packaging line performance system john coetzee sab business systems manager manufacturing paul...

Packaging Line Performance SystemJohn Coetzee

SABBusiness Systems Manager

Manufacturing

Paul KotzéEOH

MES Specialist

Abstract

Packaging Line Performance System

Faced with the challenge of commissioning a new packaging line in time for the annual summer run on soft drinks, SAB (ABI) turned to line performance for a solution.

This solution came with its own implementation challenges, including: OEM coding standards, infrastructure

installation and technology maturity.

Add 1 part Performance Software to 1 part soft drink line…

Agenda

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Business Requirements

► Improve and accelerate line commissioning▪ Machine performance▪ Reduce manual capture▪ Improved accuracy ▪ Reference point vs. OEM reporting

► Serve as a “proof of concept” ▪ OMAC/PackML▪ OEM interaction▪ Evaluation of toolset▪ LMS benefits determination

Business requirements

• Project scope

• OEM

• Landscape & architecture

• Implementation

• Benefits

• Summary

Definitions

► OMAC—Organization for Machine Automation & Control

► The PackML standard by OMAC*▪ Defines line types from standalone unit – fully integrated system▪ Defines machine states – e.g. running, stopped, paused▪ Defines a list of tag names, definitions and data sets▪ Use of these for communication and use of information from

machinery to other machinery; and higher-level systems

► ABI – Amalgamated Beverage Industries, the soft drink division of The South African Breweries Limited (ABI)

*Source: www.omac.org

Business requirements

• Project scope

• OEM

• Landscape & architecture

• Implementation

• Benefits

• Summary

Project Scope

Implement Wonderware MES Performance System V3.4 on the soft drinks line being commissioned

at ABI Pretoria

▪ User requirements specification▪ Filler thin-slice▪ Develop - ArchestrA to Reporting▪ Factory Acceptance Test▪ Commission▪ Train

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Project Scope

Additional requirements

▪ Leverage SAP process order/DPR▪ Adhere to International standards

• OMAC/PackML*

▪ Adhere to SAB standards• HMI & Archestra• Naming • “DPR”

▪ Interface directly to OEM▪ Downtime capture

• Filler• Rest of line equipment

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

* abridged

Project background

Context

► Existing SAB ABI – SAP PP & QM (“DPR”)► Previous LMS projects► OMAC / PackML development► OEM interaction► SAB Manufacturing systems

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Project background – “DPR”

Project background – LMS

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Project background - Context

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Project background - structure

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Garth BassonBusiness Systems Executive Manufacturing & Supply Chain

John CoetzeeBusiness Systems Manager

Manufacturing

Sandeep SeeripatBusiness Systems Manager

Supply Chain

Lucia BeukmanSystems Manager

Control and Automation

Sadie OberholzerSystems Manager

MES

Colleen MullerSystems Manager

SAP ‘WCM’

Deon BarnardEOH Project Manager

Paul KotzeEOH MES Engineer

Project team

Kivern SinghProcess Control Manager

ABI - Pretoria

Project background

Project details

► Start: August 2008► Planned End: September 2008*► Combined engineering approach

▪ ABI Process Control Manager – Process and Procedures▪ SAB Manufacturing Systems – Design Guidelines and Standards▪ EOH Mining and Manufacturing - Engineering

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

* PLC datatables and line commissioning delays –> still ongoing

OEM

KHS► Turnkey line delivery – incl: 3rd party equipment (e.g.

Labeller, inspectors)► OMAC & PLC data structure► Ibhayi brewery project – 1999/2000

▪ Data collector▪ Defined data structure – DB100

► Challenges▪ Controller code▪ 3rd party supply

► Customers need to drive the standards adoption by OEMs▪ International open standards▪ Partnering with OEMs▪ Partnering with software suppliers

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Landscape & Architecture

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

SAP PP / QM

SAP BW

• Creation of daily production process order• Capture of material usages• Capture of lost time

• Consolidated daily production report

ArchestrA

• Machine states• Fault codes

Packaging Controllers

PerformanceSoftware

HMI – WW Panel

• Line mimics

• ↓ Production order

• ↑ Lost time**

• ↑Production quantities**

• Contextualisation of machine states, fault codes• Production volumes• Process order delivery tracking

** future

Packaging Process

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Blow Moulder Labeller Filler Blender

Caser

Palletiser

Case Washer

Bottles are produced (blown)

Bottles get labelled

Syrup concentrate blended

Returned crates get washed

Filled bottles packed into cases

Filled cases palletised

Bottles filled

Information flow

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Architecture

Microsoft 2008Hyper V

Design - Methodology

► “DPR”-biased standard► Common components ► OMAC / PackML standards► Centralised configuration

▪ Development▪ Deployment

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Node Deployment

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Software Implemented

► Wonderware▪ Performance 3.4▪ System Platform 3.0▪ InTouch 10▪ Information Server 3.0▪ Historian 9.0

► Microsoft ▪ Hyper V 2008 – Virtualization

• Host Node (MES)• Virtual Machine (Application Engine/Communication)

▪ SQL 2005/Reporting Services▪ Windows 2003/Server Platform

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Software Implemented

► Software Toolbox▪ Siemens S7 300/400 Suite Driver

► ProsCon OPC client▪ Interface to Palletiser and Caser

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Network & Hardware

► Network▪ 2 x VPN with 3x managed Switches

• Control Level 0 Network (2 switches)• Supervisor/Business ( 1 switch)

► Hardware▪ 1 very big server with lots of RAM and processing

power………▪ 2 x Wonderware Touch Panels stainless steel

• Filler• Blowmoulder

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Application Overview

Machine details

Job Progress

Process Order Handling

Live/Historical Trending

Quadrant Navigation

Reports – Manager

Reports – Reporting Services

Current Status

► Implemented▪ Automatic logging of machine reasons▪ Operator created SAP process orders▪ Operator selected reason codes for

filler downtime > 2 minutes▪ Downtime & production reports▪ Touch panel

► Outstanding▪ Detailed line daily report▪ Some counters and machine speeds

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Current Status

► Future?▪ Performance Software-SAP interface via MII

• Upload downtime reasons• Download process orders

▪ Formal solution evaluation▪ LMS approach & business case

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Benefits

► Downtime reporting▪ OEM usage▪ Business usage

► Estimate reject counts/crates on line► Downtime accuracy

▪ PLC driven ► Openness – OMAC/PackML & S95 Compliance► Reporting of all micro stops► Analysis capability

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Summary

► Turnkey supply▪ SI▪ 3rd party equipment

► Engineering approach► Standards

▪ International – OMAC / PackML▪ PS requirements – DPR, Interpretation

► Project implementation – during line commissioning► Ability to interpret in context

▪ Contribution of each machine vs. line► OEM partnering► Open standards

Business requirements

Project scope

OEM

Landscape & architecture

Implementation

Benefits

Summary

Questions

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