1660317274462 Frankkulaszewiczrockewllarticle2

How services can connect the digital dots

Nov. 9, 2021

ā€œThe success of everyone really depends on understanding whatā€™s possible, and the only way you can truly understand whatā€™s possible is through the power of knowledge,ā€ began Frank Kulaszewicz, senior vice president of lifecycle services at Rockwell Automation, in his Perspectives presentation in the run up to this weekā€™s Automation Fair 2021 in Houston.

ā€œAt Rockwell Automation, our vision of a Connected Enterprise is really uniquely positioned to help transform companies,ā€ he said. He also discussed Rockwell Automationā€™s role in leading customers on their digital journeys, the acquisitions and new services designed to help these client enterprises from beginning to end.

Many companies lack the expertise and experience to realize their digital transformation initiatives, Kulaszewic added, and Rockwell Automationā€™s Lifecycle Services group helps with those challenges. Last year at the Automation Fair, Rockwell introduced its new brand: LifecycleIQ Services. As a trusted advisor for its customers, the brand combines technology with domain expertise to help solve customer challenges.

The portfolio of services, focused on product inception through production to supply chain, all the way through to the needs of its customerā€™s end-users embrace five areas: consulting, professional, connected, field and workforce services. ā€œOur services group is innovating faster than ever before and that allows us to bring more value to the customer than ever before,ā€ Kulaszewicz says. ā€œAnd thereā€™s no one better positioned to bring together the power of IT and OT in a simple, scalable and sustainable way.ā€

Connecting the whole value chain

In many different industries, customers are starting digital transformation initiatives, but they often struggle to scale, Kulaszewicz added. ā€œDigital transformation canā€™t happen in pockets, it has to happen across that entire value chain,ā€ he said.

Last year, Rockwell Automation expanded its digital business, intent on helping customers create that single value chain, with the purchase of Kalypso, which provides integration services for digital transformation. ā€œThey really fundamentally change how customers discover, create, make and sell their products,ā€ Kulaszewicz said. To establish that digital thread and continuous flow of data from connected products, equipment, processes and systems, Kalypso combines industry domain expertise with the customerā€™s strategy, technology and some change management. ā€œChange management is a big part of digital transformation,ā€ Kulaszewicz said.

Kalypso, as well as Rockwell Automationā€™s ecosystem of technology partners, have allowed the company to expand beyond manufacturing into product development and supply chain management. Recently, Rockwell Automation acquired Avata, a provider of supply chain management services, enterprise resource planning and enterprise performance management solutions. ā€œTheyā€™re also a leading consultant and system integrator for cloud-based software solutions and have been a strategic partner of Kalypso for some time,ā€ Kulaszewicz said. ā€œAvata is going to really help us provide a more comprehensive set of services and solutions for our customers as they navigate supply chain challenges.ā€

With expanding services, Rockwell is also growing into new industries with Avata and Kalypso, like its work with Fresenius Medical Care, a global medical device manufacturer. Several years ago, Rockwell worked with the company to develop a product lifecycle management foundation. The company wanted to better connect product development with its manufacturing capabilities to produce more complex therapy systems for the market.

Now, the company is working on the digital transformation piece to provide a digital thread from product development and manufacturing to the maintenance team to improve efficiency and productivity. ā€œKalypso has been guiding them to connected products and connected operations, and so what they want to do now is improve how to connect the product design digital twins and the factory digital twins to revolutionize manufacturing methods,ā€ Kulaszewicz said. The new analytics layer will provide insights to deliver the outcomes the company is after.

As another example, leveraging its LogixAI technology, Rockwell Automation is working with a global tire manufacturer to evaluate its production processes and reduce downtime. The company was not having failure issues with machines, but it was experiencing process failures.

ā€œDowntime from splice failures where they bring the sides of the tire together is their biggest production downtime,ā€ Kulaszewicz said. Kalypso, with LogixAI devices, trained an algorithm to predict when splices would happen. Once they understood the conditions under which failures occurred, they could identify the machine process variables and adjust them in real-time to bring splice tolerances back in line. ā€œThat might seem like something simple, but it significantly reduced downtime,ā€ Kulaszewicz said. One plant was able to produce an additional half a million tires per year.

Cybersecurity: merging IT and OT

As more and more companies venture on the digital journey, data connectivity and cybersecurity become larger concerns. With more and more cyber criminals targeting industry and critical infrastructure, these companies need advanced cybersecurity solutions. ā€œThere are more processes and tools available now than ever before to help companies understand and mitigate these risks,ā€ Kulaszewicz said. ā€œBut itā€™s not easy finding the right solution capabilities to mitigate cybersecurity risk in an OT environment.ā€ Rockwell believes it is uniquely positioned to address the cybersecurity challenges across information technology (IT) and operational technology (OT) environments.

ā€œToday weā€™re doubling down on our security investments to build the most responsive industrial cybersecurity offering on the market, so no matter where you are on the journey, we can build an adaptive plan for before, during and after a cyber incident,ā€ Kulaszewicz said.

Last year at the Automation Fair, Rockwell announced it would build a security operations center (SOC) in Israel, which is now available to provide remote security management services, continuously monitoring security for customers. Likewise, Rockwell Automation is also growing its cybersecurity partnerships, including projects with Dragos and CrowdStrike. The Dragos partnership will focus on response and recovery, and the work with CrowdStrike on OT end point security.

Many plants full of aging equipment have infrastructure that wasnā€™t designed with cybersecurity in mind. Rockwell helped one of its global food and beverage customers faced with this challenge to assess, design and modernize its critical infrastructure. ā€œWhatā€™s interesting about this is we used our infrastructure as a service offering and migrated all their networking services onto an OT network,ā€ Kulaszewicz said. ā€œToday weā€™re managing over 100 plants for them, keeping infrastructure up to date and secure.ā€

Rockwell Automationā€™s customers range across broad and diverse industries, often complex in nature, but this is where the organization thrives, Kulaszewicz said. ā€œWe help customers do the hard stuff, and we try to deliver value in whatever way that works.ā€

The lifecycle services group has a comprehensive portfolio to cover all manufacturersā€™ needs, and the flexibility to partner with customers at any stage of the lifecycle. ā€œWhen youā€™re challenged with something that feels impossible,ā€ Kulaszewicz said, ā€œwe can help you see whatā€™s possible.ā€

Get the best of Automation Fair 2021

The editors of Control, Control Design and Smart Industry are reporting live from Automation Fair. When the event comes to a close, the editors will compile a report of the best, most important coverage from the event. Register now to pre-order the report and be among the first to receive it in your inbox.Ā Pre-order your copy now.

Sponsored Recommendations

Make Effortless HMI and PLC Modifications from Anywhere

The tiny EZminiWiFi is a godsend for the plant maintenance engineers who need to make a minor modification to the HMI program or, for that matter, the PLC program. It's very easy...

The Benefits of Using American-Made Automation Products

Discover the benefits of American-made automation products, including stable pricing, faster delivery, and innovative features tailored to real-world applications. With superior...

50 Years of Automation Innovation and What to Expect Next

Over the past 50 years, the automation technology landscape has changed dramatically, but many of the underlying industry needs remain unchanged. To learn more about whatā€™s changed...

Manufacturing Marvels Highlights Why EZAutomation Is a Force to Be Reckoned With

Watch EZAutomation's recent feature on the popular FOX Network series "Manufacturing Marvels" and discover what makes them a force to be reckoned with in industrial automation...