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An Introduction to the Wonderware MES Portfolio

An Introduction to the Wonderware MES Portfolio. Australia F&B Seminar Series March, 2014 Grant Kelly MES Business Development, APAC. Impact on Manufacturing Strategy. Strategy. visibility. R&D: more recipes. Procurement: more items!. variety. velocity. Marketing: more choices!.

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An Introduction to the Wonderware MES Portfolio

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  1. An Introduction to theWonderware MES Portfolio Australia F&B Seminar Series March, 2014 Grant Kelly MES Business Development, APAC

  2. Impact on Manufacturing Strategy Strategy visibility R&D: more recipes Procurement:more items! variety velocity Marketing:more choices! Execution Product Portfolio SupplyNetwork Is product moving faster than informationon your factory floor? Consumer Markets

  3. Wonderware MESMESA 11 Point Coverage Invensys MES/MOM Solution Space • Order Execution & Management • Materials Movement Management (Receive, WIP, Ship) • Recipe Definition Management (BOM, Process Parameters) • Batch Management • Performance & Efficiency (OEE, Labor, Waste, Loss) • Quality Management (Specification, Sample, SPC) • Non-Conformance Management (HACCP, Genealogy, EBR) • Procedural Execution (BPM, Workflow) • “Paper-on-Glass” (Electronic Work Instructions) • Sustainability (Utilities, Energy Management) • Reporting and Notification (Real-time) • Mobility (Mobile workforce) • Integration (PCS, ERP, Peer Systems)

  4. MES/MOM – An Integrated Experience ISA-95 Application Levels Enterprise-centric platforms Level 4 Business Planning& Logistics “For many, MES is no longer a point application, but a platform that serves a dual purpose: integrating multiple business processes within a site and across the manufacturing network, and creating an enterprise manufacturing execution capability. Gartner Group, Vendor Guide for MES 2012 Level 3 Manufacturing Operations Management(MOM/MES) Level 2 Control, Monitoring& Safety Level 1 Automation-centric platforms

  5. Impact on IT Strategy • COTS • Modular, Flexible & Open • SOA • Centralised Configuration and Decentralised Deployment • Error Handling • Data Validation & Correction • Security • Unified HMI • Platform Agnostic (Mobile Technologies) • SAAS (Cloud)

  6. Invensys Response - A Platform to Help Drive Sustainable Process Excellence & Results • Process Data • Temperature • States • Pressures • Cycles • MES • Inventory • Work Orders • Quality • Recipe • Maintenance • OEE • Operations Intelligence • Dashboards for multi-site / db • Any SQL source • KPI’s , Benchmarks & analytics • Collaboration • People & Systems Work Process Management • Governance • SoP’s, GMP’s • Alerts, Escalations, Approvals • Audit

  7. Top Tier Food & Beverage Companies

  8. Wonderware MES Performance Business Value • Improve Asset Utilization (OEE) • Reduces Capital Expenditures • Increases the Capacity of Existing Assets • Empowers Operators Key Capabilities • Detect, Capture & View Utilization Events • Manual & Automated Data Collection • Real-Time Visibility to Production Performance • Bottleneck and Root-Cause Analysis

  9. OEE Results – Phase I and Beyond Bottling Plant Decreases Downtime and Achieves Swift Payback with Wonderware Software Solution “We have to make the right decisions everyday because it has a huge impact on our bottom line. Wonderware helps us make those decisions.” Scott Jamison Vice President of Engineering OEE by Year SKU Additions • PepsiCo Concentrate plants on Wonderware & MES, In-Batch • 130 Pepsi Sites use Wonderware.

