Migration Solutions

Moving Toward a Competitive Tomorrow

Representing a major capital investment, automation components, software, and systems are instrumental to the success of any manufacturing company. But no technology, regardless of how innovative, can last forever. To address product maturity without negatively impacting productivity, you need to rely on forward-looking suppliers who can help you prepare for the demands of tomorrow without compromising your ability to meet the requirements of today. Rockwell Automations commitment to helping you protect your investment and strategically migrate your installed base makes our products a sound investment today, tomorrow, and well into the future.
Contents Why migration makes sense for your business. What makes us stand out as your migration partner. How the right migration solution offers your business the competitive advantage. Identifying the right strategy to meet the specific demands of your business. How Rockwell Automation can help you develop your plan.

Why Should I Migrate?

1 3 7 8 9

Why Rockwell Automation?

Whats The Advantage For Migrating?

How Do I Get There From Here?

Where Do I Begin?

Why Should I Migrate?

Optimal equipment utilization and long lifecyclesLower operation and maintenance costs Competitive advantage and global presenceCompliance with industry regulations Data accessibility and securityInnovative technologiesProduction flexibility Todays demanding market conditions pose significant challenges for your manufacturing operations

Productivity. Across the enterprise and throughout the lifecycle

Globalization. In todays global economy, you are increasingly you are continuously striving for ways to improve. Today, you are driven to right size your manufacturing footprint and synchronize your under more pressure than ever to leverage your existing automation supply chain in order to drive greater efficiencies and compete in the investment to create an architecture that allows global marketplace. This means you need easy you to maximize the return on your assets, access to actionable, plant-wide information One day of downtime at our increase your production flexibility, and and the ability to securely transfer data on the facility can cost us up to $35,000 minimize risk. This means addressing: shop floor to executives on the top floor. in lost profit, and unexpected . Product Obsolescence. The demand for Sustainability. To meet productivity shutdowns can cause unsafe reliability and the need to quickly and easily objectives, you need to utilize resources conditions for our employees. find replacement parts is driving you to efficiently to overcome the rising costs of convert your legacy systems to more When you operate 24 hours energy and raw materials, as well as protect contemporary equipment. per day, there is no opportunity your workers and the environment Coupled Rising Maintenance Costs. Disparate legacy to make up for profits lost as a with the demand for regulatory compliance, systems require more maintenance than result of downtime. Our return ideally, you want to have a plan in place that integrated contemporary systems. Having a addresses new standards before compliance on the investment on a new single control architecture helps you to is mandated. system has been tremendous. minimize synchronization issues, lessen spare Roger Hill, General Manager parts requirements, reduce training, and Golden Triangle Energy Cooperative remove unnecessary redundancies.
Missouri, USA

Innovation. Todays modern platforms can help you adapt quickly to market changes and target overall plant-wide optimization. You need a highly flexible and scalable architecture that takes advantage of emerging technologies and opens the door to innovation.

Why Should I Migrate? Addressing Your

Greatest Concerns

Identifying obsolete productsQuantifying obsolescence risk to management Reducing operations risksTaking control of the migration timelineKeeping your equipment running You might be tempted to say, My current system is working fine it can wait. Migrating your legacy systems to newer technology may seem like a daunting proposition until you consider the benefits

What if migrating from your legacy system could provide you with a competitive advantage compared to sticking with your current system? What if upgrading to newer technology helped you to: Improve equipment utilization and manufacturing performance: Better asset management, simplified architectures, greater information access, and lower maintenance costs all add up to increased productivity. Increase data availability and security: Integrated production and enterprise systems allow for a better flow of information from the plant-floor to the top floor. This makes for faster, more informed business decisions.. Increase production flexibility and quality: Less time spent in development means more time spent on creating new intellectual property. In addition, quicker production modifications allow for quicker response to changing market demands..

