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User Story	
  
Le	
  contrôle	
  qualité	
  des	
  automates	
  avec	
  PLC	
  Checker	
  dans	
  l’Aérospatial,	
  la	
  ...
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[EN] Success story Herakles

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Herakles benefits from a 184% Return of Investment when using PLC Checker thanks to quicker commissioning and easier maintenance.

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[EN] Success story Herakles

  1. 1. User Story                                                                                                                       Improving  PLC  programs  quality  in  the  Aerospace  and  Defense  industries  -­‐  1/5       The context Herakles is a world leader in the design, development and manufacture of solid rocket motors for missiles and space launchers. Its products meet demanding requirements for safety, performance, reliability and availability. The challenge The very demanding domain of activity of Herakles requires advanced quality control of the manufacturing process. However, the company had no way to verify software quality for its industrial control systems. The solution PLC Checker, automatic verification tool for PLC programs is used systematically since 2010 on each and every new or significantly modified program. The result Return on Investment estimated to 200% by Herakles with significant improvements of programs quality and more efficient maintenance. Improving the quality of PLC programs in the Aerospace and Defense industries How Herakles benefits from PLC Checker
  2. 2. User Story                                                                                                                       Improving  PLC  programs  quality  in  the  Aerospace  and  Defense  industries  -­‐  2/5   Herakles has defined formal rules for the development of its PLC programs. THE CONTEXT Herakles  is  a  world  leader  in  the  design,  development  and  manufacture  of  solid  rocket   motors  for  missiles  and  space  launchers.  Its  products  meet  demanding  requirements  for   safety,  performance,  reliability  and  availability.     Drawing  on  more  than  60  years  of  experience  and  on  unrivalled  know-­‐how  in  Europe  in  the   field  of  energetic  materials  and  thermostructural  composites,  developed  for  the  defense  and   space  sectors,  Herakles,  a  Safran  Group  subsidiary,  has  broadened  the  scope  of  its   technologies  and  diversified  the  application  of  its  expertise  into  a  wide  range  of  industrial   sectors.   Herakles  has  always  been  very  focused  on  the  quality  of  its  manufacturing  system  but  had   no   solution   to   measure   and   verify   the   quality   of   the   programs   embedded   in   its   Programmable  Logic  Controllers  (PLCs).  Software  quality  was  measured  by  sampling  and  this   approach  was  regarded  as  too  limited  to  meet  Herakles  strict  quality  requirements.     THE CHALLENGE Itris   Automation   has   first   been   working   with   Herakles  to  define  the  process  of  how  to  follow   the   quality   of   the   PLC   programs   thanks   to   a   better   measurement   of   the   compliance   with   Herakles   rules   and   standards.   The   original   method   used   by   Herakles   consisted   in   manual   code   reviews   to   verify   compliance.   Unfortunately,   this   approach   had   many   drawbacks:   relevance   and   precision   of   the   review   was   highly   dependent   on   the   person   in   charge   and   exhaustive   review   was   basically   impossible  because  of  the  huge  volume  of  code.  The  cost  of  the  approach  was  also  a  strong   limit  when  reviewing  large  applications.  Finally,  the  return  on  investment  of  this  mandatory   activity  was  considered  as  very  low.       As  a  consequence,  the  development  teams  were  looking  for  a  solution  and  they  discovered   the   PLC   Checker   tool,   a   collaborative   cloud   based   solution   for   the   static   analysis   of   PLC   programs.  PLC  Checker  allows  detection  of  programming  mistakes,  computation  of  quality   metrics  and  verification  of  compliance  with  standards.  Herakles  was  also  very  interested  by  
  3. 3. User Story                                                                                                                       Improving  PLC  programs  quality  in  the  Aerospace  and  Defense  industries  -­‐  3/5   PLC Checker improves the maintainability and readability of PLC programs thanks to more consistent programming style. the  fact  that  industry  leaders  such  as  Schneider  Electric,  EDF,  Areva,  PSA  Peugeot  Citroën  or   GDF  Suez  were  already  using  the  solution.       After  a  first  pilot  project,  Herakles  concluded  that  PLC  Checker  was  the  right  solution  to   control   automatically   and   systematically   software   quality   as   requested   by   its   internal   standards  and  with  an  independent  third  party  approach.       