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Packaging Line Performance System

Packaging Line Performance System. John Coetzee SAB Business Systems Manager Manufacturing. Paul Kotzé EOH 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,

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Packaging Line Performance System

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  1. Packaging Line Performance System

    John Coetzee SAB Business Systems Manager Manufacturing Paul Kotzé EOH MES Specialist
  2. 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…
  3. Agenda Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary
  4. 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
  5. 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
  6. 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
  7. 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
  8. 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
  9. Project background – “DPR”
  10. Project background – LMS Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary
  11. Project background - Context Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary
  12. Project background - structure Garth Basson Business Systems Executive Manufacturing & Supply Chain Deon Barnard EOH Project Manager Project team Paul Kotze EOH MES Engineer Sandeep Seeripat Business Systems Manager Supply Chain John Coetzee Business Systems Manager Manufacturing Lucia Beukman Systems Manager Control and Automation Colleen Muller Systems Manager SAP ‘WCM’ Sadie Oberholzer Systems Manager MES Kivern Singh Process Control Manager ABI - Pretoria Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary
  13. 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
  14. 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
  15. Landscape & Architecture SAP BW Consolidated daily production report Creation of daily production process order Capture of material usages Capture of lost time SAP PP / QM HMI – WW Panel ↓ Production order ↑ Lost time** ↑Production quantities** Line mimics Performance Software ArchestrA Contextualisation of machine states, fault codes Production volumes Process order delivery tracking Machine states Fault codes Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary Packaging Controllers ** future
  16. Packaging Process Labeller Blow Moulder Filler Blender Bottles are produced (blown) Syrup concentrate blended Bottles get labelled Bottles filled Case Washer Caser Returned crates get washed Filled bottles packed into cases Palletiser Filled cases palletised Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary
  17. Information flow Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary
  18. Architecture Microsoft 2008 Hyper V
  19. Design - Methodology “DPR”-biased standard Common components OMAC / PackML standards Centralised configuration Development Deployment Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary
  20. Node Deployment Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary
  21. 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
  22. 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
  23. 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
  24. Application Overview
  25. Machine details
  26. Job Progress
  27. Process Order Handling
  28. Live/Historical Trending
  29. Quadrant Navigation
  30. Reports – Manager
  31. Reports – Reporting Services
  32. 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
  33. 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
  34. 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
  35. 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
  36. Questions ?
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