Post on 20-Apr-2018
20/09/2017
1
Creating an IoT platform for Arla Foods’ Supply Chain.
Arne Svendsen, Senior IT Manager
Steffen Lundgaard Jørgensen, Senior IT Architect/Industry 4.0
20 September 20172
Arne Svendsen
https://dk.linkedin.com/in/arnesvendsen
1980: M.Sc. EE(P) + Computer Science1980-1991: PLC firmware and SCADA software development1990-2002: Consultant, Computer Integrated Manufacturing2002->now: Driving Arla corporate IT standards within Manufacturing-IT & Automation
Engaged in Open Industry Standards. Board member in OMAC & SESAM organisations.
Background
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2
20 September 20173
1. Arla Foods, Introduction (3 slides)2. IoT & I4.0 – which Business Benefits ? (5)3. Using ISA-95 in building the future Platform (10)4. Industrie 4.0 – look out to Germany ! (4)5. The IT/OT dilemma - solved at Arla Foods ? (2)6. Take aways + Q&A
Agenda
Arla Foods Introduction
Our vision: Creating the future of dairy to bring health and inspiration to the world, naturally
13,500+FARMER OWNERSFROM 7 COUNTRIES
70 Production Sites(EU, US,CHN)
MILK INTAKE12,5+ BILLION KILO
19,000+COLLEAGUES
10 BILLION EUROREVENUE
PRODUCTS SOLD IN100+ COUNTRIES
20/09/2017
3
Arla Foods Introduction1000’s of Variants - Arla Brands & Private Label
Farmer owned Cooperative since 1880
Rødkærsbro Mozzarella Dairy
Aylesbury, UK
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20 September 20177
1. Arla Foods, Introduction2. IoT & I4.0 – which Business Benefits ? (5)3. Using ISA-95 in building the future Platform (10)4. Industrie 4.0 – look out to Germany ! (4)5. The IT/OT dilemma - solved at Arla Foods ? (2)6. Take aways + Q&A
Agenda
Industry 4.0 - high levelMy view – one of many ..
The 1st (Steam)
The 2nd (Ford T)The 3rd (www, PC)
The 4th Industrial Revolution
InternetofThings(IoT) ”DIGITAL”
NewBusinessModels
INDUSTRIE 4.0INDUSTRIALInternetofThings(IIoT)SmartManufacturing
Thegoodoldwww:Internet(ofPeople)
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5
Supplier Owner/ farmer Inbound Production Administration Outbound Consumer ActivitiesCustomer
Why I4.0 is on our agenda?
Arla Value Chain
Motivators:
September 20, 201710
I 4.0 (IIoT, Digital Supply Chain)
Digitalisation, IoT, etc.
Food Quality
Flexibility, scalability,
& NPI
Data foundation for digital services
Future logistic of
food
Volume production
& Speciality
. . . .
Industrial IoT – Why
Examples
September 20, 2017 Steffen Lundgaard Jørgensen (STJOB)12
Power up Digital Supply Chain, increase Value from Data
3.8°C
4.5°C
4.2°C
Batch:XXXXXBBF:XXXX
spcReal time transparency
Data science
Data for new digital technologies
Plug&Play External Digital Services
Product story
Supplier Owner/ farmer Inbound Production Administration Outbound Consumer ActivitiesCustomer
IT OperationsBalancing On-Premise
& Cloud
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20 September 201713
1. Arla Foods, Introduction2. IoT & I4.0 – which Business Benefits ?3. Using ISA-95 in building the future Platform (10)4. Industrie 4.0 – look out to Germany ! (4)5. The IT/OT dilemma - solved at Arla Foods ? (2)6. Take aways + Q&A
Agenda
....
. .... .... ... . ... ..
. .
....
. .... .... ... . ... ......
. .... .... ... . ... ..
Fortrådning Fieldbus/sensorbus RemoteI/O
PLC PLC
Procesnetværk
Fabriksnetværk
Koncernnetværk
Fieldnetværk
SCADA
MES
ERP
Wanted: “Faster and more flexible”Yes – but with structure.
