Driving Operational Performance by building Manufacturing Capability one step at a time…..

1. Driving Operational Performanceby building Manufacturing Capability one step at a time….. Phillip Terlesk

2. Agenda

3. Global population will exceed 7 billion Best In Class Demands Operating Excellence Compliance Dynamic Value Creation More than 70 million will enter the middle class Middle class adding $8 US trillion to consumer spend $8

4. Growth Matrix – Wine is a STAR!

5. Growth Matrix – Infant Formula

6. Infant Formula / Nutritional Powders

7. Value Add will drive growth

8. Adding Value will build export $$

9. Dynamic Value Creation Succeeding in a Changing Market Place Capability To Bring Profitable Products to Market Faster v Product Innovation Raw Materials Time MANUFACTURING OPERATIONS CAPABILITY People Process Innovation Chemical / Energy Market Data Reduce Waste 9

10. Agenda • Opportunity • Questions • Present State For Many Manufactures • Collaborate to leverage the Opportunity • Customer Use Case

11. Did we stay within range on all Quality parameters during Fermentation • Did we meet the CIP targets during the cleaning cycle? • Temp • Time Questions We Face On a Daily Basis ? Are our labels and packaging material correct & serialised Have I completed & signed off all the preflight checks before starting the new batch? Have we set up our coders correctly

12. Business, IT & Automation Investment may not be 100% Aligned Laboratory Information Management Systems Other Database s Alarms/Events Manufacturing Operations Management Quality Systems HMIs Control Systems Production Historians Computerized Maintenance Management Systems Performance Management

13. Building Capability one investment ata time ERP Manufacturing Operations Management Standard Operating & Procedures Change & Asset Management Process Optimisation Manufacturing Intelligence Process, Packaging & Safety Automation

14. Deliver the correct Information Plant Mgmt. • For the Executive • Costs, schedules, production output • Financial indicators, sustainability • For the Production Manager • Schedule, track production activity • Way production is running, ways to improve Production • For the Quality Manager • How product was made, ensure compliance • Ways to improve product and yield Quality • For the Engineering / Maintenance Manager • Keeping plant running • Predicative maintenance, asset optimization Engineering Operator • For the Operators • Monitoring process to keep production running • Identifying relationships to optimize the process

15. Agenda • Opportunity • Questions • Present State For Many Manufactures • Collaborate to leverage the Opportunity • Customer Use Case

16. Collaborate to PrioritiseObjectives & Align Capability Line & Site Specific Reports & KPI’s Performance Focus High level Business Objectives People Quality / Yield Execution Innovation Compliance Processes Throughput Business Drivers Align Capability Material Energy Equipment xxx $$$ xxx

17. Agenda

18. APC & Industry Use - Case Phillip Terlesk Sales Executive

19. Rockwell Improves Manufacturing Processes Enhance Profitability through: • Improve Product Quality • Minimize variability • Reduce deviation from specifications • Increase Production • Unlock capacity Maximize throughput • Reduce Manufacturing Costs • Use less energy per unit of output • Maximize yield MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value

20. Model-based Applications Approach A Hybrid Model explains or emulates the behavior of a process. Soft Sensors

21. Pavilion8 Model Predictive Control Controller executes at 5 sec to 1 min intervals

22. Soft Sensors (Virtual Online Analyzers or VOA) Neural Networks • Replace sparse, or infrequent, feedback from Lab or analyzer ProcessData Product Quality output VOA Calcs Process Parameter LabData … neural networks can fit general non-linear relationships artificial neuron with weight parameters Heat and Material Balances input A input B Traditional Empirical Correlations

23. How APC Enables Operational Objectives Minimize operational variance Reduce Variability 30 – 50% CV DV Achieves Uplift - closer to spec or performance limit whilst managing the process within constraints and safety margins BENEFIT $ Transition effectively SPECIFICATION OR LIMIT CV KEY TARGET BEFORE MODEL PREDICTIVE CONTROL Follow operational plan WITH MODEL PREDICTIVE CONTROL AND OPTIMIZATION CV The Business Value is Achieved by “raising the bar”

24. PLC/DCS PID PID PID Operator Interaction with a Standard Regulatory Control System ?!?!? Step A,D,B,C Process Lab

25. PLC/DCS PID PID PID Operator interaction with aModelPredictive Control System Production Target Soft Sensor Pavilion8 MPC Process Lab

26. Milk Powder Processing • Farm Cows • Tankers / Rail • Raw Milk Silo Storage • Separation into skim milk and cream • Standardization to specifications by combining skim milk, cream, and lactose or permeate • Falling Film Evaporation • Spray Drying • Powder Packing

27. Dairy Solution Production Landscape Receiving Area & Raw Milk Silos Future Automation Landscape ERP Milk Separation into Skim Milk & Cream ERP MOM CPGSuite Quality Standardization to specifications by combining skim milk, cream, and lactose or permeate / Milk Treatment Utilities Pavilion Fat / Protein Optimisation Milk Treatment Evaporation / Drying / Fluidbed Pavilion Moisture Optimisation Powder Drying Rockwell FT Historian - Reporting and Tools Packaging /Logistics/Mass Serialisation CPG Suite Labeling / Serialisation Packaging Plant Pax - Visualisation SCADA Controls & Safety Plant Pax - Logix

28. Scope for both Protein & Fat Optimisation & Pavilion8 Dryer & Evap MPC Butter Processing Permeate / Lactose etc Cream Hot Air Pavilion8 Protein & Fat Optimisation Analysis – this overview Wholemilk ProcesScan™ FT Separation Pasteurization Standardizing Streams Standardized buffer Storage Rockwell’s MPC Solution-Dryer & Evap Optimization Rockwell - Protein & Fat Optimisation Solution Product In 8-15% solids Pavilion8 MPC Dryer & EvapOptimisation Solids In Hot Air Product Out 45 -55% solids Cold Air Powder Out HP Pumping Drying

29. Dairy Standardisation Solution • Rockwell’s Pavilion8 Model Predictive Control (MPC) platform provides a closed loop standardising solution with superior targeting of final powder Fat and Protein composition. • Minimising giveaway of protein and fat in the standardisation process optimises yield providing substantial financial benefit.

30. Dairy Standardisation Solution Performance and Visability

31. Visualisation: Performance Metrics Distribution curve comparison (mean & standard deviation) against baseline Accepted moisture lab value against specification limit and controller target Moisture benefits, control performance & how hard moisture is pushed Standard deviation improvement against baseline Downloadable & accepted moisture lab values report Cp – how good is distribution within limits: Cpk – how centre is the distribution within limits A key Differentiator 31

32. Dairy Standardisation Solution Benefits • Composition variability reduction of 50% or greater • Tight compositional control allows fat and protein targets to be driven to the specification minimums. • Superior final powder compositional targeting. • Performance visualisation facilitates proactive decisions

33. Questions?