Safety is Good Business

Prepared for: By:

Copyright 2011 Rockwell Automation, Inc. All rights reserved. 1

Rockwell Automation Today

Global Leader of Automation and Control SolutionNo. 1 in North America. World Headquarters Milwaukee, WI, USA Annual Sales $5.0 billion Employees About 21,000 Serving customers in more than 80 countries Strategic & Business global technology companies More than 100 years
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Rockwell Automation in Latin America

Latin America Region Offices

42 Sales & Support Offices RA Latin America Headquarters Located in Weston, Florida. USA
3,761 Employees in LA Region 581 Sales, Marketing and Administration 338 Services, Engineering, Support and Training 2,842 Manufacturing Manufacturing Facilities Mexico, Dominican Republic and Brazil

Rockwell Automation covering PepsiCo Plants South America

Guatemala Gustavo Jordan Electrical Eng. (19) Years of Experience in Automation Caribbean Luis Fonseca Mechanical Eng. (4) Years of Experience in Automation Colombia Zully Laverde Electrical Eng. (11) Years of Experience in Automation Venezuela Vanessa Moreno Electronic Eng. (3) Years of Experience in Automation Peru Ingrid Zuleta Electrical Eng. (5) Years of Experience in Automation Brazil Gilson Gajardoni Electrical Eng. (12) Years of Experience in Automation Team Leader for the PepsiCo Coverage in Brazil

El Salvador Gustavo Jordan Electrical Eng. (19) Years of Experience in Automation

Ecuador Braulio Quionez Electrical Eng. (18) Years of Experience in Automation Carlos Morales Electrical Eng. (12) Years of Experience in Automation

Chile Claudio Antileo Electrical Eng. (10) Years of Experience in Automation Argentina Roman Fernandez Electronic Eng. (9) Years of Experience in Automation

Uruguay Ariel Bursztein Eng. Electrical Eng. (12) Years of Experience in Automation

Paraguay Mauricio Colanzi Automation Eng. (6) Years of Experience in Automation

Rockwell Automation in Mexico & CA

With a main office in Mexico City and 6 major branch offices and 28 distributor locations in Mexico and Central America, we are ready to serve and attend to all your needs with local sales and support personnel. Rockwell Automation is always available to respond to your technical support needs, engineering, project management and training. These capabilities are complemented by a network of local authorized distributors and systems integrators.
(Confidential For Internal Use Only) Copyright 2008 Rockwell Automation, Inc. All rights reserved. 8

(Confidential For Internal Use Only) Copyright 2010 Rockwell Automation, Inc. All rights reserved.

Traditional Perspective of Safety: Safety and Productivity are Mutually Exclusive Objectives
Reduced Machine Utilization Reduced Operational Efficiency Increased Nuisance Shutdowns

Reduced Healthcare costs Reduced Litigation costs

Evolving Perspective of Safety: Safety and Productivity are Complementary

Compliance with Standards Improved Morale of the Workforce Improved Machine Speed & Utilization Improved Operational Efficiency / Labor Costs Improved Maintenance Downtime / Efficiency Reduced Nuisance Shutdowns Reduced Healthcare costs

Reduced Litigation costs

Reduced Labor grievances

SAFETY = PRODUCTIVITY = PROFIT

Rockwell Automation Safety Machine View

Laser Scanner

Safety Contactors

Safety PLC

Safety Relays

Safety Drives

E-Stops & Signaling

Light Curtains

Safety Mats Non- Contact Switches

Gate Switches

Safety Motion Safety Enabled Switches

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Trap Key

Safety Edges

Cable Pull Switches

Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Conventional Safety System

Safety System

ControlLogix chassis

EtherNet/IP PV+ EOI SERCOS PowerFlex 755 DeviceNet POINT I/O

Kinetix 6000

ArmorBlock I/O Safety Relay

Safety Relay

Contemporary Safety System

Benefits
ControlLogix chassis

Information enabled. Fewer components. Less training. Streamlined maintenance. Optimal connectivity with multiple networks.
Kinetix 6000

DeviceNet EtherNet/IP

Safety Data & functionality diagnostics can now be can be integrated displayed into on one HMI. E GuardLogix.
T A P

Safety System

PV+ EOI PowerFlex 755

POINT I/O

Armor Block I/O

Safety relays & contactors may not be required.