Use leading-edge technologies to gain competitive advantage and global presence: Updated technology, using inteIIigent devices, often heIps to improve uptime, increase speed, and simplify integration. In addition, information that is easily extracted and shared can be used across the enterprise or around the world. Reduce operation and maintenance costs, as well as downtime: New equipment and integrated control systems require fewer spare parts, minimize downtime needed for repairs, and lessen operator training requirements, meaning appreciable cost reductions. Achieve regulatory compliance: Integrated systems allow for greater communication and standardization across multiple disciplines and locations.
1

Let Rockwell Automation Help You Rest Easier

Colorado Springs Utilities1 migrated its outdated DCS system to Rockwell Automations PlantPAx Process Automation System. In the process, they: Reduced annual operating costs by $240,000. Increased system availability to nearly 100% (formerly near 50%, including 20% unplanned outages) a cost savings of $50,000 annually. Improved troubleshooting capabilities, saving $40,000 on system support and maintenance. Standardized equipment across facilities, allowing them to leverage a shared parts inventory. Completed the project one year earlier than projected.

These results are specific to Colorado Springs Utilities use of Rockwell Automation products and services, in conjunction with other products. Specific results may vary for other customers.

Why Rockwell Automation?

Change is never easy, and when it comes to your control system, you have too much invested to take those changes lightly. At Rockwell Automation, we understand how important it is to protect your investment, and to have a long-range strategy for increasing your productivity and maximizing your competitive advantage.

When the time comes to upgrade your existing control system, you need a partner who understands your industry, will help you develop a plan that suits your application needs and goals, and has resources worldwide to support you through that transition. As the worlds largest company dedicated to industrial automation and information, Rockwell Automation is the partner you can turn to for: Did You Know A track record of providing long term support throughout the product lifecycle. A global presence, with locations in more than 80 countries worldwide. Experience in helping to achieve plant-wide optimization, machine builder performance, and sustainable production across a wide range of industries. A comprehensive network of partners, consisting of best-in-breed companies with products, technologies, application specialists, and distribution to help build a complete solution. Our unwavering commitment to supporting your automation investments is founded on: Exceptional product longevity and communication At Rockwell Automation, we take pride in staying with you for the long term. With planning, tools, and programs, we support our products and your business with a longstanding commitment to providing solutions and services to help you be successful. Our history of endurance results in long product life cycles, and an outstanding return on your investment.

Flexible migration options When youre ready to migrate, well be there to help with an extensive migrations toolkit and a unique, phased approach that helps to minimize the costs, risks, and complexities involved with managing legacy products and systems. Global solutions and services Because we know your company is unique, we offer a scalable range of support options, allowing you to choose the level of service that best matches your corporate goals, internal technical capabilities, and budget. These comprehensive capabilities are delivered globally, and they uniquely qualify us to help maximize your investment.

Rockwell Automation
Has some controllers and I/O products with lifecycles of 30 years or more Communicates product retirement as far as 2 years in advance Supports our products for twice as long as the automation industry average Provides assessment, training and support services to help you identify/mitigate risks Can help you migrate all at once or in a phased approach, depending on your unique requirements Can help you bring much of your existing line forward, intact or with minimal reconfiguration Has the industry expertise and global execution capabilities to support you anywhere in the world Who else can offer you all that?

Why Rockwell Automation? Exceptional

and Lifecycle Communication

Product Longevity

At Rockwell Automation, we give you notice, and we give you options. Rockwell Automation has a strong track record of keeping products viable, resulting in long product lifecycles relative to our competition.

As our products age, we provide options to help you extend their life as long as possible, and enough advance notification to allow you to transition as seamlessly as possible to the next generation. As part of our lifecycle support, all of our products progress through the same four lifecycle phases Active, Silver, Discontinued, and Obsolete. Throughout this progression, we provide you with options to help you manage the issues that go along with aging products. We understand how critical it is for you to be able to leverage your investment in knowledge and equipment, so as our products age, we communicate lifecycle changes as early as possible, and provide options that help extend the life of your system as long as possible.
Active

Throughout the lifecycle, as products mature, Rockwell Automation will be there as your partner to help you get the most out of your current equipment, to help you determine your next steps, and to help you lay out a plan for the transition to newer technology.

