Customer ProfileA major metal processor in North America with worldwide operations in 30 countries.

The company is recognized as an industry leader, introducing and directing new business opportunities in markets such as aerospace, packaging, automotive, and building and construction.

CountryUnited States

IndustryMetals, Metal Processing

Challenges • Provideasecurenetwork environment with high availability

•Deliverscalabilityforfuture changes and upgrades

•Adheretobudgetconstraints

Panduit Solutions • PhysicalInfrastructure DesignServices

•Deploymentand Management Services

•IntegratedNetworkZoneSystem

•MicroDataCenter

•ControlPanelOptimization

Benefits • Reduceddeploymenttimeby up to 75%

•NoBatteryUPSbackupthat lowersriskofdowntime

•Maintenance-freeUPSwith lowercostofownership

•Highavailabilityandincreased process network

•Robust,integrated, secure network

ChallengesThelocationofenterpriseandfactorynetworksonthesamefiberbackbonewasfound to be a risk and caused a major metal processor to experience lengthy, unnecessary network downtimewhenevertherewasafailure.Toreducethelossofvaluableproductiontimeand lost revenues, the company needed to separate the two network systems.

This separation would address growing network demands to increase network bandwidth, throughput and security, whichwerecriticalforthecompany’s futuregrowth.

Also, upgrading the original 1940s brownfieldphysicalinfrastructure would provide the ability to maintain a competitive advantage and meet customer demands by increasing network uptime and availability. The implementationoftheseimprovements

woulddeliverasecure,reliableandfuture-readynetwork,enhancingthecompany’s ability to enter into untapped markets.

The company also needed a central network distribution point to accommodate the multipletunnels,outdoor,aerial,undergroundandindoorareasthatfunctionasoutdoor environmentalspacestoeasilyperformmoves,adds,andchanges.

Redesigningandbuildinganewprocesscontrolnetworkwouldinvolvestandards-based designelementstocomplywithcurrentregulationsandrequiredthecompanytofocuson key needs such as:

•Choosingtherightframeworkofthelogicalarchitecture •Selectingthemediatypeandaddressingenvironmentalconsiderations •Developingaphasedplanfornetworkdeployment •Planningforswitchdeployment

Finally,thecompanyneededasolutionforamaintenance-freeUPSwithdevicemanagementandpredictivemonitoringtoensurethatthenetwork’soperationalconditionwasmaintainedat an optimum level.

Toaddressthesechallenges,thecompanyneededasolutionsproviderthatcouldidentify and provide best practices to help accommodate its anticipated growth and maintain a competitive edge through proven expertise. The solution provider also needed to provide assistance to establish a realistic budget that would meet the network requirements and allowittodeploythesolutionoveraperiodoftime.

Case Study: Metal Processor Integrated Network Zone System Reduces Downtime and Increases Network Uptime for Major Metal Processor

Solution Partnering with Panduit Advisory Services helped the company apply the proper design attributes to the complete physical layer ofitsnewprocessnetwork.Italsohelpedthecompanyconsidervaryingenvironmentalfactors,meetregulatorycompliance mandates,optimizeoperationalsystemsandperformance,andreducedeploymenttime,operationandMaintenanceRepair Operations(MRO)costs.Toaccommodatethecompany’sfinancialconstraints,PanduitAdvisoryServiceshelpedestablish arealisticbudgetthatmettheneedsofthisgrowingcompanywithaphasedplanfornetworkdeployment.

ThesolutionPanduitrecommendedconsistedoftheIntegratedNetworkZoneSystem,MicroDataCenter,andControlPanel Solutions.Itiscomprehensivefromthecontrolroomtothemachinecontrolpanels,andincludedanetworkgroundingand bondinginfrastructure.ThisofferingallowedPanduittoprovidejointengineeringandproductdevelopment,interoperability testingandenhancedinfrastructuredesignthroughstrategicpartnershipswithCisco(networkingandswitchingtechnology) andRockwellAutomation.

ThePanduittailoredphysicallayersolutionaddressedthefollowingareas:

Control Room–Pre-configured42RUITServerCabinet(EnterpriseLayerandDMZ);GroundingandBondingInfrastructure; Pre-configured24RUMicroDataCenters(Layer3RoutingandSwitching)

Plant Floor–IntegratedZoneSystems(Stratix8000andPanduitUPS)

Enclosures–ControlPanelDINRailMountingPatchingSystems

Connectivity–OptimizedOSPBackboneFiberSpecificationusingTIAStandardsandNEC

Compliance & Safety–ComprehensiveGroundingandBondingSolution;LabelingSolution

Results TheIntegratedNetworkZoneSystemenablesrapid deploymentduetoitsintegrationwithanAllen-Bradley® StratixIndustrialEthernetSwitch,meetingthecompany’s requirementsofsecuringastandardizedsolutionthat enablesscalabilityonaglobalbasisforgreateragilityand fastertimetoproduction.TheAllen-Bradley® Stratix Switch offersmanagementanddiagnosticsfromwithinIT,controls environmentsandoptimizesnetworktraffic.Thissystemis pre-engineered,thermallyvalidated,IP66andNEMA4 rated,andpre-testedwithstructuredcablingandRockwell Automation active equipment, providing optimized building-blockarchitecturesforthecompany’snetwork.

TheIntegratedNetworkZoneSystemsupportsthedemands ofreal-timecontrolanddatacollectionandhelpsensurethe industrialnetworksandcontrolsystemsoperateatasufficientperformancemarginwithinthespecifiedenvironmental conditions.Thepre-testedandpre-engineeredqualityof the solution gives the company deployment and operations confidencethroughtheminimizedeffortandcomplication usually associated with deploying a network in segments.

