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Enabling & Deploying Operational Performance

Enabling & Deploying Operational Performance. Rob Aleksa Procter & Gamble. Objective. Motivate You to Adopt PackML Technology Suppliers: Embed Directly in Control System OEMs & End-Users: Apply!!. Discussion Agenda. 1. Introduction. 2. Challenges. 3. Using standards.

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Enabling & Deploying Operational Performance

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  1. Enabling & Deploying Operational Performance Rob Aleksa Procter & Gamble

  2. Objective • Motivate You to Adopt PackML • Technology Suppliers: Embed Directly in Control System • OEMs & End-Users: Apply!!

  3. Discussion Agenda 1. Introduction 2. Challenges 3. Using standards 4. Implementation Strategy 5. Summary

  4. Software Development Typical or Traditional Project Modular Project & Good Software Methodology Barry Boehm, Software Engineering Economics Data from projects at IBM, GTE, and TRW

  5. How Standards Benefit P&G? • We buy equipment • Globally • Commercial and customized/unique equipment • Sometimes we’re the OEM • Implication: Integration of many different types of engineering designs & technology • Standards • Reduce initial and life cycle costs • Enable P&G and OEMs to focus on innovation • Help in information gathering to drive effective machine management, utilization, and continuous improvement “When you do things right, people won't be sure you've done anything at all.”

  6. Software Management Challenge • Machine systems are increasing in complexity • Many axis of servo drives • Coordinated axis, registration, phasing • Vision system integration • Fault management • Information capture & MES integration • Machine to machine coordination • Global coordination (Engineering, training, maintenance) • Strategies • Structured, modular object coding • Code encapsulation for reapplication • Consistent software methods across OEM machines • Apply standards Traditional Mechanical Machine Flexible and Unique Performing “Electronic” Machine

  7. Information Management Challenges • Information complexity • Horizontal integration (machine-machine, machine-process) • Vertical integration (production management & coordination) • “Make-pack-and-ship” replaces “make-to-stock” • Regulatory compliance • Strategies • Apply standard interfaces • Common nomenclature and organization • Modular, structured standard code across machines • Reduces validation costs • Simplifies asset verification and management

  8. Typical PLC Software Techniques?

  9. NOT FUNCTIONALLY ORGANIZEDNO CONSISTENT TAG STRUCTURE Typical PLC Software Techniques?

  10. Templated Solutions

  11. INDUSTRY TEMPLATES LEADS TO CONSISTENT & SUPPORTABLE STRATEGY (Higher Quality Product Logical) Templated Solutions

  12. PackML • Covers • Auto Mode State Model (S88 derived) • Data Definitions (Pack Tags) • Assists • Derive efficiency information through Pack Tags • Maintenance & Trouble Shooting through common approach in Machine Sequence • Consistent data format makes integration go smoother, adoption of a OEM machine is easier.

  13. PackML - Common Operating Structure Mode Manager Program Producing (Auto) Maintenance Mode Cleaning Mode

  14. Reporting Software OPC Server Plant Controls Network Line Controller HMI ` Accumulator Line Case Packer Palletizer Stretchwrapper PackTags – Common Nomenclature Consistent nomenclature reduces interface complexity PackTags is about Driving a Data Standard – a Common and Basic Machine Data Record. PackTags PackTags PackTags PackTags PackTags PackTags PackTags

  15. Standard Software Methodology Benefits • Users (operators, engineers, managers) learn only one system • Protects future flexibility to grow, the same methods can be re-used • Multiple machine types are interoperable • Integration time is reduced • Uptime is maximized (Common method increases familiarity, improving ease of maintenance and troubleshooting) • Investment in learning and applying a controller is lessened with each subsequent purchase • Common network tags among machines are configured identically

  16. Latin American Application

  17. Storage A Process Discrete (Packaging) Storage B LA PackML (Mode Manager) • PackTags used to communicate and interlock. • Example : Cartoner gets jammed and goes to a Stopped State, its Mode Manager communicates to the Labeler Mode Manager and make the Labeler transition to Holding and then to Held state, until jam condition is cleared. Wrapper Filler Labeler Cartoner

  18. LA Learnings • Methodology Feedback • Clear Functional Specs → Solid Control System Design • Integrated with P&G systems • Integrated & Holistic Machine View

  19. P&G Implementation Strategy • PackML into each Global Business Unit’s practices • Build capability to program, troubleshoot and operate state based machines • Implementation plan in each Business Unit • OEM communication method document and expectation when purchasing • Leverage control vendor training programs and templates • Engineering aids • Leverage into information systems, specifically for OEE calculations • Ensure continued industry compliance and alignment between End Users, OEMs, and Control Vendors

  20. P&G Results to Date • Standards • Phased rollout into GBU OEM Machine Specifications • Part of Corporate Global Machine Application Guide • Implementations • Over 6 on-going machine developments implementing PackML • Over 4 OEM’s plan on using PackML – delivering over 100 machines globally over the next 3 years • Upgrades planned on existing machines • Multiple installations to date – no negative comments • Training • Multiple engineering contractors trained on PackML • Formal training earliert

  21. Implementation Testimonials

  22. GBU Project #1 “In February, a new PLC software on Line 6…. an 8% gain in PR realized. This gain was accomplished using modular code for programming called PackML….” GBU Project #2 “On the packaging job PackML helped a lot during the startup of the multiple machine modules…. the whole line came up in no time at all. Engineering went faster once the State programming was complete.” GBU Project #3 “On new machines there is a huge advantage in only learning one programming methodology….” GBU Project #4 Line 68 Cartoner delivered in April ’07….“Plant E&I loves it.” Implementation Testimonials

  23. P&G OEM Requirements Are Here! • Beauty Care GBU Electrical Specification Packaging and Making • All machines other than making skids shall follow OMAC guidelines (version 3), including the OMAC state model for automatic operation shown below….

  24. Our Next Steps • Continue deployment to new engineers • Develop internal detailed software specification • Develop training video • Work with internal MES partners to standardize on Machine-to-MES interface using PackTags

  25. Final Thoughts • Deploy the PackML standards, support future standards and free up resources to innovate • Standards enable improved operational performance

  26. Questions ?

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