Silver

Discontinued

Obsolete

Active

Current, in-stock product. Full support (consulting, repair, training, transactional, and contract services).

Silver Global Solutions & Services StepForward Lifecycle Services Notification End-of-Life Services

Low inventory, support through forecasted date. Well-defined migration path.

Discontinued Obsolete

No new product; repair services available. Product and repair services unavailable.

We distinguish ourselves among suppliers by providing you with the help you need, every step of the way, to make the transition as seamless as possible.

Why Rockwell Automation? Phased

Migration Strategies and an Extensive Migrations Toolkit

We help you migrate at a pace thats right for you! When the time comes for you to migrate, Rockwell Automation will be there to help you plan your approach, and well support you with an extensive migrations toolkit.

Whether you choose to migrate all at once or use our unique, phased approach to help minimize the costs, risks, and complexities involved with managing legacy products and systems, we have the tools and the experience to guide you through the transition.

You also have the option to choose the implementation plan thats right for you. Choose from: Global execution of complete Turnkey Migration Solutions, with the power of Rockwell Automation behind you.

A global network of trusted Systems Integrators and Solution If you choose a phased migration plan, our methodology of modular Providers offering broad experience in Rockwell Automation automation coupled with backward compatibility allows you to technology. maintain productivity as you upgrade portions of your automation Self-Serve Tools and Programs developed by Rockwell Automation system over time. The StepForward Program offers a comprehensive to help you expertly and quickly migrate to newer technology set of tools to facilitate this phased approach, including conversion at your own pace. and selection tools, as well as consultation, planning, and training services. This broad range of conversion enablers allows you to take a proactive approach to upgrading StepForward. . .Migrating your control system at your own pace with tools to guide you through the transition.1 your systems at a pace that makes the most sense for your application and budget, by allowing you to I/O And Field prioritize migration tasks while mitigating the risks Visualization Devices to your overall operation. HMI
Existing Control System
Integrated Architecture Builder Installed Base Evaluation

Program Logic
Code Conversion Utilities Software Translation Tools 1756-RIO Module

Logic Controller
1756-RIO Module I/O Wiring Conversion Tools

Conversion Tools

I/O Wiring Conversion Tools 1756-RIO Module

The Rockwell Automation delivery team was fantastic to work with. They made the extra effort to get input from all personnel, from executives, to operators, to maintenance, to make sure we got everything we wanted. They really listened and discussed everything as a team.
Steve Moore Senior Instrumentation Control Specialist McCullough Complex

1Note: This image represents one possible Control System Migration path, with associated enabling tools. Rockwell Automation can recommend similiar paths for additional products to help you achieve your migration goals. Specific details of each migration may vary.

United States Air Force Academy Colorado Springs, Colorado USA

Why Rockwell Automation? Global

Solutions and Services

Rockwell Automation Solutions and Services Bringing You a World of Experience. Across industries and processes, Rockwell Automation understands that a profitable, safe, and sustainable operation is your goal. As your partner, we offer you industry and technology-specific expertise to meet these goals and your unique challenges.

Our commitment to you is to use our broad and deep domain By leveraging our global experience and partner resources, we expertise, extensive global capabilities, and proven project can tailor our solutions and service capabilities to meet your needs. management methodology to help reduce project risk and provide Beyond our solution delivery capabilities, our global infrastructure specific solutions, executed globally and supported locally. of support centers and subject matter experts helps protect your automation investment. Whether it is meeting your everyday technical needs with our on-demand services, providing consulting Global Execution: Worldwide talent and local expertise means you services to help you determine where and get the right team for your projects, from a global organization how to get started, or partnering with with a local touch. RADE DES G you to maximize your automation P IGN Domain Expertise: Our industry and application /U investment through personalized TE experts have streamlined processes in the major managed services, our services industries worldwide, in all levels of production Assessments Asset Management and support can help you FEED environments, to help increase productivity, lower Repair Services optimize plant assets, increase MEC / MAC MEC/ manufacturing risk, speed time to market, and Turnkey Engineering Migrations/Conversions Migrations / Conversions productivity, and improve your reduce costs of quality and compliance. overall financial performance. Project Management: Common project Preventive Maintenance Integration Online & Phone Support Fabrication management methodology, based on the PMI By understanding your Remote Monitoring Commissioning PMBOK, helps ensure that you receive consistent requirements, our Global Training Start-up Services project management for every project, delivered Solutions team draws on our by certified project managers. T S wealth of in-house expertise and IM N I I . / ZE partner resources to deliver repeatable, T

MIG RA

EER GIN / EN

scalable, and maintainable solutions, tailored to your specific challenges.

