Author: Robin Buxton

GE seeks to drive MES adoption with their latest Plant Applications 7 software

With the recent release of GE Digital’s new Plant Applications Manufacturing Execution (MES) solution, hybrid manufacturing companies are now able to benefit from improved operational visibility for more effective decision-making.

Plant Applications, commonly referred to as ‘Plant Apps’, has been consistently updated over the last 20 years to develop into a true best-in-class product. Used by over 700 manufacturers worldwide, the eagerly awaited Plant Apps 7 upgrade was demonstrated at this year’s Hannover Messe. Key selling points include the support of efficiency, safety and quality initiatives, ‘Off the shelf’ supportability and product road map. The new software is also built with GE’s Brilliant Manufacturing and industrial internet developments in mind, such as the Web HMI and Thingworx interface.

The product spans two parts of business activity: traditional control systems and business systems (MRP II/ERP). Despite promising significant operational benefits, MES software solutions have historically been somewhat sticky for vendors and system integrators to sell; overlaps in ERP, MRP and MES offerings have made it difficult for customers to distinguish the systems worthy of investment. This has resulted in widespread and woefully inadequate practices, such as recording downtime events and reasons on basic spreadsheets, or even handwritten records. So the question remains: why should companies change now? The difference is that although big gains in efficiency (>10%) are relatively easy to achieve without dedicated systems, it is the smaller gains that provide the competitive edge. Finely tuned efficiency requires advanced analytics and powerful computing systems. Most companies recognise the benefits of some kind of over-arching IT system, and MRP software offers SMEs a better solution without the need to invest in expensive global ERP products. Where MES comes into its own is the production-specific functionality it offers for manufacturers. It can also be designed flexibly to meet individual business needs.

MES Production Management ‘Track & Trace’ – what to expect

  • MES communicates between the MRP system, users and automation systems, including any batch execution systems and its recipes
  • It controls the ‘Bill of Materials’ – quantities and types of raw materials, precision timings and packaging
  • Enables traceability and genealogy
  • Manages shift patterns and teams
  • Provides real time visibility and efficiency: in the event of broken parts or machine failure, it will inform where the failure has taken place and, provide a targeted number of reasons why this will have happened so the user can choose the best-fit answer, and measure unexpected downtime
  • Quality control via automated spot checks, accurate recording of events
  • Waste minimisation

Andy Tripp, Managing Director of Astec comments,

“This isn’t about fancy technology and data collection for vanity’s sake. Investment in modern MES will form an integral part of the journey towards building a digital factory for future survival. This particular software product from GE has evolved from a rich heritage of best practice improvements. Once implemented, it will form a pivotal part of an organisation’s network infrastructure, industrial internet-readiness and digital strategy.”

Astec are the sole Premier Solution Partner (PSP) in the UK for GE Digital. While Astec remains vendor agnostic, the company’s unparalleled GE product knowledge results in GE-centric solutions that are engineered using product-based configuration. This maximises existing product features and functionality and avoids unnecessary customisation for fully supportable, future-proof solutions. To find out more about how Plant Applications from GE Digital take your operations to the next level, contact us or download the product datasheet.

Astec joins with Keele University to improve efficiency through data

Astec has joined forces with Keele University to participate in their Smart Energy Network Demonstrator (SEND) to investigate data analytics solutions focused on smart energy applications.

The initiative has been set up to demonstrate how smart energy supply networking, storage and monitoring can improve security and reduce costs and carbon emissions.

Part-funded from the European Regional Development Fund, and the Department for Business, Energy & Industrial Strategy, the SEND project will promote the production of energy derived from renewable sources to research communities, local communities, government authorities and to the energy industry itself.

The project will see Astec work closely with the academic specialists at Keele University over the next 3 years, to help support research activity and commercialise the technology in the marketplace. As a GE Digital Alliance Partner, Astec will be using GE’s Predix Platform to collect and analyse data through the development of apps and micro services.

