|Project title:||Automation Systems Audit|
|Description:||Compile a detailed hardware and software inventory of 178 automation systems.|
|Client:||Wyeth Newbridge, Ireland|
|Technology:||Rockwell, Siemens, Mitsubishi|
|Timeline:||Feb 2008 – Apr 2008|
|Contact:||Darrin McCrudden / firstname.lastname@example.org / +353 (0)1 885 3400|
- A periodic review required the client to review and access all automation equipment onsite.
- There were 178 separate automation systems within the scope of the review.
- The systems were diverse and comprised a broad spectrum of hardware, software and technology.
- Compile a detailed inventory of all automation equipment onsite.
- Check and verify availability of backups for all systems.
- Check and establish availability of automation spares onsite and from the vendor.
Key Challenges & Solutions
- Tight project deadline and a large number of systems.
We built a multi-person and multi-disciplined team (5) and used detailed planning to target available production windows.
- Consistent data.
We developed a series of audit sheets that helped ensure each audit team member consistently and quickly gathered all required data during the survey.
- Access to systems in a restricted production environment.
We compiled a photographic record of all automation equipment surveyed. This was an invaluable crosscheck reference for the project and was subsequently used by the client’s production support team.
- Diversity of automation systems and age of systems.
We used a multi-disciplined team onsite and remote support from other office-based experts.
- Developed centralised database for the audit data. This was structured and coded to facilitate ease of interrogation and cross-referencing.
- Developed a suite of audit sheets for survey team to gather data.
- Photographed all systems, racks and ancillary hardware.
- Compiled all audit data in to a centralised database.
- Checked availability of spares and backups for each system.
- Checked occurrence of each hardware cards across site to help establish spares stocking strategy.
- Compiled a list of all spares and quantities retained onsite.
- Checked continued support for software and availability of hardware from the vendor.
- Produced and presented a report of finding and recommendations.
- The audit tool (database) was a key deliverable and a useful asset for the client in that it provided:
– A clear and accurate detail of all automation hardware/software onsite.
– The ability to quickly identify systems with common hardware cards for emergency spares.
– The ability to quickly assess impact of hardware/software notices of obsolescence.
– A reference to establish requirement and verify availability of backups.
– A reference to ensure availability of maintenance hardware, tools, applications etc.
- A photographic library of in-situ automation systems and hardware which reduces the need to enter the production environment, saving time and cost (gowning process).