Safety Relay

Safety Relay

Technology is IMPORTANT

1. Keep PepsiCo Safe

Automatic Notification of changes

2. Keep Machines Productive

Realtime and detailed Diagnostics

3. Keep Machines Simple

Single Machine Interface Elimination of SR and Contactors

Safety Services Portfolio Supported World Wide by Safety Professionals

Assessments
Arc Flash Analysis Hazard Risk LOTO

Training
TUV Certification Risk Assessments Safety Standards Safety Products Arc Flash LOTO

Validation
Safety circuit analysis Machine stop time services Conformance audits Safety system validation

Integration / Start Up
Circuit/logic design Installation Arc flash remediation MCC Arc Flash upgrades Project Management

Compliance Consulting
CE conformance Functional safety (ex. ISO 13849-1 and IEC 62061, ISO, ANSI, IEC, CE, OSHA, NFPA, CSA, AS )

Remediation Solutions
Complete Turnkey Systems

Global Support. Local Execution. Peace of Mind.

Copyright 2011 Rockwell Automation, Inc. All rights reserved. 25

Risk Reduction Methods

Hierarchy of Protective Measures Design it out Fixed enclosing guard Monitoring Access / Interlocked Gates Awareness Means, Training and Procedures (Administrative) Personal protective equipment
Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Most Effective

Least Effective
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Global Supplier Agreement

Contract originated in 2004 Updated in 2010 (3 year)

Covers Automation, Information, Process, Software, Motion, Drives and Safety

Summary of Agreement:
Highly Negotiated MRO Pricing Plant Pricing MRO Rebates based on Volumes Paid to PepsiCo 3rd Rebate 4% (EPC, SI, OEMs ) Paid to PepsiCo Training Seats: Americas 90% Volume Europe & AMEA Extended HW Warranty 24 Months

OEM Growth YOY Program Impacts MRO pricing discount

Global Agreement requires NO changes for Safety Program

PepsiCo Some recent Engagements

Food and Snack Business Gamesa / Quaker / Sabritas (MX)
Training (LOTO & Risk Assessments), LOTO and Risk Assessments

Gatorade (US)
Depalletizer Safety Upgrade (29) Remaining Depals in Gatorade Fleet

Frito-Lay (US) Process & Packaging

Machine Guarding Risk Assessments LOTO Training

PepsiCo Worldwide Flavours (PWF)

Plant-wide Risk Service Texas, Ireland, China Current State Evaluation + Remediation Budgetary + Detailed Risk Assessment training

Frito-Lay Warehouse ASRS (US)

Team-based Risk Assessments

RA authoring Safety Specifications that meet Global Safety Standard (ESH-50)

PBC Specification - Safety PLC and Safety Components Gatorade Safety Guideline

PepsiCo Safety Standard EHS-50

PepsiCo Safety Standard EHS-50

PepsiCo Safety Standard EHS-50

PepsiCo Safety Standard EHS-50

Safety Systems & Methods

Solving the Problem

Maintain & Improve
1.

5.

Risk or Hazard Assessment

Safety Lifecycle
4.

Installation & Validation

2.

Functional Requirements

3.

Design & Verification

System design based on integrating safety & machine functionality.

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Safety Project - Spend Analysis Know where the largest spend will be and develop techniques to manage.

Safety Project Spending Analysis

Remediation (80% - 88%) Maintain (10% - 16%) Assessment (2% - 4%)
Assessment Phase is small $ but has major impact to remediation Phase costs. Remediation Phase has largest impact to Programs Financial success. Maintenance & Improvement Phase critical for ensuring ongoing Safety and productivity
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Copyright 2011 Rockwell Automation, Inc. All rights reserved.

Thank You !

Copyright 2011 Rockwell Automation, Inc. All rights reserved. 41