Astec’s Managing Director Andy Tripp says,

“It is a fantastic opportunity to be able to utilise the University’s facilities and smart energy network for research and development of innovative commercial product solutions. By identifying previously hidden patterns and relationships in data we will be able to positively impact on customers’ efficiency and cost base to provide them with a competitive edge.”

Commentating on the tie-up, SEND Director at Keele University Prof. Zhong Fan said,

“Astec is a great example of a technology company in Staffordshire now poised to exploit the potential of the Internet of Things, and our collaboration with them will be of mutual benefit.”

About Astec

Astec Solutions has been delivering automation and production management software solutions into the Manufacturing, Utilities and Broadcast sectors for over 17 years. As well as solving the immediate operational challenges which often drive project engagement, Astec strives to ensure installed solutions turn the data within clients’ systems into insight, allowing them to achieve real improvements in the effectiveness and profitability of their business. As a GE Digital Alliance Partner, Astec leverages tools and technologies from GE to deliver real-time data solutions.

Chris Barlow, Astec Technical Director explains more about why Astec signed up to the SEND programme in this short video.

Astec exhibiting at PPMA 2017 to help manufacturers take their operations to the next level

Automation systems integrator Astec Solutions will be returning to Birmingham’s NEC this September to exhibit on stand H84 at PPMA 2017.

For the last three years Astec has been an active member of the Processing & Packaging Machinery Association, and has exhibited at the annual PPMA show. The event attracts manufacturers and packers from all over the world, from sectors ranging from food and beverage to pharmaceutical and personal care.

As specialists in SCADA, Batch Execution, Analytics and Manufacturing Execution Systems, and experts in GE software, Astec will be offering practical guidance on how manufacturers can take their operations to the next level: from automation through to decision support, analytics and even IoT.

In particular, Astec will be seeking to address the void between what is being talked about in the media regarding developments in connected technologies, and what is actually happening in factories across the UK today. According to research firms such as Gartner, we are on the cusp of mass adoption of IoT solutions, but the associated disruption is causing some OEMs to look for less radical options.

The proper utilisation of IoT solutions demands significant business re-modelling, so to satisfy customer needs for an interim solution, Astec will be recommending the latest versions of proven software products that have been designed with industrial internet compatibility and support in mind.

Astec MD Andy Tripp comments,

“We are able to provide manufacturers with a clear strategy so they can progress and take the next steps of their digital journey. Highly regulated industries such as Food & Beverage and Pharmaceutical have so much to gain from the industrial internet – better stock traceability, safety, reduced wastage, improved quality control and reduced downtime to name but a few areas which can benefit.

SCADA is a great place to start as it already has connectivity to real-time intelligent analytics. GE’s iFIX 5.9 for example, enables web HMI. This OT/IT convergence with Predix and the industrial internet is driving improvements to user interfaces. Better visualisation, predictive early warning systems and even augmented reality SOPs [standard operating procedures] will empower the workforce to work effectively, instead of constant fire-fighting.”

About Astec

Astec Solutions has been delivering automation and production management software solutions into the Manufacturing, Utilities and Broadcast sectors for over 17 years. As well as solving the immediate operational challenges which often drive project engagement, Astec strives to ensure installed solutions turn the data within clients’ systems into insight, allowing them to achieve real improvements in the effectiveness and profitability of their business. As a GE Digital Alliance Partner, Astec leverages tools and technologies from GE to deliver real-time data solutions.

Astec recommends multi-faceted approach to mitigate risk of ransomware attacks

On 12th May 2017 the WannaCry ransomware affected over 200,000 victims and infected more than 300,000 computers worldwide.

Among the victims were the NHS, who were forced to run some services on an emergency-only basis during the attack. A second major attack struck several large organisations again last month, using ‘Petya’ type ransomware. Both attacks involved self-duplicating network worms, which rapidly spread using the EternalBlue vulnerability in Microsoft Windows. The cyber-attacks spread across the world, crippling hundreds of businesses from shipping companies to advertising firms.