4. Business-IT- ERP, BI, …
3. Production-IT- Manufacturing Execution Systems/ MES
2. Automation- PLC, HMI, EDGE-units, Arduino, Rasberry, ….
1. Devices- Drives, valves, motors, analyzers …
HMI
20 September 201714
ISA 4-LayerModel
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7
Arla Production IT Platform & Solution Modules
20 September 201715
OrderExecution(LMS)
RecipeManagement
(RMS)
Printer&LabelControl
(PXS)
PackingVerification
(PVS)
ProductionReporting
EfficiencyManagement
(EMS)
SCADAQualityManagement
(LRM)
Track&TraceFilterreportBatchReports OEE
HistorianAlarm
WonderwareSystemPlatform(ApplicationServer,HistorianServer,DigitalIntegrationServer)
SAPMII(IntegrationERP)
BatchExecution(RMP)
OptimizedCleaningReports
CIP
ProdutionDataWarehouseProductionReports
OEEReports
PDWPDW
EnvironmentalData(EDM)
CarbonDesktop
PLCLinecontroller(Orderhandling)
PLCGatewayPLC
OAS2
AdvancedProcesControllStatisticProcessControll
SPC
SAPMII(IntegrationERP)
SAP(ERP)
ProductionITInfrastructure(Server,Client,Virtualization..)
MaterialFlowSystem(MFS)
WarehouseManagement
(WMS)
LocationControl
PLC
OAS1
AdvancedProcesControll
APC
4. IT-ERP
3. MES
2. Auto-mation-
16Vallebehandling
Indvejning / UdvejningSkummesalSyrekulturService anlæg
Rødkærsbro MejeriMasterplan for automation og Produktions ITBILAG A. Produktions IT arkitektur
Globale applikationer
Blok pakkeri & HF lagerPakkeri & FV lager
SattLinePLC
SQL
Datafangst og emballagekontrol
Adminitrativt netværk
Produktionsdatabase
server
SQLserver
IAS server
Produktions netværk
Operatørstation
Operatørstation
Operatørstation
InTouchOperatørstation
PLC Eng. Station
IAS Eng. Station
WW GR server
LIS router
NNPC ISCOSYSTEMS
Router
Operatørstation
Operatørstation
Operatørstation
PLCSimatic S7
PLCSimatic S7
OP panel Remote I/O
Profibus
Operatørstation
Operatørstation
Operatørstation
InTouchOperatørstation
Operatørstation
Operatørstation
Operatørstation
Food ScanMilco Scan
SAP palleprint
Produktmærkning
Operatørstation
Operatørstation
Operatørstation Oper
atørstation
Operatørstation
Operatørstation
PLCSimatic S7
OP panel
Profibus
iFixOperatørstation
Veje enhed
Back-upserverFil server
SQC 9000vejesystem
Eco Lab
Easy Label
SAP klienter
Produktionsdomæneserver
xMIIserver
Special objekter
TQM
SQLserver
SAP R/3
Data Ware House (DWH)
Remote I/O
Profibus
Remote I/O Remote I/O
IO bus
Remote I/O
OP panel
SAP integrations
server
Osteri Drænsystem
PLCSimatic S7
PLCSimatic S7
OP panel Remote I/O
Profibus
IAS server
IAS server
Operatørstation
Operatørstation
Operatørstation
InTouchOperatørstation
Operatørstation
Operatørstation
Operatørstation
Remote I/O
Profibus
Remote I/O
IAS server
IAS server
PLCSimatic S7
PLCSimatic S7
OP panel Remote I/O
Profibus
IAS server
IAS server
Operatørstation
Operatørstation
Operatørstation
InTouchOperatørstation
Operatørstation
Operatørstation
Operatørstation
Remote I/O
Profibus
Remote I/O
IAS server
IAS server
Simatic PLC netværk
The large Dairy/Factory has:
2 redundant, large Virtual Data centers.
80-100 Windows ServersAdmin NetworkFirewall(s) !Production Network(s)
100-300 PLC CPU’s with large amount of program code. PLC-networks
10-50.000 IO’s and/or Devices
A Dairy is a complex factory with a large numberOf 24x7-critical systems. Handle with care !
20/09/2017
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Analysis newAnalysis
PredictiveMaintenance
ProductionServer
SAPIntegration
AutomaticUnitAutomaticUnit
.......
UnitControl
UnitControl
Analytics
Processcontroller/Packaging(LineController)
ProductionDataCollection
MES(ExecutionPart)
SAP
Prod
uctio
nIT
Shop
Floor
Level4
Level3
Level2
Level1
Level0
SCADA&HMI
OEEReporting
ERP
AutomaticUnitUnit
Control
20 September 201717
Today’s ”I4.0” solutions
……...
……...
……...
……...
