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