TES

TA

LL

OPERA

TE

/O

I cant say enough about the support weve received from Rockwell Automation. From start to finish, theyve been right there with us, giving expert insight and analysis. This support has been instrumental in helping us maximize the value of our existing plant assets, as well as our new technology investments.
Rich Steward Senior Project Engineer Evergreen Packaging

The Rockwell Automation Solution offered the flexibility and modularity our facility required. Rockwell Automation really took a partnering approach with us on this project. We were a team. Even when things went wrong, they were there to fix it. I truly consider them a partner.
Bruce Partlow Chief Operation Officer Texas Municipal Power Agency

Anderson, Texas USA

Tennessee, USA with operations in El Salvador, Israel and Saudi Arabia

Whats The Advantage of Migrating?

In todays challenging market, you are being tasked more than ever with leveraging your existing automation investment to drive continuous optimization. To remain competitive, you need to converge your production disciplines into an integrated plant-wide architecture.

The Rockwell Automation Integrated Architecture is an integrated control and information system that improves manufacturing productivity and helps reduce the total cost of ownership by providing unparalleled functionality, flexibility, and scalability. Using sophisticated control, motion, networking, visualization, condition monitoring, and information technologies, the Integrated Architecture addresses a full range of control and information needs, spanning discrete, process, batch, motion, drive systems, and safety applications, while information technologies address performance and visibility, production management, quality and compliance, asset management, data management and design and configuration. By emphasizing third-party connectivity, interoperability and use of open industry standards, the Integrated Architecture provides seamless information integration with the entire site and/or enterprise.

With our Integrated Architecture system, we help you build a business where information flows across the organization to better address key market challenges: Improve Productivity with better asset utilization and system performance. Promote Globalization with easy access to actionable, plant-wide information. Support Sustainability with extended product lifecycles and better asset utilization. Cultivate Innovation with increased system flexibility and technical risk mitigation.

Choosing Rockwell Automation made complete sense for us, because it allowed us to create a more integrated system thats easier to operate, configure, and maintain.
Headquarters in Golden, Colorado USA with installations worldwide

Don Bersell Project Manager, Meurer Research

How Do I Get There from Here?

When an ultralight pilot uses his aircraft to teach captive-raised birds how and where to migrate, he likely understands that they already know how to fly. They just need someone to guide them along the right path.

When you choose Rockwell Automation as your partner, youll experience that same skilled guidance. To help you stay on top of the lifecycle challenges that resuIt from the continuous advancement of technology and, more specifically, the obsolescence of automation products, we offer Lifecycle Management Services. These services wiII help you to identify, mitigate, and eliminate automation obsolescence risk. Starting with an Installed Base Evaluation (IBE), we can help you to better understand and pinpoint your risk by site, area, line, machine, and panel. Once the risks are identified, we provide you with options for immediate migration to newer technologies, or we can develop a service bridge via a Lifecycle Service Agreement to help you minimize the risk associated with continued operation of older or discontinued automation until youre ready to migrate. Bridge to Plant-wide Optimization The major obstacle to opening up your automation assets is the control system fragmentation that exists today. While your goal is to simply make better decisions, faster, with the lowest support costs and the least risk, Risk non-flexible, disconnected control systems

contribute to the inability to meet these goals. Legacy systems historically last many years, inhibiting new investments due to high maintenance costs. Furthermore, it can be costly to turn off some of these systems; many times you might choose to maintain them because of their customized and supported nature. Standardized off-the-shelf technology can handle this, but a concerted effort to retire legacy systems requires you to partner with a supplier that can deploy new technology that integrates the same data in a more effective way. Rockwell Automation can help bridge legacy systems to newer automation platforms. This transition can make a significant improvement on the your quality, reliability and efficiency, which in turn has a direct impact on things like return on net assets and cost of goods sold. Given the significant impact, this plant-wide optimization is a relatively inexpensive investment on improving financial outcomes.