  10. Wonderware MES Operations Business Value • Foundation for Agile Production Processes • Improve Production Consistency • Empower Supply Chain Applications • Enforce Compliance & Governance Key Capabilities • Open, Modular, Scalable, Extensible • Full-Featured MES Capability – “Dock-to-Dock” • Real-Time Visibility to Production Activities • Comprehensive Manufacturing Genealogy

  11. New BelgiumBrewing • Results • Improved Resource Utilization • On line Product Traceability reducing Business Risk • Improved Asset Utilization with reduced turnaround times. • Increased Product Quality RFT and Compliance • Improved Operating Efficiencies (OEE > 86%) • Better Customer Service • Business Challenge • Operating Information resided in several silos including systems, spreadsheets, logs and people. The information was typically dated and disintegrated. Achieved Step change in the business from often great to predictable excellence

  12. Wonderware Quality Business Value • Improve Quality and Consistency, Reduce Process Variation • Identify, Correct Deviations in Real-Time • Meet Regulatory, Customer Compliance Key Capabilities • SPC Alarms, Alerting and Charts • Integrated Specification Management • Sample Plan Definition, Execution 6

  13. Wonderware Batch Business Value • Increased Capacity through Optimal Utilization of Equipment and Materials • Effective and Consistent Management of Complex Batch Processes • Reduced Lifecycle Engineering Key Capabilities • Flexible Recipe Definition and Management • Sophisticated Batch Execution and Control • Comprehensive Batch Genealogy • FDA / 21 CFR Compliance

  14. Beam Global Wine & Spirits Brouwerij MartensBelgium • Challenges • To support strategy, need real-time visibility/results of operations • Results • InBatch automated production processes, • stores & enforces recipe adherence • Right steps at right time delivers consistent • product quality batch to batch • Simplifies changeovers, downtime • Integrated to HMI, MES, SP as well as ERP • system for full visibility and seamless IT • architecture • "Wonderware software is open, flexible and & very good at pulling together and analyzing production data and turning it into the actionable data we need to improve our production processes.”

  15. Wonderware Corporate Energy Management Business Value • Improve Energy Performance Indicators (ISO 50001) • Enables accounting for Energy in COGS • Provides allocation of Energy and Utility cost to plant consumers • Supports demand response and demand curtailment programs Key Capabilities • Measures all energy flows: Electricity, Gas, Air, Water, Steam • Uses energy rates schedules to compute real-time cost • Automatically computes cost of manufacturing events (lots, orders, batches, etc.) • Compares usage to targets by day, week, month, etc. • Reporting , Analytics, and Real-time view

  16. Results in Brewing & Beverage Operations “The comprehensive Invensys MES solution has provided a significant increase in the accuracy of our process control system enabling our operators to monitor the manufacturing lines in real time and more quickly react to anomalies that might occur.” Yuriy Chentyrev Director of Operations >86% Improvement in Operating Efficiencies • Improved Resource Utilization • On line Product Traceability reducing Business Risk • Improved Asset Utilization with reduced turnaround times. • Increased Product Quality RFT and Compliance • Better Customer Service …from “often great”to “predictable excellence” Reduction in Production Energy Usage 8% Reduction in Steam Consumption 5% Reduction in Packaging Material Cost 1.8% Reduction in Extract Loss 0.56% “If a process requires 500kWh there is not a lot that can be done about it apart from shaving off say 5% energy usage, but if the process is shifted to non-peak hours, costs can be reduced significantly. This just goes to show that energy cost need not be dependent on energy usage.” Wiseman Magagula Automation Engineer Coca Cola Swaziland, Conco Limited “We have to make the right decisions everyday because it has a huge impact on our bottom line. Wonderware helps us make those decisions.” Scott Jamison Vice President of Engineering Corporate target for energy reduction in one year 20% OEE By Year • Visibility into energy usage & cost per plant & subsection • Implementation of smarter energy usage/cost control protocols • Tighter grip on corporate departmental budgets & targets • Ability to control high energy operations to take place during low-cost periods SKU Additions Page 17

  17. Wonderware WorkflowOverview Business Value • Enable Change, Improve Process Agility • Improve Procedural Quality & Consistency • Adhere To and Enforce Regulatory Compliance • Increase Collaboration Across People & Systems Key Capabilities • Digitally Capture, Institutionalize Best Practices • Sophisticated Human Workflow Management, Calendar Management and Task Escalation • Seamlessly Embedded into Invensys Applications and 3rd Party Applications

