Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
National Symposium on
Automation & Digital Transformation of
Food & Beverage Industry26th & 27th February 2016
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K V Rehani
Automation Consultant
Mail ID: [email protected]
Tel: +91 9730018676
Solutions for Adoption of Automation
Technologies
In the F&B Industry
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K V Rehani
Academic:
- B. Sc. Physics Hons., Delhi University 1970
- M. Sc. Electronics , Delhi University 1972
Formerly:
- With Unilever.Head of Control & Automation Group . Worked for 30 years at different locations & positions. Implemented many green field & brown field projects. Developed solutions for many inhouse developed technologies.
- Instrument Er , IFFCO, Phulpur Unit (1979-81), commissioning of Ammonia ,Urea Plants & Site Utilities
- Assistant Instrument Er , Shriram Chemicals & Fertlisers ,Kota (1972-79), had formal training in Instrumentation while working in Ammonia, Urea, PVC, Caustic Soda & Power Plants
Currently:
- Independent Automation Consultant for CPG industry. Pune based
- Advisor to Rockwell Automation for their CPG business & other MNC’s for green field project
- Advisor to innovation led start up groups for young entrepreneurs
Association:
- Senior Life Member. Past President, ISA Pune Section (2013-15)
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Automation Solutions in F & B
Welcome to wonderful world of Automation
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• Manufacturing: Business Perspective
• Challenges of F & B Industries
• Manufacturing Challenges
• Automation Compulsions
• F & B Processes
• Opportunities & Focus Areas
• Challenges & Mitigation Strategy
• Q & A
Agenda
Automation Solutions in F & B
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Manufacturing: Business Perspective
Make DeliverSource
Plan
Supply Chain
Suppliers
Quality
R & D
Manufacturing
Engineering
Administration
Logistics
Warehouse
Value Creation is in Manufacturing ,therefore always in focus.
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Challenges of the F & B Industries.
Availability of products at all times at a price & quality which will help any Industry grow, increase its market share: Changing consumer preferences
Innovations to excite end users & create new marketsStay ahead of competition : Market Share & Sustainability.
Products are Safe & Fresh: Safety & Legislation factors.
Rising raw material & Energy Cost : Productivity & Performance
#
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Manufacturing Challenges
#
Productivity
Quality
Safety & Hygiene
Ageing Workforce
Ageing Plants
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Manufacturing Challenges
#
Productivity: What can go wrong, Will
How do you increase productivity to keep up with rising demand?stay competitive when cost of raw materials is constantly changing?meet safety norms?become more sustainable & cost efficient?improve performance, increase speed and overall productivity.
Top four areas where technology can increase
production, performance & agility.
Machinery,Materials, Methods & Manpower
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Manufacturing Challenges
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Quality,in Quantity
Investment in Technology as fundamental to growth.How do you accommodate different sizes of products(SKUs) on any given line ?ensure the best chance of maintaining quality & consistency ?innovate with expensive downtime ?What if your equipment could plan for next batch ?
End to end assurance keep quality high and reduce cost by controlling waste & process.
New Mixing Technology gives you ability to change production at short notice without losing impetus.
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Manufacturing Challenges
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Building-in-Safety
Minimizing Risks to operatives with no compromise on
Productions
Enhancing Machine Safety
Safety design, standards & validations
Achieving desired Performance Levels
Injuries in F & B manufacturing represent
around 25 % of all manufacturing injuries
reported.
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Manufacturing Challenges
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Ageing Workforce : How to Defy Ageing ?
Getting skilled manpower is a challenge.Qualified & motivated people are hard to find.
Loss of knowledge /experience is a business threat.
How to minimise downtime in absence of skilled people?
Implement standardised network that require
fewer employees to Manage, Monitor &
Maintain plant assets.
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Manufacturing Challenges
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Ageing Plant: What’s Next for your System?