Identification

Risk Mitigation
Service contract designed to maximize life of discontinued plant-floor automation

Risk Elimination
Migration Planning Support Services

Installed Base Evaluation with Lifecycle Analysis

Assessment

Lifecycle Service Agreement

Migration Services

Lifecycle Services
To find out more, call your local Rockwell Automation sales representative today!

Where Do I Begin?
We know that todays market conditions present you with a number of lifecycle challenges. Because of this, we provide a number of Lifecycle Management services designed to help you identify, mitigate, and eliminate automation obsolescence risk.

We work as your partner to help you avoid these risks and the possibility of any financial consequences in the form of extended downtime. To begin, we identify your obsolescence risks by performing an Installed Base Evaluation (IBE), which generates a Lifecycle Analysis. The IBE is a site delivered service that provides actionable intelligence to help you make data-driven decisions regarding the support of your installed base assets. This helps you to: Identify legacy obsolescence risks Identify product lifecycle status via plant hierarchy Identify migration candidates Identify excess/shortage of spare parts Develop a baseline for determining a Strategic Maintenance Program Note: Mechanical and other OEM electronics may be included in the analysis.

Once the legacy assets are identified, we can provide you with recommendations for migrating to newer technologies, or we can develop a Lifecycle Service Agreement. Included in the agreement are a critical set of services reserved repair, remote support, and on-site services to help you avoid the costs associated with unplanned downtime, parts and repair and unplanned costs to upgrade equipment. No matter which approach to migration you choose, the lifecycle reporting services provided by the Installed Base Evaluation are a great place to start. Every step of the way, Rockwell Automation will be there with you to provide you with the critical information necessary to help you plan and prioritize your migration activities. To find out more, call your local Rockwell Automation Sales Representative today, or visit us at: http://www.rockwellautomation.com/solutions/migration

Rockwell Automation, Inc. (NYSE:ROK), the worlds largest company dedicated to industrial automation, makes its customers more productive and the world more sustainable. Throughout the world, our flagship Allen-Bradley and Rockwell Software product brands are recognized for innovation and excellence.

Follow ROKAutomation on Facebook & Twitter.

Connect with us on Linkedin.

LISTEN.THINK.SOLVE. and Rockwell Automation are registered trademarks of Rockwell Automation, Inc. All other trademarks and registered trademarks are property of their respective companies.

Publication MIGRAT-BR002A-EN-P September 2011

Copyright 2011 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.

Lifecycle Communication
Extending product longevity through development planning, phased obsolescence, and transition support.

Active

Silver

Discontinued

Obsolete

At Rockwell Automation, We Give You Notice, and We Give You Options! As our products mature, we provide the means to help you extend their life as long as possible, as well as enough advance notification to allow you to transition as seamlessly as possible to the next generation. As part of our lifecycle support, all of our products progress through the same four lifecycle phases Active, Silver, Discontinued, and Obsolete. Throughout this progression, we provide you with options to help you manage the challenges that go along with aging products. Extending the Active Phase is Our Primary Goal When we develop new products, we use clear product development standards and procedures, and we design with a migration path in mind, taking into account both backward compatibility and future technology. Our commitment to helping you get the most out of your existing equipment is coupled with our ability to help you plan for the eventual transition to new technologies, based on your unique requirements. We understand how critical it is for you to leverage your investment in knowledge and equipment. By providing resources like our Global Solutions and Services team, our StepForward Program, and our Lifecycle Services offering, we help you to take a proactive approach to managing your evolving control and information system needs.

