AP14 - Monin Increases Production and Achieves S95 Standard on path to The Connected Enterprise

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved.

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Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

Monin Increases Production and Achieves S95 Standard on Path to The Connected Enterprise

Monin Increases Production and Achieves S95

Standard on Path to The Connected Enterprise

Company Overview

• Founded in Bourges, France in 1912.

• Production facilities in France, the United States and Singapore.

• More than 200 different flavors of syrups.

• Presence in more than 100 countries around the world.

Clearwater Plant

• Opened in 1996.

• Max capacity reached.

• New batching system in 2011.

• Production facility to serve more than 45,000 restaurants in 22 countries across the Americas.

Monin Team • Patrick O’Donnell

– Process Engineer

– >20 yrs experience in Automated Control Systems

– Designer of the system

• Todd Cummins

– VP of Information Technology

– >20 yrs experience in Information Technology.

Plant Overview

• Three main batching tanks.

• One tank utilized as a shared resource small ingredient tank moving through a 400 LPH pasteurizer, into three main finished goods holding tanks.

• Multiple valve clusters, VFD's, Micro Motion mass flow meters all communicating via Ethernet IP.

• Product recipes stored in ERP (Navision). Required to keep that storage, and get the recipes into the batching system as requested.

Project Background

• Challenge:

– Develop a new batching system capable to satisfy an increased production demand.

– Single-line system with high demand: Near zero downtime.

– Leverage standard technologies.

– Integrate batching system into existing ERP (Navision)

– Automate and reduce Q&A cycles.

– Automate batch corrections.

– Log manual operations.

– KPI Reporting to ERP.

Microsoft Navision (Dynamics NAV) • Microsoft Dynamics NAV (Navision) is a ERP software developed and distributed

by Microsoft

• In first quarter of 2014 NAV reached 102,000 current customers. An increase of 8,000 in under a year.

• Microsoft Dynamics NAV delivers integrated functionality to provide support for: – Financial management

– Supply chain management

– Manufacturing

– Distribution

– Customer relationship management

– Sales and marketing

– Service management

– Human resource management

– Project & Resource management

Expected Deliverables • Reduced time and programming cost to add new

equipment.

• Seamless connection between recipe managing

existing on Navision and the new system.

• Offline testing and validation of recipe changes.

• Expanded Event logging and process trending.

• Batch reporting

Project Team

• Multidiscipline team formed by R&D, Production, IT,

Engineering, Q&A people.

• IT and Process Engineering resources involved

together since design phase.

• SI selection based on experience on S-88 Batch

systems and integration of software solutions from

Rockwell Automation® and different vendors.

Solution Proposal

• Rockwell Automation

– Use of S95 Model.

– Use of S88 Standards.

Solution Proposal • Solution:

– Complete turnkey, ground-up batching system following S88

Batch standard, using Rockwell Automation FactoryTalk®

Batch Server communicating with Microsoft Navision

planning ERP software.

– The main SCADA system driving this is FactoryTalk Server

edition with multiple thin clients throughout the operation.

Navision

Navision/FactoryTalk Batch

FactoryTalk Batch/HMI

PLC

I/O

S95 Implementation

Core Components and Technologies

• Virtualization

• PlantPAx®

• ControlLogix®

• PhaseManager™

• FactoryTalk® View SE

• FactoryTalk® Batch

• eProcedure

• Navision integration

Level 0: Ethernet IP I/O

• Faster I/O and device testing.

• Better control of Micromotion mass flow meters.

• Mettler Toledo Ethernet IP scales.

• Reduced cost for cabling and panels.

Level 1: ControlLogix and PlantPAxObjects

• Best Automation controller in market:

– 1756-L74.

• PlantPAx Libraries: provide us all required control

modules for our process, no need for custom

development.

– Example: the P_DoseFM and P_DoseWS reduced give us all

the tools to do precise dosing with no code to control the CM’s

Level 1: PhaseManager

• Simplified phase programming.