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Benefits PanduitAdvisoryServicesappliedprovenmethodologiesandbestpracticestoeffectively managerisktothecompany’sphysicallayer,mitigatedproblemsinitsphysicalinfrastructure systemsbyprovidingtotalsolutionsforavailability,reliability,andintegrationandhelpedreduce costsofownershipbyimprovedscalabilityandbetterservicemanagement.PanduitAdvisory Servicesalsounderstoodtheimportanceofthelogicalandphysicaltopologiestomeetsystem requirements,identifiedin-housecapabilitiestomaintaininfrastructureandfuturegrowthneeds whensuggestingsolutions,andincreaseditsengagementastheprojectlifecycleevolvedinto the deployment phases.

TheIntegratedNetworkZoneSystemandMDCallowedthecompanytoupgradethenetworks with minimal downtime, ensuring high availability. The structured, engineered approach to physical infrastructuredesignaddressedtheproperpathwayidentification,distancelimitations,regulatory requirementsandenvironmentalconsiderationstoensurethecompany’sinvestmentsinnetwork distributiondeliveredoptimumoutput.Thedesignofthesystem,aswellasitsbuilt-inintegration allowallphasesoftheimplementationprojecttorunsmoothly,improvingreliabilityandsafety while reducing deployment, labor, and operating costs.

TheadditionofthePanduitUPSsolutionprovidedthecustomerwithimprovedavailability thateliminatesswitchrestarttimeafterbriefpoweroutages,lowersriskofdowntimebecause thesystemhasnobatteryandismaintenance-free,removingthecostsofbatteryinspections, maintenance,testing,replacementanddisposal.TheUPSsolutionprovidesaTotalCostof Ownershipthatis50to70%lowerthanaconventionalUPS.Itsimproveddevicemanagementandpredictivemonitoringfeatureaholdtimebasedonactualloadconsumption.

Results (continued) ThePanduitUninterruptiblePowerSupply(UPS)solution,whichusesultracapacitortechnology,wasspecificallyselectedtoallowthecompanytomaintainoperationalefficiencymoreeffectivelythrough improved device management, employing a smaller width that saves valuable space, and betterintegration,andzonemonitoring.TheUPSsolutionworksinconjunctionwiththeIntegratedNetworkZoneSystemtolowertheriskofdowntimeassociatedwithpowerinterruptionstokeepfacilities’criticalequipmentoperatingatfullcapacity.

TheMicroDataCenter(MDC)helpsseparatenetworksandreduceconflictpointsbetweenthenetworksandenterpriseteamsthatsupportthem.Iteffectivelymaintainsrobust,integrated, and secure networks, bridging the gap between the corporate and industrial networks while maintainingflexibilitytoquicklydisconnectthenetworklinksintheeventofaproblem.The MDCfacilitatestheconnectivityfromtheplantfloortotheenterprise,givinggreatervisibilityintothemanufacturingprocessestoidentifyproblems,optimizeprocesses,andplanforthefuture.

OtherproductsetsthatcreatedthesolutionincludetheOutsidePlantFiber(OSP)which leveragesPanduitOptiCam®FiberOpticConnectors,whichwereusedforapproximately35,000sq.ft.ofoutsideplantfiberand1600fiberconnections.OptiCam®FiberOpticConnectorsinstallinlessthanhalfthetimeoffieldpolishconnectors,virtuallyeliminatingoperatorerrorand delivering yield rates approaching 100%.

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Panduit Corp.World Headquarters

Tinley Park, IL 60487

cs@panduit.com US and Canada: 800.777.3300

Europe, Middle East, and Africa: 44.20.8601.7200

Latin America: 52.33.3777.6000 Asia Pacific: 65.6305.7575

www.panduit.com

Lessons Learned WiththeimplementationofthePanduitsolutionthecustomerwillbeabletoachieve:

Speed of Deployment–Reducesimplementationtimeandcostsbyremovingcomplexityanddeliveringavalidatedsolutionoptimizedforpartnertechnologyapplications

• Reducesdeploymenttimebyupto75%

• Providesasinglepartnumberwhenorderingafullsolutionforzonearchitecture deployment in an industrial environment

• SegregatedsystemenablesITtosafelyaccessandmanagetheplantnetwork tomaintainServiceLevelAgreements(SLAs)

Mitigated Risk of Downtime

• Increasesreliabilitywithpre-testeddualfiberuplinkandmitigatedriskofthe delayedplantuptimeafterscheduleddowntime

• Providesexpansionofswitchandportsasthenetworkgrowstomakethis afutureproofenclosure

• Deliversactiveequipmentwithinanoptimizedphysicallayertoprovidea consistentlyhighnetworkperformance

• NobatteryUPSsolutioneliminatesthemaincauseofUPSfailures

Redundancy

• Minimalchanceoffailureaffectingproductionduetohighlevelofredundancy

Reliability

• Well-builtsystem

• Activeequipmentdeliveredwithinanoptimizedphysicallayerforconsistently highnetworkperformance

• NoBatteryUPSsolutionextendslifeupto20yearswithoutperiodicmaintenance

Safety

• Protectsfromshockhazardsandallowscleansegmentationbetweenthe upper level plant network and the machine level network to help maintain networkSLAs

Learn More Now

Find Solutions informationat:

www.panduit.com

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