We Accomplish This by Making Sure Our Products Age Gracefully Through our Silver Series Program we communicate details of impending product retirement. This program helps you to plan for and manage the migration from existing equipment to updated Rockwell Automation products that help you take advantage of new technology, lower cost, and increased productivity. During this Silver phase, you can continue to order new products before their official discontinuation. Typically, this phase lasts around two years.1 By communicating these lifecycle changes as early as possible, we give you time to effectively plan and optimize your transition without sacrificing current productivity. and Supporting Them Through Their Retirement Throughout the lifecycle, as products mature, we will be there as your partner to ensure that you get the most out of your current equipment, to help you determine your next steps, and to help you lay out a plan for the transition to newer technology. As those products retire, well provide you with End-of-Life Services to help you bridge the gap from one generation to the next. At Rockwell Automation, we distinguish ourselves among suppliers by providing you with the help you need, every step of the way, to make the transition as seamless as possible.
1

Note that in some situations, the Silver Series timeframe is shorter due to circumstances beyond Rockwell Automations control (e.g., when a third-party supplier stops making an essential element for a Rockwell Automation product). In those cases, Rockwell Automation will provide as much advance notice of obsolescence as possible.

Phased Migration
Using StepForward to help you plan your migration, and supporting you through it with an extensive migrations toolkit.
We created the StepForward Program to make it easier for you to maintain productivity as you upgrade portions of your automation system over time. This program offers a comprehensive set of tools to facilitate a phased approach, to migration, including conversion and selection tools, as well as consultation, planning, and training services. This broad range of conversion enablers allows you to take a proactive approach to upgrading your systems, at a pace that makes the most sense for your application and budget, by allowing you to prioritize migration tasks while mitigating the risks to your overall operation.

StepForward. . .Migrating your control system at your own pace with tools to guide you through the transition.1

Visualization

I/O and Field Devices

Logic Controller Program Logic Existing Control System

The next phase often begins with converting your application logic. Our logic and tag database conversion utilities will help you quickly upgrade your processor code allowing you to take full advantage of the Rockwell Automation Logix family of Programmable Automation Controllers (PAC). Once the converted code has been downloaded to the Logix PAC, the new 1756-RIO Remote I/O module can be used as the network interface to the 1771 I/O over the existing Remote I/O network. Enabling Tools: Code Conversion Utilities Software Translation Tools 1756-RIO Module Next, you might consider replacing your existing controller, while continuing to use your current I/O. For example, you might replace your PLC-5 controller with the Logix PAC and the 1756-RIO Module. The same 1756-RIO Module used in the last phase is now configured to perform as the master instead of the monitor. The Logix PAC can now control any I/O that resides on an 1771 network. Enabling Tools: 1756-RIO Module I/O Wiring Conversion Tools During the next phase of the migration, you might choose to replace your existing HMIs or EOIs with FactoryTalk View products using our Application Conversion Utilities (ACUs). ACUs not only make operator interface conversion much more cost effective, but give you greater flexibility regarding the final product. This means that you can account for how operators use your equipment and design interfaces that help maximize their productivity. Enabling Tools: HMI Conversion Tools

The first and undoubtedly most important phase of the migration process involves a thorough analysis of your existing control system. We are there to help with services like Installed Base Evaluation to analyze your current environment, and Integrated Architecture Builder to help you envision your next generation operation. Enabling Tools: Integrated Architecture Builder Installed Base Evaluation

Finally, because I/O replacement represents a large investment, we provide the I/O Wiring Conversion System to replace your 1771 I/O with ControlLogix I/O. This system provides a method thats right for your schedule and budget, and allows you to connect your existing 1771 I/O wiring to the 1756 I/O modules without disturbing the field wiring connections, dramatically reducing labor time and eliminating the potential for downtime that could result from wiring mistakes during migration. Planning your migration is more manageable as I/O can be swapped one rack at a time or all at once based on your schedule and budget. In either case, you can run both new and old I/O networks simultaneously. Enabling Tools: I/O Wiring Conversion Tools 1756-RIO Module

Migration path, with associated enabling tools. Rockwell Automation can recommend similiar paths for additional products to help you achieve your migration goals. Specific details of each migration may vary.

1Note: This image represents one possible Control System