Almost 90 percent of manufacturers employ Microsoft platforms in their industrial applications, yet common problems persist. Key concerns include reliability, security and version management. The Microsoft Manufacturing Users Group (MS-MUG) was formed within the OMAC (Open Modular Architecture Controls) user group to address these issues through cooperation among users, suppliers and Microsoft Corp., based in Redmond, Wash. The group’s new chairman, Ashok Nangia, senior staff engineer at 3M, discusses recent developments and future directions for the MS-MUG with Automation World editorial director Jane Gerold.
AW: What is the Microsoft Manufacturing Users Group, how did it come into being and who are its members?
Ashok Nangia: The Microsoft Manufacturing Users Group, or MS-MUG, is a working group within the Open Modular Architecture Controls user group (www.omac.org). It was formed to address issues manufacturers face in applying commercial software technology to industrial applications. The working group got its start in February 1999, when some users, including myself, met at an ARC Advisory Group (www.arcweb.com) forum to discuss common problems in using Microsoft platforms in manufacturing.
For example, some installations were experiencing instability associated with using the Microsoft DLLs (Dynamic Link Libraries) to communicate among applications. An existing application on a personal computer (PC) employed a set of DLLs, and then, when a new application or update was loaded, the old DLL links would break, which caused reliability issues.
Other users reported version management issues in tracking software changes and managing DLLs, as more and more software was loaded on the same PC. Therefore, the initial issues the MS-MUG decided to tackle were reliability and version control management.
The group of users invited several of the leading industrial software vendors to join us in our efforts. We also sought and received support from Microsoft to work with us in the group to address our key issues.
Currently, the MS-MUG has over 70 members, including users, application software suppliers, technology providers and Microsoft. ARC provides support by managing the Web site and performing other administrative functions.
AW: In what types of applications are Microsoft-based products used in manufacturing, and what concerns do manufacturers have in their implementation?
Nangia: Microsoft platforms are used in supervisory control and data acquisition (SCADA) systems, HMI (human-machine interface), wireless and hand-held applications, programming PCs and application development servers. As the use of Microsoft technology in manufacturing continues to expand, it’s increasingly important that we address users’ concerns.
In a recent survey that the MS-MUG developed with ARC, we asked users to rank concerns about security, reliability, version management, ease of use and training. On a scale of one to five, almost 40 percent of respondents ranked security and reliability as their highest concerns. (See chart for a summary of results.)
AW: What are the current initiatives of the Microsoft Manufacturing Users Group and why is this work important?
Nangia: One of our initiatives is to promote a “Designed for Windows XP” program for plant-floor software certification. This is a self-certifying program specifically geared to industrial control applications. We recommend that Independent Software Vendors (ISVs) and manufacturing end users adopt Microsoft’s “Designed for Windows XP” logo program as a minimum certification level for plant-floor PC applications. While the “Designed for Windows XP” logo program does not meet all of the certification requirements that the MS-MUG had recommended to Microsoft, it does provide a common platform of application stability, install/uninstall procedures and upgrade predictability.
Thus far, two industrial software pro-viders have been awarded the “Designed
for Windows XP” logo—Wonderware (www.wonderware.com) for its InTouch 8.0 HMI software and National Instruments (www.ni.com) for its data acquisition software, Measurement Studio 6.0.
We would like to see more vendors participate in this program. Although companies such as Boeing, Procter & Gamble and 3M are driving the initiative, there are many other users who are not aware of it. When users demand participation in the certification program from their suppliers, we’ll see more reliable software.
Another initiative and accomplishment for the MS-MUG is the release of a “Best Practices” document. The purpose of this document is to provide information that will help users implement systems that are more reliable, cost-effective and easier to support. There are seven topics covered in the document: architecture, security, redundancy and reliability, system monitoring, change management, support, and back-up and recovery.