The hacks can cause major disruption to global infrastructure, and while the threat of repeat attacks looms, the real issue is how to avoid falling victim to them in the future. IT and Engineering departments who have been paying lip service to cybersecurity risk mitigation are waking up to a priority re-think.

Blame game

Part of the blame for the WannaCry attack was apportioned to the US intelligence agencies CIA and NSA, who were accused of stockpiling the software code for their own use, instead of reporting the issues to Microsoft. Others find the affected companies at fault for not updating their unsupported systems – or for not installing the patches supplied by Microsoft as they were released.

It was revealed the new state of the art £3.5 billion HMS Queen Elizabeth aircraft carrier is running on Windows XP, and Britain’s nuclear submarines are also still believed to run on XP. XP is still more widely used than Windows 8.1 (released in 2013) or any version of Apple’s Mac OSX or the open-source Linux OS. Although Windows XP, Windows Server 2003 or older systems are most at risk, many victims of the WannaCry attack were running on Windows 7, and the recent attack on the Ukraine is believed to have been seeded through a software update mechanism built into an accounting program.

Some researchers claim the recent spate of cyberattacks (which uses malware structured differently to the original ‘Petya’ code) are merely masquerading as ransomware, as the hackers put little effort into designing an effective payment system. This raises questions over possible motives for purely malicious and destructive attacks, which could be political rather than money-orientated.

The advice

For end users of Automation Systems however, the who and whys are largely irrelevant. Astec Technical Director Chris Barlow comments,

There will always be someone looking to spoil someone else’s party for money, vanity or more sinister motivations. I have witnessed numerous people in the IT and Engineering domain squabbling over who knows the most, and who has the best advice. Better to rise above it and simply do all you can to reduce the ever-present risks presented by cyber security.

Remediation activity can start with the following steps:

  • Ensure all operating systems are currently supported by the vendor
    Develop an obsolescence plan for any systems running on Operating Systems older than Windows 7 or Server 2008. Then plan ahead for the phasing out of support for Windows 7 and 2008. Windows NT, 2000, XP or 2003 are not acceptable platforms on which to run your business.
  • Check you have the right patching regime to ensure supported systems are up to date
    Typically, users of Automation Systems avoid patching of real-time systems so as not to threaten production. However this is unnecessary, as any risks associated with patching can be easily mitigated by the implementation of test systems and/or redundant architectures.
  • Check your network is as secure as it can be
    Although it is wise to only have ‘open doors’ for the communication methods employed by active systems, securing your network is not about isolating the system from other internal networks – or even from the internet. A well-managed and protected connection to the internet can actually be what saves a site from a cyber threat. It can be used to obtain operating system or antivirus updates, as well as issuing email or SMS alerts to warn of impending production system component failure.
  • Isolation is no guarantee of protection
    Isolation of systems should never be reason for complacency, as many issues arise from local engineering laptops or operators using USB ports to charge phones. Air gaps do not provide inherent protection, despite being given as a popular reason as to why a system does not require updating or patching.
  • Use Anti-Virus software
    Engineering departments continue to be wary of implementing antivirus software within Automation systems, but this does not need to be the case. All antivirus engines can be configured to enable systems to function correctly.
  • Back it up
    Finally, as a fail-safe contingency, a well-managed and monitored backup strategy will enable the system to be rebuilt and restored if all goes wrong.
  • Understand the risks, have a plan and start to implement it!

About Astec

Astec Solutions has been delivering automation and production software solutions into Manufacturing, Utilities and Broadcast sectors for over 17 years. Core capabilities are focused on the provision of Manufacturing Execution Systems, Batch Execution and true Supervisory Control and Data Acquisition (SCADA). The Astec team is passionate about exceeding expectations, combining deep technical knowledge with extensive marketing experience to work with customers throughout their improvement journey.

For further information on how Astec can assist with building your cyber security strategy please contact +44 1543 888134 or email enquiries@astecsolutions.com.