• Reduced time to develop

solution using phase templates

for common tasks:

– Agitate

– Transfer

– Additions

• Better RSLogix™ structure

• FactoryTalk Batch area model

synchronization.

Level 2: FactoryTalk View SE

• Network distributed

architecture simplified

deployment of VMware

Horizon thin clients.

• Pre build PlantPAx templates.

• Integration with FactoryTalk

Batch and eProcedure

controls.

Level 2: FactoryTalk Batch and eProcedure

• S88 compliance.

• Recipe templates for different product types.

• Manual operation logged and recorded.

• eSignatures for different operations: – Manual additions.

– Corrections.

– QA.


• Integration with Logix

controllers.

• EBR, automatic report to

Navision.


• All manual additions

instructions entered in

Navision and transferred to

FactoryTalk Batch and

displayed in eProcedure.

Level 3: FactoryTalk Batch and Navision • Master recipe creation and edition done in Navision.

Level 3: FactoryTalk Batch and Navision • Production Scheduling done in Navision and control recipes

created in FacoryTalk Batch using API.

1 • Navision production order posted.

2

• Interface take the order and process it.

• Interface create the batches for the order and write back to Navision the createID.

3

• Batches are posted on the batch interface.

• Operator start the batches.

4 • FactoryTalk Batch executes the batch, running automatic sequences and asking operator

for actions.

5 • Batch completes and reports are uploaded to report database.

Level 3: FactoryTalk Batch and Navision

• Select which template to use based on: – If the batch doesn’t have any minor ingredients: Blend tank only.

– If the batch is less than 950 liters: Mix Tank only.

– If the batch have no ingredients > 30 kg: Blend tank only with ingredients on top.

– Rest of the cases: Blend tank and Mix tank.

• if a ingredient addition in tank 801 is > 1400 kg split the ingredient into 2 or more additions. All the parameters are kept the same for the split addition, for example if the addition is set to flush the tank and you get 3 additions all 3 will flush the tank.

• If any liquid addition is > 30 kg on the mix tank, it set the recipe to prompt the operator to use the wand and set a wand flush at the end of the additions.

• Transfer all Navision recipe information to the template and create the batch on the FactoryTalk Batch interface.

Key Features Between Navision and FactoryTalk Batch

Project Highlights

Production:

• 48 hours downtime to replace whole batching system.

• 1 week later running at full speed.

• Schedule production Campaigns in Navision with no 3rd party software required.

• Decrease in batching time.

• Automatic production reports.

• Batch scalability.

Project Highlights

R&D:

• Recipe management remains unchanged controlled by Navision.

• Added new recipe parameters and functionality: (Defining operators instructions in Navision that will show up in FactoryTalk Batch and eProcedure)

• No longer needed to keep printed versions of recipes.

• Reduce operator error to 0.

• Reduced time to market as recipes are ready to produce or test as soon the process engineer releases them.

Project Highlights QA:

• Increased batch consistency.

• Reduced time and paperwork to execute QA

testing.

• Corrections can be made on the fly, with

direct input of correction values from Lab.

Project Highlights IT:

• Integration between Navision and plant floor.

• Use of standard technologies.

• Virtualized infrastructure

Project Highlights Process Engineering:

• PlantPAx libraries simplified code development.

• PhaseManager simplified batch and phases

code. Easy to maintain and debug.

• Standard Rockwell Automation products.

Plant running for >2 years with a minimum of service calls

Project Future • Migration to FactoryTalk Batch 12.

• Major Navision release upgrade.

• Test and move virtualized infrastructure to

data center.

Copyright © 2015 Rockwell Automation, Inc. All Rights Reserved. Rockwell Automation TechED 2015 @ROKTechED #ROKTechED

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AP14 - Monin Increases Production and Achieves S95 Standard on path to The Connected Enterprise

Technology

Transcript of AP14 - Monin Increases Production and Achieves S95 Standard on path to The Connected Enterprise