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ALL IN ONE SOLUTION FOR THE PROCESS INDUSTRY
Savings and Expertise for your plant
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Discover a new level of Data Safety for
Automation Technology
Discover a new level of Data Safety
for Automation Technology
Version Control Smart Compare History
Audit-Trail Archiving Check-In/Out Access
Controle-SignatureAutom.Backupsemail
ReportReporting
in line with ISO 900x and FDA 21 CFR 11
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Consistent data management
Problem
Problem
It doesnt matter whether you produce cars,
drinks or pharmaceutical products
The problem
Planning, maintenance production vital data
is changing all the time!
Reasons for changes Product mods., bug
fixes cycle time optim., safety measures,
botched mods....
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Risk assessment for data management
Risks
Risk assessment for data management

• How likely is it that something will go
  wrong?(FMEA Failure Mode and Effect Analysis)
• How serious would the consequences be?
• How often does the risk arise?
• How many people could be affected?
• How much product could be affected?
• What are the financial implications?
• Are the effects immediate or chronic (long term)?
• What does the law require?

Risks
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Risks to be controlled and prevented
Risks
Risks to be controlled and prevented

• Are the correct software releases operating the
  production?
• Do software changes effect quality and safety?
• Can unauthorised software modifications be
  detected?
• Are all systems software secured and accessible?
• Is there control over data access and handling?
• Can a replaced device be restored in acceptable
  time?

Risks
and, and ......
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Which measures have been taken?
Reality
Which measures have been taken?

• Filing on HDs and server
• Backup on CD, DVD (monthly, weekly)?
• LAN integration of PCs and workstations
• LAN enabled (SoftnetTM) programming software
• Formal work instructions and procedures
• .... and your actions?

Reality
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Have you gained control?
Reality
Reality
Have you gained control?...
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Or does this seem familiar?
Reality
.... or does this seem familiar?

• Where is the correct version?
• What exactly has been changed and why?
• Who has overwritten my changes on the server?
• What software version is our system really
  using at present?
• Why is it that nobody knows the answer...!!!

Reality
. and now?
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The current situation?
Reality
The current situation?
Enormous efforts, poor quality,
lots of risks!
Reality
Action must be taken!
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The requirements
Requirements
The requirements

• Server based, central project data storage
  withuser and access management
• Copy management between workstationsand server
• Automated program editor operations
• Version control and archiving
• Change management documentation
• Change history, reporting and audit trail

Requirements
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The requirements
Requirements
The requirements

• Scheduled automatic backup of controller and
  device programs, including change detection
• Automatic change notification via e-mail
• Efficient and speedy disaster recovery
• Documented change process in line with ISO 900x
  and FDA 21 CFR 11
• Proven solution with reference sites

Requirements
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The type of data to be managed?
Requirements
The type of data to be managed
PLC / PC
SCADA / HMI / ROBOTS

• WinCC, ProTool, PCS 7
• InTouch
• Citect
• Ghost Images
• ABB, KUKA
• FANUC, ADEPT
• usw.

Requirements

• Siemens
• Rockwell
• Schneider (Concept, Unity)
• 3S CoDeSys
• TwinCAT
• NC, CNC, DNC (840D)
• usw.

• .bin, .xls,
• .exe, .ppt,
• .txt, .mdb,
• .doc
• E-CAD
• Specifications
• etc.

• Indramat
• SEW
• Lenze
• Leutze
• Datalogic
• etc.

FIELD DEVICES AND DRIVES
FILES / DOCUMENTS
A well designed concept can manage
the data of any application
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Vital data totally under control!
Solution
Vital data under total control!
Version Control Smart Compare History
Audit-Trail Archiving Check-In/Out Access
Controle-SignatureAutom.Backupsemail
ReportReporting
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A closed loop control for data flow
Solution
A closed loop control for data flow
- developed from practical experience -
Archive Server
Work process
Workstations
Devices
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Eindeutige Datenablage
Solution
Direct overview

• Easy to use with the Commander Easy Mode
• Project components, including all versions
• Instant access to change history
• Filing order and structure as required

Work bench Commander Easy-Mode
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Eindeutige Datenablage
Solution
Transparency and functionality

• Search function for the project tree and master
  data
• Overview of all components which are under
  construction
• Indication of the PG- and AG- Actuality
• Backup- and Restoring on push of a button

Work bench Commander Power Mode
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Detailed changes - S7
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detailed changes - S7
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detaillierte Unterschiede - S7
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detailed changes - WinCC
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detaillierte Unterschiede PCS 7
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detaillierte Unterschiede PCS 7
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detailed changes - InTouch
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detaillierte Unterschiede - Schneider
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detaillierte Unterschiede - Citect
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detailed changes - Word
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Detailed changes - KUKA
Solution
Version control
S7
Rockwell
Codesys TwinCat
WinCC
PCS 7
InTouch
Schneider
Citect
Word
KUKA

... and more
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Components history
Solution
Component history

• Electronic change records audit trail
• Smart Compare between any two versions

History Audit-Trail
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Central data vault
Solution
Central data vault

• User administration with account policies
• Automated file and directory management of
  all copying procedures (check-in/ -out)

Archiving
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User security policy
Solution
User security policy

• Unique user administration and management
• Electronic signature of specific actions

Access controle-signature
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Sicherheitsrichtlinien für Benutzer
Solution
Release procedure - Workflow

• Release procedure according to the
  four-eye-principle for new versions
• Electronic Signature
• Escalation Management
• Deputy Regulation
• Email Notification
• Audit Trail for all actions

Release Procedure
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Automated Backups
Solution
Automated, scheduled device data backupvia LAN
(device upload via PLC-Saver)

