Automation Risks

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RiskNotTakingRisksCartoon

This table highlights some of the process control and automation environment scenarios that Versiondog addresses, and the Versiondog functionality that relates to each problem in order to reduce business risk and contributing to profitability.

 

Risk

Chance

Consequence

Versiondog function

A contractor makes code changes for new product. Later in day the machine will not run an existing product.

Medium

High

Versiondog allows you to roll back to previous versions and allows you to compare codes and see where changes have been made

A Maintenance Engineer makes changes to code in order to complete the batch, but the change is not documented.

High

Low

With Versiondog any changes will be spotted during a scheduled backup and the appropriate person will be notified.

Drive fails, a replacement is fitted but the default parameters do not work.

High

High

Versiondog scheduled backup takes a copy of the drive parameters and stores them in its central repository. This can be retrieved and downloaded to a new drive so the system can be running again with minimum downtime.

At a time of redundancies, an unhappy employee decides to make malevolent changes

Low

High

Versiondog constantly monitors your system, and will alert you if an unauthorised change has been made from the master version.

A PLC fails and each of the PLC programming devices on site has a slightly different version of code on it.

High

Medium

Versiondog automatically performs scheduled backups from your device. The most up to date copy is always on the server.

A Maintenance Engineer makes a temporary change to get over a sensor fault in the middle of the night. The person then goes off shift but does not inform anyone of the change.

High

Medium

The next scheduled backup will alert you to changes in the code and the smart compare feature will highlight what the change is. If Versiondog had been used the change could have documented there and then as well as the system having a record of who made the change.

A regular contractor comes in to make makes changes to the system for a new piece of plant, then leaves site without a backup or communicating what has been changed and where.

Medium

Medium / Risk

Scheduled backups will automatically spot changes in PLC code and keep the backed up versions. The contractor could then be called back to check in the new code and document all changes made, from the automatic audit.

Latest version of code in PLC but the only commented code on site does not match the PLC version.

High

Medium

The automatic backup from Versiondog has the latest version. This can then be merged with the comments from the earlier version to give an up to date commented copy – maintaining the value of the comments.

Contractor has been working on code but meanwhile a number of changes have been made to the site copy.

High

Medium / High

Before the contractor downloads the modified version of the code he creates a report in Versiondog which lists all the changes that had been made to the code since it was release to the contractor. These changes can then be made back into the new version to ensure it’s up to date.

SI receives a warranty claim from an end user that software they had created for the customer has a fault.

Medium

High

SI checks out the latest copy of the software to go to site. On site they then back up the software from the device and compare it to the checked out version. On finding a difference the SI can then point out where a change had been made and legitimately charge the customer for the visit.

SI Engineers commissioning on site are updating software and documentation.

Medium

Low / Medium

The Versiondog remote server they have on site takes frequent backups of all the devices and periodically synchronises with the server back at the main office, automatically undertaking the administration.

A manufacturer starts producing a product which was last produced two years ago. Because of the changes made since the last time this product was made, production of the product is very slow resulting in low OEE and high downtime.

Low

Medium

Because a complete set of versions spanning many years are stored on the Versiondog server this can be checked out and rolled back to the code for the last time this product was made. The parameters in the code are set up for this product resulting in much improved production performance, and comments can be added for subsequent use.

 

In the development of the PLC code multiple engineers are involved – this risks changes being made simultaneously

High

High

Versiondog avoids ad hoc sharing violations by properly administering the logging out and return of programs, streamlining the administration of the project.

The PLC code is highly developed and tested for various machine configurations – a little used special variant machine is being manufactured – what was the code for that type, and where is it?

Medium

Medium

Versiondog, supported by program comments, will have that version in back-up and allow you to both easily find it and utilise it on that machine type.