SCADA Vendor Selection: Innovation over Imitation

In this day and age, is it even possible to select the wrong SCADA vendor?

Back in the 1990s, part of a greenfield control system architecture proposal would include a detailed SCADA vendor selection process. This process would focus on variables such as the features and benefits list, cost, ease of use and speed of development. Those days are long since over, since there is no doubt almost every SCADA product on the market is capable of providing a comprehensive solution at a reasonable price. This has been great news for the customer, who is free to use the product they are familiar with and a preferred vendor they feel they can trust. Most products can be configured in any graphical style, provide wide connectivity, and usually all of the more complex features such as distributed architecture support, detailed historical trending and remote alarm alert services. With product differentiation becoming a difficult part of the purchasing process, and largely pointless, many end users have opted to stay with the same SCADA product for the last decade or so. But they may have been getting a little too comfortable.

Whilst Astec is vendor agonistic, the business continues to be closely aligned with GE Digital. Astec founder and MD, Andy Tripp asserts the motivation behind the alignment is for good reason. GE’s SCADA products, iFIX and CIMPLICITY, form part of a much wider software product portfolio which has benefited from a staggering level of investment. In the last few years, GE has ploughed billions of dollars into development to ensure its software products have strong future road maps. This has ensured their products remain relevant for tomorrow’s Industrial Internet as much as today’s Automation and Control solutions. Astec is confident that GE’s software stack can provide customers with the best possible future extensibility of their system, as well as maximising return and keeping total cost of ownership low.

GE’s drive to improve their own manufacturing facilities (with locations in more than 170 countries across sectors such as healthcare, transportation and power) re-focused their commitment to automation and control software and the Industrial Internet. This was cemented by the creation of GE Digital in recent years, following CEO Jeffrey Immelt’s vision to re-invent GE as a ‘digital industrial’ organisation.

For SCADA solutions, the task for today’s end user is to challenge potential integrators around their experience and methodologies on key subjects such as security, compliance, standards, support and future system extension. Andy comments,

“You can have the best product in the world and still deliver it poorly. The outcome of a below-par delivery can stay with a manufacturing facility for decades, harming its competitive position in the market.”

As the sole Premier Solution Partner for GE Digital in the UK, Astec boasts an unrivalled depth of knowledge in the GE product family, which allows them to provide product-based solutions with the least amount of engineered customisation. This is one of the tell-signs Andy advises looking out for when sourcing a suitable integrator,

“End users need to determine if the system integrator can get the most out of the chosen product, or if they have a natural inclination to engineer their way out of trouble with custom code and custom solutions. If it’s the latter, the likelihood of the system being less supportable and extendable significantly increases. It’s also essential the integrator has sufficient knowledge and experience to work with the end user’s IT departments to ensure supportability, maximum security and resilience. The implications of the IT world must be fully understood, so systems can work in harmony with the existing architecture, and not against. These factors also will begin to directly affect the pace that customers can adopt and leverage cloud-based technology.”

For those end users who may already have a poorly configured or poorly performing system, a ‘RAG’ (red amber green) survey can be carried out to determine its effectiveness, and highlight any areas requiring improvement and updates.

Over the last few years, Astec have been working with GE to push forward the latest user interface standards to enhance the user experience. In addition to impacting traditional SCADA, this enables cloud technologies of the Industrial Internet to become a seamless extension of existing systems.

Astec are able to use the new interface to exploit the world of analytics and artificial intelligence within a manufacturing environment. Predictive algorithms can inform users of impending failure of process hardware and production tolerances, with dynamic workflow and decision support preventing basic mistakes and downtime. KPIs and large volumes of production system data from an individual site can be elevated to display user-centric, actionable insights using Predix, GE’s platform for the Industrial Internet. Astec recently joined GE Digital’s ecosystem of Alliance Partners to develop new applications for Predix, with 50% of business expected to come from cloud-based solutions within the next 5 years.