• Backup of PLC programs (including Soft-PLC),
  SCADA or HMI, robot controllers, NC, etc.
• Backup of recipes, setpoint values and
  parameters (for S7 according to selected
  words or variables)
• Backup of any files via shared network resource
  or FTP
• Change detection between backup and archived
  version
• Backup and change report via email
• Support of manual program backups for non LAN
  accessible devices

Automatedbackups
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Automated change report
Solution
Automated change report

• Email report
• Smart Compare of any change

Change report via email
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Project State and reporting
Solution
ProjectState and Reporting

• Audit trail of all activities
• Predefined and user defined selections and
  filtering
• Time-stamped to local- and UTC time
• Print functions and export to CSV-file

Audit-TrailReporting
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Highlights of VersionWorks
Highlights
Highlights of VersionWorks

• Archiving of program- and data files on a server
  with secure user-, access- and copy management
• Support of all PC based data types
• Version control and archiving
• Change history and audit trail
• Scheduled automated backup of controller and
  device programs including change detection
• Automated change notification via e-mail
• Efficient and speedy Disaster recovery
• Documented change process and audit trailin line
  with ISO 900x and FDA 21 CFR 11
• Proven solution with reference sites
• 170 companies approximately 2000 user administer
  approximately 20.000 devices

Highlights
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What do we gain by this?
Benefits
What do we gain by this?
Benefits
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Quality improvement due to VersionWorks
Benefits
Quality improvement due to VersionWorks

• Complete version control and archiving of all
  data and software releases as a foundation for
  disaster recovery
• Exact reproducable production conditions
• Association and traceability of software releases
  and product batches
• Secure user and access administration
• Electronic signature for all relevant actions
• Documented change process and audit trail in
  line with ISO 900x and FDA 21 CFR 11
• Automated change check and e-mail reporting

Benefits
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Cost reduction due to VersionWorks
Benefits
Cost reduction due to VersionWorks

• Reduction of production down time
• Prevention of down time and bad product, due to
  accidentally activated old software
• Prevention of financial loss, due to loss of
  vital data
• Prevention of loss of know-how, due to personnel
  changes/movement
• Quick training of new personnel
• Time saving for the searching of valid Software
  releases
• Extreme improvement of daily procedures and
  routines
• Short amortization time (ROI)

Benefits
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Referenzen - Automobilindustrie
References
Automotive Industry
DaimlerChrysler Rastatt, Wörth, Mannheim
Audi Ingolstadt
BMW Dingolfing
DaimlerChrysler Sindelfingen
References
BMW Landshut, Leipzig
DaimlerChrysler Berlin, Bremen
BMW Regensburg
Ford Köln
BMW München
Volkswagen Brüssel (BELGIEN)
Shanghai GM Shanghai (China)
Volkswagen Hannover, Braunschweig
DaimlerChrysler Germersheim
Volkswagen Wolfsburg
DaimlerChrysler Mettingen
FAW-VW Changchun (CHINA)
Automotive Associated Industries
Behr Mühlacker
Continental Teves Morganton (USA)
Brose Coburg
Corning Kaiserslautern
Continental Teves Frankfurt
KS Aluminium Neckarsulm
Continental Teves Mechelen (BELGIEN)
LuK Bühl
Continental Teves Culpeper (USA)
Mann Hummel Marklkofen
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References Food Beverage/Parma
References
Food and Beverage Industry
Bavaria Lieshout (HOLLAND)
Nestlé Hamburg-Wandsbek
Becks Bremen
Nestlé Biessenhofen
References
Carlsberg Northampton (UK)
Nordwest Getränke Soest
Danone Ochsenfurt
TetraPak Glinde
Indag Eppelheim
Veltins Meschede
Krombacher Kreuztal
Wagner Nonnweiler-Braunshausen
Langnese-Iglo Reken
Warsteiner Warstein
Molkerei Alois Müller Fischach
Pharmaceutical and Chemical Industry
BASF Minden
Roche Mannheim
Boehringer Ingelheim Ingelheim
Roche Penzberg
Fresenius St. Wendel
Salutas Pharma Magdeburg
Merck Gernsheim
Wacker Chemie Burghausen
Novartis Basle (SWITZERLAND)
Wella Weiterstadt
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References - Various
References
Steel and Metallurgy Industry, Machine builder
and various Industries
AluNorf Neuss
Salzgitter Flachstahl Salzgitter
Alstom Birr (SWITZERLAND)
SAP St. Leon-Rot
References
Datev Nuremberg
Sekurit Saint-Gobain Herzogenrath
Eckart-Werke Velden
Schott Rohrglas Mitterteich
EKO Stahl Eisenhüttenstadt
Schweizer Electronic Schramberg
Forbo Linoleum Assendelft (HOLLAND)
Stihl Waiblingen
Franz Viegener II Großheringen
VA Tech Elin Linz (AUSTRIA)
Gebr. Heller Nürtingen
Knauf Immingham (UK)
Kocher-Plastik Sulzbach-Laufen
Miele Gütersloh
NECSA Pelindaba (SOUTH AFRICA)
Neumag Saurer Neumünster
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Contact Information
BIConsulting Inc.Miami, USA 9050 Pines Blvd.
Suite 480 Pembroke Pines, FL 33024 Tel.  1
[phone]Fax. [phone]E-mail 
sales_at_biconsulting.com
BIConsulting C.A. Valencia, Venezuela Centro
Comercial Paseo Tarbes Planta Alta, Oficina
PA-4 Valencia, Venezuela Tel.  58 (241)
8242139 Fax. [phone] E-mail 
ventas_at_biconsulting.com