“The accuracy of the downtime reports provided by the Wonderware software solution were so good that even our equipment supplier is using them to troubleshoot its equipment at our plant instead of using manual tracking sheets normally used when servicing the equipment.”

John CoetzeeSAB Business Systems Manager, Manufacturing

Invensys Improves Packaging Line Performance of South African Breweries’ Soft Drink Division

Goals• Toeffectivelyaddresstheannualsummer

demandforsoftdrinks,theplantneededtoimprovetheoverallproductionperformanceandacceleratecommissioningofanewpackagingline

• Theabilitytotrackmachineperformance,electronicdatacaptureandreportingofmeasurementswerekeycomponentstoensuringthatthepackagingfacilityoperatesefficiently

Challenges• ThefacilityneededtoconformtoPackML

standardstoensureefficientoperationoffacilitymanufacturingequipment

• TheautomationsystemhadtoworkwithexistingSAPprocessorderapplicationsanddailyproductionreportingfacilities

• ThecompanywantedtocapturealldowntimedatausingtheOMACmodelofopencontroltechnologiesformanufacturingapplications

Solutions and Products• WonderwareInTouchHMI• WonderwareSystemPlatform• WonderwareMES4.0/PerformanceSoftware• WonderwareHistorian• WonderwareInformationServer

Results• OnceAmalgamatedimplementedthePackML

standardsusingtheOMACmodelandWonderwaresoftware,thecompanywasabletoaccuratelyachievereal-timedowntimereporting

• Thecompanywasabletoaccuratelyestimaterejectcountsandcratesonthelinetoimplementimprovementstothemanufacturinglineprocess

INDUSTRY:FOOD&BEVERAGE

Amalgamated Beverage Industrieswww.abi.co.za

Pretoria, South Africa –Assummerrollsaround,thoughtsofbarbequesandfamilyget-togetherscometomind.Andwhatwouldagoodhotdogorhamburgerbewithoutacoldsoftdrinktoquenchahotsummerthirst.Forsoftdrinkmakers,preppingforthisbusytimeofyearentailsreviewingmanufacturinglinestoensuretheyareoperatingatpeakperformance.Thechallengeofcommissioninganewpackaginglineintimeforthisannualsummerrunonsoftdrinkproductscanbedaunting.ButnotforAmalgamatedBeverageIndustries,adivisionofSouthAfricanBreweries(SAB),whichchosetoimplementanewmanufacturinglinebasedonWonderwareautomationsoftwarefromInvensysOperationsManagement.

Amalgamated’smainbusinessgoalwastoaccelerateproductionofitspackaginglinewhichincludedtrackingmachineperformanceparameters,reducingmanualdatacapture,improvingtheaccuracyofmeasurementsandestablishingreferencepointstobetterevaluatethereportsfromOEMsregardingperformanceofitsmachinery.Amalgamated’smachineOEMsuppliersareresponsibleformanagingtheperformanceandcommissioningoftheirequipmentuntilfinalimplementationofthemanufacturingfacility.

Anotherimportantobjectivespecifiedthattheprojectwastoserveasa”proofofconcept”fortheeffectiveimplementationofPackML(PackagingMachineryLanguage)standards,whichareanopensystemofguidelinesusedinthedesignofautomationmachinery.ThePackMLstandardswereestablishedbythePackagingWorkgrouparmoftheOMAC(OrganizationforMachineAutomationandControl)group,aconsortiumofautomationandmanufacturingprofessionalsdedicatedtosupportingthemachineautomationandoperationalneedsofmanufacturing.

“Withoutaccesstovaluableprocessdataitwouldbedifficultforustoevaluatethestatisticswhicharedesignedtoassistthecompanywithdeterminingperformanceimprovementsandascertainwhatpartoftheprojectyieldedthemostvalue,”saidJohnCoetzee,SABBusinessSystemsManagerofManufacturing.

AmalgamatedworkedwithsystemintegratorEOHMiningandManufacturing(EOHMM)whichprovidesfullyintegratedoperationssolutions,MES,enterpriseintegrationandintelligencesolutionstotheminingandmanufacturingindustriesinAfrica.EOHMMdevelopedandmanagedtheprojectparametersincludingcompilingtheuserrequirementsandspecifications,developingandimplementingthefullapplicationcreationofperformancereports,managingfactoryacceptancetesting,commissioningthesystem,andtrainingusersandthetechnicalteamonhowtomanageandmaintaintheapplication.

“Wetookacollaborativeengineeringapproachinvolvingourprocesscontrolmanagerwhoprovidedinputonprocessandprocedures,theSABManufacturingSystemsdivisionwhichconsultedondesignguidelinesandstandards,andEOHMMformanagementofalltheengineeringaspects.Thiscollaborationofeffortsworkedverywellinsuccessfullyimplementingthisproject,”Coetzeesaid.

Challenges and Successes of Collaborative Line Commissioning

Thegreatestchallengeinthesoftwareprojectwasthefactthatitwasbeingimplementedatthesamepackaginglineitwastomonitorwhileitwasbeingcommissioned.Duringcommissioningofanewfactoryline,allfocusandeffortiscenteredonthisprocess.

However,Amalgamatedwaschallengedtoimplementboththehardwarecomponentandthesoftwaresimultaneously.Normally,thehardwarearchitectureofthelineisimplementedfirst,followedbythesoftware--Amalgamatedwantedbothcompletedintandem.