• Losing control• Complex setup• Vendors holding our data• DISCONNECTED Clouds
Industrial IoT – How
September 20, 2017 Steffen Lundgaard Jørgensen (STJOB)18
We think, we need an IIoT Eco-system
20/09/2017
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Black Box Digitalization Eco system based Digitalization
Industrial IoT Platform– Why
September 20, 2017 Steffen Lundgaard Jørgensen (STJOB)19
2 Ways to Digitalization, only ONE with Arla Control
++
Quick to get startedLow internal competence level needed
÷
÷÷
No cross service data use or possibility to do our own analysisHard to control securityEnd in high complexity, high vendor power, low flexibility, & costly setup
PLM
ArlaIoTPlatform
ExternalDigitalServices
++
+
Plug & play digitalizationArla data ownership & ability to do analyze, develop, & change vendorsPossible to have one shared front-end
÷÷
Initial investment & project dependenciesRequire internal competence, developers and platform operations/maintenance
We need Connectivity: Both Carrier protocolsAND Semantic OPEN-INDUSTRY-Standards
20 September 201720
Level4
Level3
Level2
Level0&1
ProductionSite
SAP
Processcontroller/Packaging(LineController)
MES(executionPart)
DataCollection,Analysis,&Reporting
AutomaticUnitAutomaticUnit
...
Unit
Control
Unit
Control
AutomaticUnit
Unit
Control
Order
Execution
(LMS)
Recipe
Management
(RMS)
Printer&
LabelControl
(PXS)
Packing
Verification
(PVS)
Production
Reporting
Efficiency
Management
(EMS)
SCADAQuality
Management
(LRM)
Track&Trace
Filterreport
BatchReports OEE
Historian
Alarm
WonderwareSystemPlatform
(ApplicationServer,HistorianServer,DigitalIntegrationServer)
SAPMII(IntegrationERP)
Batch
Execution
(RMP)
4. Business-IT Applications
3. MES Platforms& Modules
2. PLCs, EDGE-units, ..
1. Equipment, Devices, …
OPC-UA
Level-1 SemanticProtocol
Carrier protocols: OPC-UA, MQTT, …
Semantic Standards: Cross-industry: ISA-95, PackML, …Many existing Industry-Specific …
Level-2 SemanticProtocols
Level-3 SemanticProtocols
Level-4 SemanticProtocols
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10
DATA need to be in CONTEXT to become valuable INFORMATION
20 September 201721
Level4
Level3
Level2
Level0&1
ProductionSite
SAP
Processcontroller/Packaging(LineController)
MES(executionPart)
DataCollection,Analysis,&Reporting
AutomaticUnitAutomaticUnit
...
Unit
Control
Unit
Control
AutomaticUnit
Unit
Control
Order
Execution
(LMS)
Recipe
Management
(RMS)
Printer&
LabelControl
(PXS)
Packing
Verification
(PVS)
Production
Reporting
Efficiency
Management
(EMS)
SCADAQuality
Management
(LRM)
Track&Trace
Filterreport
BatchReports OEE
Historian
Alarm
WonderwareSystemPlatform
(ApplicationServer,HistorianServer,DigitalIntegrationServer)
SAPMII(IntegrationERP)
Batch
Execution
(RMP)
”Any” Prod. Data !
Materials view:Ø Material Classes
Ø Material-IDØ BOM
Recipe
Plant Asset view:Ø Equipment Model
Ø Site, Areas, Units ..Ø State-EngineØ Parms, Alarms, OEE
People view:Ø Peoples
Ø Competencesper shift ..
