Rockwell PLC integration
Rockwell HMI – Rockwell PLC
Amgen standard, Ease of integration, minimize training/ customization between vendors
iFix Data Collection/ Trending
PI Interfaces for each building
Amgen standard, more robust & reduce complexity/SPOF
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CEMS Implementation
Business Case Detailed Design
Implementation/Testing
Commissioning
Traditional New Design BenefitsiFix-based Alarm Generation
PLC-based Alarm Generation
More robust & reduce complexity
Custom HMI design Rockwell GEMS library Amgen standard, Rockwell COTS support
Win911 and HMI on common workstation
HMI on ServerWin911 on workstation
Dedicated workstation for Alarm Notification
Automation Hardware on business network (VLAN)
Automation Hardware on Manufacturing Network
Secure, dedicatednetwork for automation assets limits exposure to threats
Innovation and best practices helped drive our strategy
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CEMS Implementation
• GMAX contract (i.e. T&M Not Too Exceed)
• Competitively Bid
• Leverage a Bundled Approach
• Drive Savings
Business Case Detailed Design
Implementation/Testing
Commissioning
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CEMS Implementation
Business Case Detailed Design
Implementation/Testing
Commissioning
• Leverage common documents for multiple buildings• URS, FS, NDS, OIDS
• Generate site/building-specific documents• SDS, DT, IV/OV, RTM, VSR
Software Builds:
CEMS Implementation
CEMS ImplementationGEMS Library:
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CEMS Project Implementation
Business Case Detailed Design
Implementation/Testing
Commissioning
• Module Configuration Tool• Tag Rung Tool• Document Development Tool• Development Test in Parallel with live system• Development System on VM Environment• Mobile PLC for Parallel Communication
Module Configuration Tool:
CEMS Project Implementation
Tag Rung Tool:
CEMS Project Implementation
CEMS Project ImplementationDocument Development:
CEMS Project Implementation
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CEMS Implementation
Business Case Detailed Design
Implementation/Testing
Commissioning
• Software tools developed, translate design docs to commissioning docs
• Minimal Validation Requirements• Minimal Downtime• I/O Wiring Conversion
I/O Wiring Conversion:
CEMS Implementation
• What is Virtualization?
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UCS Implementation
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• Benefits:• Less Physical Infrastructure to Maintain• High Application Availability• Stable System Modifications• Lifecycle costs
• Risks:• Network Issues• Software/Application Compatibility• VMWare Robustness• Novel technology
UCS Implementation
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UCS Implementation
Project Results
• CEMS downtime required for startup 4 hours.
• On time under budget for 8 consecutive startup scheduled 1 month apart
• Solution can perform JackPanel functions with no invasive action
• Automation solution is on a segregated Manufacturing Network
• Maintenance cost reduced
• 30% Cost Avoidance/Savings from Original Estimate
Questions?
Tom Lopez, Amgen
Richard Kleinfeld, M+W Automation
Copyright © 2014 Rockwell Automation, Inc. All Rights Reserved.
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