Tosuccessfullyachievethecompany’sobjectivesforleveragingexistingSAPprocesses,conformingtothePackMLstandardandcapturingdowntimedata,AmalgamatedselectedanInvensysOperationsManagementsolutionusingWonderwaresoftware.ThecompanyimplementedtheWonderwareMES/Performance,WonderwareSystemPlatform,WonderwareInTouchHMI,WonderwareInformationServerandWonderwareHistorianapplications.ThecombinationofthesepowerfulsoftwaretoolsenabledAmalgamatedtoachieveitsobjectiveofacceleratingtheproductionofitssoftdrinkmanufacturinglineduringpeakdemandcycles.

ThefoundationoftheAmalgamatedsystemistheWonderwareMES/PerformancesoftwarebuiltontheWonderwareSystemPlatform.Theperformancesoftwarecollects,tracksandcommunicateskeyperformanceindicatorsinreal-time.Thisinformationisthendeliveredtooperatorswhocantakeimmediateactiontocorrectaproblemontheline.BuiltonWonderwareSystemPlatform,theperformancesoftwareishighlyscalableforallSCADA,supervisoryHMIandMESapplications.

Delivering Information to the Right People at the Right Time

WonderwareInTouchHMIisusedforvisualizationofmanufacturingoperations.SophisticatedgraphicsaredisplayedonoperatorscreensshowingstandardizedPackMLinformationtoassesstheoperationalefficiencyofvariousmachinesonthepackagingline.Topreventoperatorconfusion,onlymachineOverallEquipmentEffectiveness(OEE)informationisshown,althoughthefullOEEdashboardisavailableonrequest.

“Becauserawdataisshortonanalysisandfacts,WonderwareMES/Performancesoftwareaddsimportantdetailstotheinformationcapturedbythesystems,”Coetzeesaid.“Thesoftwarealsotracksproductionvolumesandprovidesdetailsontheproductdeliveriestoensurewearemeetingtherequirementsoftheoriginalproductionorder.”

InadditiontoOEEdashboards,anyspecificportionoftheHMIscreenscanbecustomizedtodisplayvariousinformationsuchasdowntime,Paretocharts,linestoppagesincludingdurationandfrequency,jobprogress,andliveorhistoricalperformancetrending.

“BecausethedowntimereportsprovidedbytheWonderwaresystemaresoaccurate,Amalgamated’smachineOEMisusingthemtotroubleshootitsequipmentinsteadofusingthemanualtrackingsheetsnormallyused,”Coetzeesaid.

WiththeimplementationofWonderwareHistorian,Amalgamatedhasaccesstoawealthofhistoricalinformationfromitsproductionprocesses.Asahigh-performance,real-timedatabase,Historianisabletocollectawidevarietyofplantdata,atfullresolutionandveryhighdatarates.

Thisensuresthatdecision-makersatalllevelshavetheinformationneededtodrivevitalproductivityimprovements.ThisinformationissharedthroughouttheorganizationusingWonderwareInformationServerwhichaggregatesandpresentsplantproductionandperformancedataoverAmalgamated’sintranet.

WiththehelpofWonderwareHistorianandWonderwareInformationServer,Amalgamatedhasaccesstoaccuratedowntimeandstoppagereports,canmoreaccuratelyestimaterejectcountsanddeterminethenumberofcratesontheline.Theeliminationofmanualloggingoftheseactivitieshassignificantlyincreasedtheefficiencyoftheproductionfacilitybymakingtheinformationreadilyavailableforbusinessanalysis.

Invensys Open Architecture – Making It An Easy Choice

Today’sMESimplementationsareafarcryfromthe“bigbang”approachofthepast.Wonderwaresoftwaresolutionscanbeinstalledgraduallywithsuccessmeasuredateachstageoftheimplementationbeforecontemplatingthenextstep.WithadherencetostandardssuchasPackML,manufacturersareassuredthatallpiecesofthepuzzlewillactuallyfittogetherandoperateeffectivelyovertime.“Packaginglinehardwareandsoftwaresuppliersusedtoonlyofferproprietarysolutions.ThismadeAmalgamatedverywarybecauseproprietarysystemswouldlockusintoaparticularvendor’ssolution,”Coetzeesaid.“ButsincecompaniessuchasInvensyshaveadoptedopenstandards,wearemoreopentobuythesesolutionsbecauseweknowtheywillhaveinteroperabilityandwillintegratewithothersystems.Sotheironyisthatthetacticofproprietarysystemsthatweredesignedtolockincustomerstoaparticulartechnologyactuallysoldlessthanopensystemswithinteroperability.Thisenablesflexibilityofmanufacturingoperationstoquicklyaddressthechangingdemandsofsoftdrinkconsumers.”

Sogoaheadandopenthatbottleofsodaatyournextpicnicorcookout,becausethankstoautomationsolutionsfromInvensys,softdrinkbeveragemakerAmalgamatedispreparedtosatisfythethirstforfrostybeverageswhenthesummersunblazes.

Invensys,theInvensyslogo,ArchestrA,Avantis,Eurotherm,Foxboro,IMServ,InFusion,SimSci-Esscor,Skelta,Triconex,andWonderwarearetrademarksofInvensysplc,itssubsidiariesoraffiliates.Allotherbrandsandproductnamesmaybethetrademarksorservicemarksoftheirrepresentativeowners.

©2011InvensysSystems,Inc.Allrightsreserved.Nopartofthematerialprotectedbythiscopyrightmaybereproducedorutilizedinanyformorbyanymeans,electronicormechanical,includingphotocopying,recording,broadcasting,orbyanyinformationstorageandretrievalsystem,withoutpermissioninwritingfromInvensysSystems,Inc.

Invensys Operations Management • 5601 Granite Parkway III, #1000, Plano, TX 75024 • Tel: (469) 365-6400 • Fax: (469) 365-6401 • iom.invensys.com

Rel.03/11PNWW-4085