Ø Training plans Ø …
Planning/Execution/QA view:Ø Production Plan
Ø OrdersØ BOM, Recipe
Ø ”Reporting”Ø QM, Trends, SPC, ..Ø Traceability
We think, the
ISA-95Data Model
is the only OPEN STANDARD, answering to our Challenge …
20 September 201722
20/09/2017
11
ISA-95, Significant workgoing on …u Extend the ISA 95 Part 3 Activity model
to include the “activities” (often automated) of Levels 1 and 2
u Levels 1 and 2 will be general definition and references to other standards for specific subactivities
u Coordinate with the work of IEC 65E AHG1 to identify missing information models needed to exchange information between activities
u Coordinate with the work of IEC 64 AHG3 by providing a structure for looking at missing IEC/ISO standards
9/20/17
Dennis Brandl 201723
ProductionData
Collection
ProductionExecution
Management
ProductionResource
Management
ProductionDispatching
ProductionTracking
DetailedProductionScheduling
ProductDefinition
Management
ProductionPerformance
Analysis
Monitoringand Control
FunctionalSafety
Control andOptimization
AlarmManagement
Actuating
Sensing
20 September 201724
1. Arla Foods, Introduction2. IoT & I4.0 – which Business Benefits ?3. Using ISA-95 in building the future Platform 4. Industrie 4.0 – look out to Germany ! (4)5. The IT/OT dilemma - solved at Arla Foods ? (2)6. Take aways + Q&A
Agenda
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12
Check out ”Industrie 4.0” home
20 September 201725
Industry 4.0 ”home”: www.Plattform-i40.DE(Check out the Online Library, mainly in English)
www.acatech.de
Industrie 4.0 - Gathering momentum:2016: I4.0 & Industrial Internet Consortium/US: 2016: ”Made in China 2025” builds directly on I4.02017: I4.0 at G20 meeting2017: Germany & Japan starts cooperation on I4.0
Example reading:”Industrie 4.0 in a Global Context”p.62: Recommendations for Businesses.p.63: Recommendations for Researchers & associations
Industry 4.0
20 September 201726
Reference Architecture Model Industrie 4.0 (RAMI4.0) English translation of DIN SPEC 91345:2016-04
20/09/2017
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”Industrie-40-in-a-Global-Context.PDF”Nov. 2016
20 September 201728
Quote:”.. There is a danger that isolated, proprietarystand-alone or Silo solutions could emerge. This would expose purchasers of I4.0 solutions to the risk of technological lock-in, resulting in technological dependence and high costs.. ”
But Standards will save us, Right?
XKCD.COM
May25,201629Reference: Dennis Brandl
20/09/2017
14
20 September 201730
1. Arla Foods, Introduction2. IoT & I4.0 – which Business Benefits ?3. Using ISA-95 in building the future Platform 4. Industrie 4.0 – look out to Germany !5. The IT/OT dilemma - solved at Arla Foods ? (2)6. Take aways + Q&A
Agenda
....
. .... .... ... . ... ..
. .
....
. .... .... ... . ... ......
. .... .... ... . ... ..
Fortrådning Fieldbus/sensorbus RemoteI/O
PLC PLC
Procesnetværk
Fabriksnetværk
Koncernnetværk
Fieldnetværk
SCADA
MES
ERP
About the IT/OT dilemma – Arla Foods’ status
HMI
20 September 201731
OT
IT
Continuous Convergence – in Arla Foods
- 2002 Corporate MES/Automation teamFrom day-1 integrated into Global-IT.
- 2003 First ISA-95 based SAP/MES integration
- 2005-2017 Global MES ”rollout” – 45 sites- 2012-2017 Adoption of PackML
- 2016 ONE Arla Supply Chain Excellence ctr.- 2017 Arla-IT Going Agile => Bringing
IT/OTpeople into same Agile teams.
(There is still some ”disconnects” to local OTorganisation on the dairies)
20/09/2017
15
....
. .... .... ... . ... ..
. .
....
. .... .... ... . ... ......
. .... .... ... . ... ..
Fortrådning Fieldbus/sensorbus RemoteI/O
PLC PLC
Procesnetværk
Fabriksnetværk
Koncernnetværk
Fieldnetværk
SCADA
MES
ERP
About the IT/OT dilemma – Arla Foods’ status
HMI
20 September 201732
OT
IT
Central IT understands the needs of the localOT organisation:
- 24x7 Resilient systems on 70 local sites- Systems are build to last for many years- UPTIME is king, very short ”windows” for
upgrades
Local OT on sites understands that central IT:
- Needs strict procedures to keep a complexcentral landscape running
- Ensures Arla global IT-Security, set rules.- Central IT can ”run” local infrastructure (from
remote) if requested
20 September 201733
1. Arla Foods, Introduction2. IoT & I4.0 – which Business Benefits ?3. Using ISA-95 in building the future Platform 4. Industrie 4.0 – look out to Germany ! 5. The IT/OT dilemma - solved at Arla Foods ? 6. Take aways + Q&A
Agenda
20/09/2017
16
Message recap.
20 September 201734
Take aways .. Arla Foods is preparing our Global IT Solutions for Digitized Supply Chain by creating an Enterprise IoT Platform.
Our current focus: • INTERCONNECTION:
• Connecting Current-state MES, current state PLC, NEW Edge solutions, NEW smarter Devices. We want Plug-and-Play Open Industry Standards
• INFORMATION TRANSPARENCY: • Create an Enterprise IoT platform for fast data-collection AND Information Delivery.
• I4.0: Denmark should look to Germany and cooperate, pushing Open Standards forward.Arla Foods is presenting next time at SESAM conference 12th October in Odense, by Steffen Lundgaard Jørgensen – more details.
20/09/2017
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20 September 201736
Q & A