  18. Wonderware Intelligence Business Value • Strategic manufacturing decision support platform • Synthesizes and transforms disparate data into “contextual information” • Enables continuous improvement across the manufacturing enterprise Key Capabilities • Visualization through an easy to configure dashboard – self service access • Model KPIs to meet specific business objectives • Collaborate and share metrics through a web-based dashboard

  19. Chr HansenMES / EMI Project • Develop natural ingredient solutions for the food, pharmaceutical, nutritional and agricultural industries • Wish to have flexibility & adaptabilityto address new market requirements • Full visibility into production processes • Right information at the right place at the right time • Performance comparison across plants using common, standard KPIs • Root cause analysis of quality issues

  20. Top Tier Food & Beverage Companies [Companies with global standardization initiatives]

  21. ArchestrA System Platform • “Infrastructure” for Real-time Management of Operational Data • Unified Plant Model • Common Name Space • Software, Systems and Devices Connectivity, Independent of Hardware • Management & Extensibility • Templates Driven with Extensiation and Derivation capabilities (Objects, Scripts and Graphics) • Common Configuration • Engineering Reusability • Change Propagation • The foundation for adapting standardization to your business Templatized Approach Easier Deployment Easier Installation Easier Configuration Easier Maintenance Easier Management Reduced TCO Lower Risk MaintainableIntegration Application Standardization Future Changeability

  22. Nestlé • Key Objectives • Implement standard way to operate plants consistently at the right quality • Ensure consistency and efficiency of the implementation of Business MES Solution • Reduce time of implementation, no project delay, leverage experience across plants • Reduce development efforts and cost per plant • Results • Standard Solution ConfiguredDeployed at 8+ sites with minimal customization(additional plants to come) • Dedicated Program Team • Invensys and SI Experienced Team around the world • Consolidated and repeatable deployment model • Effective Solution Support and Governance model • Overall project services costs reduction (per site): • 25-30% of initial solution development cost

  23. Invensys ManufacturingOperational Management An Integrated Offering Level 4 Business Planning & Logistics Wonderware Enterprise Integrator (WEI) Production & Performance Applications Level 3 Manufacturing Execution System Application & Reporting Clients ERP PLM EAM SCM Level 0, 1 & 2 Control Batch Continuous Discrete 3rd Party

  24. Investment in MES Leadership in F&B 25% of theSW Business from MES is from F&B # 1 MES Industry Leader* $2 Billion MES market (Growing ~10% annually) ~7% 25% of Total R&D Investmentin MES *source: Frost & Sullivan 2012 Strategic Analysis for MES and ECQM • $100+M invested in MES in the last 6 years • We will continue to invest and lead • Committed to MES leadership in F&B/FMCG

  25. Resulting in Performance Improvements

  26. Providing Business Value • Foundation for Agile Production Processes • Improve Production Consistency • Improve Asset Utilization • Improve Product Quality and Reduce Waste • Reduce Environmental Footprint • Empower Supply Chain Applications • Enforce Compliance & Governance

  27. Most Presentations available OnDemand www.plantseminars.com Downtime and OEE A Practitioner Approach To Packaging Line Productivity Continuous Improvement: Packaging Driving Economic Profit in Food Plant Manufacturing Visualizing Hidden Information Featured Speaker:Steve Ford ,Mars Chocolates North America Featured Speaker:Eric Allen, Sr. Technical Mgr. JM Smucker Co. Featured Speaker:Mathieu Loranger, Eng Featured Speaker:Jim Whalen,Rich Products Featured Speaker:Mike Ruffner,Food Distribution Company OnDemand OnDemand OnDemand Food Safety and Temperature Integrity in food distribution facilities Learn Secrets of Enterprise Mfg. Intelligence Asset Reliability —Get Behind The Scenes at Frito Lay Driving Operations Productivity Getting Real About Real-Time Cost Management Featured Speaker:Tom Braydich, Campbell Soup Company Featured Speaker:Ed Michel,Frito-Lay Featured Speaker:Rudy Westervelt (retired), Kroger Featured Speaker:Mark Grimes Gordon Food Service Featured Speaker:Lars Johansen,Chr. Hansen OnDemand OnDemand OnDemand OnDemand

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