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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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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

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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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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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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 !

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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

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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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DATA need to be in CONTEXT to become valuable INFORMATION

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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

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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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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

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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

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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)

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....

. .... .... ... . ... ..

. .

....

. .... .... ... . ... ......

. .... .... ... . ... ..

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

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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.

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Q & A