Users, consultants and suppliers created the document, including 3M, ARC, Boeing, Cisco Systems, Louisiana Center for Manufacturing Sciences, Microsoft, Procter & Gamble, Siemens and Wonderware. Each company was assigned an area—for example, 3M looked at security and back-up and recovery—and we shared the work with each other. This is the power of users groups—several companies collaborate on best practices, and those are now available for the entire industry to share. Any user can download the 84-page document for free at our Web site (www.omac.org/wgs/MfgInfsrct/MSMUG/msmug_default.htm).
AW: What are some of the future initiatives for the MS-MUG?
Nangia: As part of our survey with ARC, we found that we need to increase the awareness of and membership in the MS-MUG. To grow membership, individual members, such as myself, will personally reach out to users in the community to share the benefits of joining the group.
Also, the MS-MUG is looking to align itself closely with the OPC Foundation (www.opcfoundation.org). OPC is doing a great job in setting standards for information integration using Microsoft-based software, but they need user community. The MS-MUG can provide that. (OPC specifications define standard interfaces and drivers to move data among automation hardware devices and software applications.)
We also want to work closely with Microsoft to discuss ways to increase the useful life of operating systems. In the past, SCADA systems would last 15 to 20 years or more. Now, with operating systems changing every three years, manufacturing users need to change the PC, as well as software, interface cards, and other devices. It’s not just a $5,000 PC hardware change; it could impact software and equipment worth $200,000 to $500,000.
The MS-MUG will ask Microsoft for longer support on existing operating systems. If users can get two more years out of an operating system, through patches or other means, we can extend the life of an automation system by 40 percent or more.
AW: What other recommendations do you have for industrial software suppliers?
Nangia: The MS-MUG is working on recommendations for software licensing and management. A license is the token that enables use of the software. We recommend that software vendors offer a combination of stand-alone licenses, using software files or dongles, and server-based licenses, so users can manage multiple nodes from one server.
Because of the mission-critical nature of manufacturing applications, users have a strong need for emergency temporary licenses, should they experience a production problem. Suppliers should provide a means for users to get temporary licenses at any time, 24/7, in order to keep plants up and running around the clock. The MS-MUG is preparing a list of requirements for managing temporary software licenses, but the main message to software vendors is this—response time is critical. The costs and mechanisms to deliver temporary licenses to users should be established in advance, so downtime is minimized.
AW: How will 3M leverage the work of the MS-MUG?
Nangia: My initial goal in helping to found the MS-MUG was to establish a network of expertise outside of 3M. We now have a Web site; we have a good working group of Microsoft users; and, we have very good relationships with experts at vendors and other user companies.
Also, we now have the “Best Practices” document, which 3M played a key role in developing. There are a lot of elements in the document that we will implement to improve the reliability of PCs in our plants. The document provides information on Microsoft and networking technologies, in a way that non-IT (information technology) people can understand.
In the last few years, the MS-MUG has been able to examine issues associated with applying commercial software to industrial applications and generate useful ideas. I think now we have to move forward and apply these ideas. We plan to apply them at 3M and we believe other users will see value in applying them in their manufacturing organizations.
One company alone can only do so much, but with our collective efforts, we can have a voice to Microsoft and the industrial software vendors. It’s a win-win situation. Vendors have to know the issues that their customers are facing. The MS-MUG can address these issues, which will benefit all industrial users, including 3M.
AW: Why did you agree to take on a leadership role as the new chair of the MS-MUG?
Nangia: We’ve been working on this for four years or so, but every member has their own jobs to do, as well. Manufacturing companies are going through a culture change of fast-moving demands.
We also realize, however, that a very small effort spent on the MS-MUG will pay big dividends. That’s the reason I’ve agreed to take a leading role as chair of the group.
If our work can extend the life of a Microsoft operating system, manufacturers can save a lot of money. If we can get more reliability out of our PCs, we can reduce production downtime. If we can build security in our systems, we can improve e-productivity and remote access. It’s time to reap these rewards.
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