Pascal  POTHIER,  Automation  Project  Manager  at  Herakles,  explains:  “We  decided  to  leverage   PLC  Checker  for  two  different  usages.  First  we  wanted  to  do  some  one-­‐shot  audits  at  the  end   of  the  development,  thus  making  a  «  picture  »  of  the  quality.  Then,  we  decided  to  deploy  PLC   Checker   during   the   whole   development,   thus   making   a   «  movie  »   to   see   how   quality   was   evolving  and  allowing  bug  fixing  as  early  as  possible.     All   system   integrators   working   on   our   programs   are   trained   and   granted   a   license   of   PLC   Checker  for  the  duration  of  the  project.  They  can  make  as  many  «  pictures  »  as  they  want  to   build   the   «  movie  »   and   we   are   very   satisfied   with   such   a   continuous   improvement   approach.”   THE SOLUTION Herakles  and  Itris  Automation  teams  have  collaborated  to  deploy  PLC  Checker  step  by  step.   First,   Itris   Automation   engineers   have   created   a   set   of   coding   rules   inspired   by   Herakles   existing  standards  and  practices  and  leveraging  Itris  experience  in  several  activity  sectors.       Then,   at   the   end   of   2009   and   beginning   of   2010,   several   tests   have   been   conducted   on   three   programs  and  quality  reports  have   been   issued.   All   three   programs   had   originally   been   written   by   three   different   system   integrators   and  the  PLC  Checker  audit  showed   a   serious   diversity   in   coding   practices.     A  couple  of  months  later,  Herakles  decided  to  use  PLC  Checker  systematically  on  each  and   every  new,  migrated  or  significantly  modified  PLC  program.  Feedback  from  developers  and   users  of  PLC  Checker  has  been  taken  into  account  to  improve  the  rules  and,  since  2010,  26   programs  from  10  different  projects  have  been  verified  with  PLC  Checker.    
  4. 4. User Story                                                                                                                       Improving  PLC  programs  quality  in  the  Aerospace  and  Defense  industries  -­‐  4/5     Pascal   POTHIER   further   explains:   “Between   2010   and   2012,   we   have   improved   our   compliance  ratio  from  63%  to  85%  and  have  thus  improved  significantly  the  maintainability   of  our  programs.  This  was  made  possible  by  the  formalization  and  standardization  of  the   development.  “       THE RESULT After   these   first   use   cases,   Herakles   has  now  decided  to  use  PLC  Checker   more   widely   and   beyond   the   scope   of  its  factory  at  Le  Haillan.       “After  a  couple  of  years  using  it,  we   can  consider  that  the  deployment  of   PLC   Checker   is   a   success   »,   adds   Pascal   POTHIER.   «  Of   course,   at   the   beginning,   system   integrators   were   reluctant   but   they   have   been   convinced  by  the  tool  itself  and  now   agree   that   this   is   necessary   in   our   industry.       Since  we  began  using  PLC  Checker,  our  Factory  Acceptance  Tests  have  been  quicker  and  more   efficient.   Plus,   the   maintenance   of   the   programs   is   easier.   We   estimate   the   return   on   investment  of  the  usage  of  PLC  Checker  to  roughly  200%  just  by  counting  the  savings  in  the   test   and   commissioning   phases.   The   programs   are   easier   to   read   and   thus   to   modify   and   correct  in  the  factory.  Also,  thanks  to  a  better  consistency,  the  training  of  our  maintenance   team  is  faster.”       PLC Checker is available for o Schneider  Electric  Unity  Pro  et  PL7  Pro   o Siemens  Step  5  et  Step  7   o CoDeSys  v2.3,  v3.2,  v3.5   o Rockwell  Automation  RSLogix  5000   o Mitsubishi  GXWorks  2   o Omron  Sysmac  Studio   o PLCopen  XML   Easier maintenance and optimized troubleshooting are a significant source of return on investment when using PLC Checker.
  5. 5. User Story   Le  contrôle  qualité  des  automates  avec  PLC  Checker  dans  l’Aérospatial,  la  Défense,  la  Sécurité  -­‐  5/5   About Itris Automation Based  in  Grenoble,  France,  Itris  Automation  is  a  software  engineering  company  that  provides   development   tools   for   the   verification,   conversion   and   documentation   of   codes   in   programmable  logic  controllers.  Due  to  its  advanced  technologies,  Itris  Automation  supports   its   clients   in   improving   their   development   processes   and   therefore   in   delivering   higher   quality  programs  in  shorter  timeframes.  Put  on  the  market  in  form  of  Software-­‐as-­‐a-­‐Service,   these   tools   are   based   on   innovative   technologies   and   on   a   team   that   is   known   for   its   expertise  and  vast  experience  in  computer  science.   Schneider  Electric,  EDF,  Ferrero,  Det  Norske  Veritas,  Sanofi,  Manz,  IMA  Pharma,  GDF  Suez,   Renault  and  Herakles  (Safran  group)  are  among  Itris  Automation’s  main  customers.   For  more  information,  please  visit  our  website  www.itris-­‐automation.com      

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