Obsolescence
Lack of support from OEMs
Expensive downtime
Have a Migration Strategy & choose
right partner
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Manufacturing Challenges
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Achieving Agility: Operational Efficiency
When reviewing opportunities for improved operational efficiency by evaluating entire production cycle spectrum-from raw material receipts to finished goods,four key areas to evaluate every stage:
Machinery: Right first time & improved first pass quality.Material : Accurate recipe control to minimise wastageMethods: Using correct tools & most efficient process.Manpower: Right skills for operators, no unnecessary activity
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Automation Compulsions
Globalization :
Collaborative Manufacturing
Manufacturing information integrated with Supply Chain Visible Factories, Shop to Top Floor
Plant Wide Optimization
Benchmarking: Internal / External
Increased focus on Energy, Environment & Sustainability
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Automation Solutions in F & B manufacturing
Batch : Integrity & Traceability
Managing Supply Chain
Packing Line Integration : Driving Productivity
Smart Manufacturing
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Raw Material
Receipts
Ethernet Network
MAIN SERVER
MaterialTrack Server
Data Base
Logix
SCADA
•Visual Inspection
•GRR Generation
•Barcode Generation
•Store Location
Assignment
Barcode
Printer
Cordless
Barcode
Reader
• Sampling in
to Bar-coded
bins
• Analysis
Results entry
in to system
mapped to
sample
Cordless
Barcode
Reader
•Store at
Assigned area
•Show Status
(lights)
•Guide
Material Issue
•Validate
Material Issue
•Guided
unloading
• Status
Display
• Track Tank
Status
• Validate
Delivery from
Right Tank
•Barcode Barrels
•Display Barrel
Status
•Validate
Dispensing
•Tag Issued
Containers
QC/LAB RM Solids
Major
RM Liquids
MajorLiquids
MinorPowder
Minor
Mixer
AreaHolding Tanks &
Packing Area
Packaging
Material Storage
• Guide, Validate
Dozing as per
Batch Sheet
• Link Batch to
material Used
•Monitor
Operator
•Prompt Operator
• Validate Correct
Additive Mixing
•Monitor and
Guide Operator
• Guide and
Monitor Xfer to
Holding tank
•Store at
Assigned area
•Show Status
(lights)
•Guide
Material Issue
•Validate
Material Issue
• Display
Batch nos
• Prompt
Batch change
• Packaging
Line
Messaging
•Production Planning
• Batch Sheets/schedules
•Monitor Progress
•Reporting
•Data Logging
DeviceNet
Batch Integrity & Traceability
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Automation Solutions: Asset Productivity
OEE
Line Integration
Performance Reliability
Intelligent Equipment
Remote Support
Integrated Architecture
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What is Overall Equipment Effectiveness (OEE)?
Quality% = Total – Scrap
Total
Performance% = Total * Ideal Cycle
Running Time
Availability% = Running Time
Available Time
Overall Equipment Effectiveness (OEE) =
Availability x Performance x Quality
One Shift
Available Time
Running Time
Production @ Rated Speed
Good Production
Sc
he
d
Un
ava
il
Lost Capacity
Do
wn
ti
me
Sp
ee
d
Lo
ss
Sc
rap
Scheduled Unavailable Time
Breaks, meetings, maintenance, etc.
Downtime
Breakdowns, setups, changeovers
Speed/Cycle Time Loss
Reduced speed, cycle time variation
Quality Loss
Rejects, scrap
Key Performance Indicator
(KPI)
Time Loss Causes
OEE
Available Time = Shift time –Unavailable Time
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Line Integration
Insist on OMAC Guidelines compatible machine
design
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Automation – keeping pace with changing requirements
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Scalable Control Solution
Regulate
Optimize
Control
Predict
Single
LoopMultiple
Loops
Process
UnitMultiple
Units
Plant-wide
Value-Add
Area
Span of ControlStand Alone
Cluster
Centralised Panels
Stand alone pkg lines
SCADA
PLC’s,DCS,
Control Network
Remote access
& Data sharing
Enterprise
PLC’s,DCS,
Control Network
Remote access &
Data sharing with
ERP thru MES
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Strategy and Vision
Vision
World Class
Yesterday
Quality Performance
GAMP & PackML Simplicity
Information Enabled
Integrated Architecture
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Control Solution Selection
#
Have a strategy for adoption of Technology.
Start small, think big.
Do not reinvent the wheel
Invest in manpower & skill development
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K V Rehani
ISA Pune Section
Automation Consultant: KVR Consulting