Industry Application for Packaging
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Transcript of Industry Application for Packaging
Industry Application for Packaging
Andrea SartoriSolution Architect EMEA
Agenda
Industry ScenarioIndustry ScenarioIndustry ScenarioIndustry Scenario
Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging
SummarySummarySummarySummary
Agenda
Industry ScenarioIndustry ScenarioIndustry ScenarioIndustry Scenario
Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging
SummarySummarySummarySummary
Industry Challenges
► Cost Controls (Energy, Commodity)
► Demand for New Products
► Global Supply Chain
► Customer Satisfaction
► Quality – Safety, Compliance
Packaging Line Business Case
Source: Packaging World Magazine
Current Situation
1. According to Packaging World Magazine Survey
2. 50 %+ of Packaging lines are not Networked3. 50 %+ of Packaging lines have 2-4 control vendors4. 50 %+ of Packaging lines have between 2-7 machines5. 50 %+ of Packaging lines don’t use standards
6. Many Packaging lines have no data collection
7. Less then 25% of machines are designed for Supervisory systems▪ Data for Supervisory systems is mostly production-related▪ Machine reliability data is available but under-exploited▪ It’s ‘difficult/costly’ for Machine builders to use different control vendors
Current SituationLine
1
OEM1
OEM2
OEM3
OEM4
Control A
Control B
SCADA/HMI
Current Situation cont.
Agenda
Industry ScenarioIndustry ScenarioIndustry ScenarioIndustry Scenario
Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging
SummarySummarySummarySummary
► Targets Packaging Area► OMAC/PackML ready
1.0 Manufacturing Value Chain
1.1Receive 1.2 Preparation 1.3 Batching 1.4 Make Unit 1.5 Packaging Unit 1.6 Ship
Fin
ishe
d G
ood
Fin
al P
rod
uct
Fin
al M
ater
ial
Com
mon
M
ater
ial
Inventory
Inventory
Inventory
Inventory
Inventory
Stage
Deliver
Deliver
Test
DeliverDeliver
Deliver
Deliver
Pack
Inventory
Batch Mix
Test
Make Unit
Test
Label
Quality Production
Transform
Manufacturing CycleProcurement CycleReplenishment
Cycle
Packaging CycleBatching Cycle Make Unit CyclePreparation Cycle
Days Inventory + Days Payables
Industry Application for Packaging
Industry Application for Packaging Top Values
► Increase Line Efficiency/Productivity▪ Faster Changeovers▪ Greater visibility into performance, downtime, problems, state▪ Higher throughput
► Reduce Costs▪ Less material waste▪ Increased quality, product consistency▪ Greater flexibility (manage many SKUs)
► Fast time to value▪ Quick deployment▪ Meets needs of Planners, Operators, Supervisors & ‘Reporters’
Industry Applications Approach for Rapid Time to Value
► Standard Products▪ System Platform and InTouch Clients▪ Performance & Operations MES▪ Wonderware Information Server
► Pre-defined objects, graphics and tags▪ OMAC-ready▪ Objects Setup Utility▪ Demo (on VMWare)
► Packaged Services (required)▪ Delivered by Endorsed SI▪ Finite scope
Introducing ‘Industry Application for Packaging 1.0’
► Enables Supervisory/MES functions
▪ Basic State Model, • Trending and Visualization
▪ Downtime Tracking, • Visualization and Reporting
▪ Order Management, • Visualization and Reporting
▪ Overall Equipment Effectiveness, • Visualization and Reporting
▪ Product Parameter Download (Premium Ed.)• to Control Systems
▪ On-Line Quality (Premium Ed.) • Visualization and Reporting
► Connects to Line and Equipment PLC-level information through PackML standard tags
“Standard Edition” Features
► Pre-Configured for ▪ PLC PackML tags (or PLC Alias names)▪ OMAC reason codes (or array if non-OMAC)▪ OMAC State Model (or custom model)
► Pre-Configured Line/Equip. User Windows▪ Adding InTouch graphics dynamically
► Data collection automatically detects IO▪ If No IO, Manual entry UI fields auto-enabled
Entry-level Features cont.
► Customer can extend Equipment Classes▪ Extend with specific UDAs
► Planned Orders can be imported/ISA 95▪ From CSV or XML files
► Planned orders can be sequenced▪ With simple priority rules (due date, FIFO, etc.)
► Equipment Mode of Operation tracking▪ Auto, Semi-auto, Manual
► Validated Manual production counts entries▪ Against elapsed time, current count, rates
Entry-level Features cont.
► Support Line Configuration▪ With Parallel processing (like Labelers)▪ Line Shared Equipment (like Palletizers)
► Pre-configured for three (3) roles▪ Production Planner▪ Line Supervisor▪ Line Operator
► Exception management workflows▪ Email planner if WO done out of sequence
► Leading Indicator▪ Signaling if packaging is falling behind plan
Addressing bothCustomer and OEM needs
OEMRank
Buyer Rank
Industry Application
Ability for maintenance to maintain/diagnose any controls systems 1 1
Ability to access machine diagnostic data 2 2
Ability to have a consistent software structure in all packaging machines regardless of the OEM 3 4
Ability to connect all sensors actuators/controllers within a packaging machine by using an industry-standard network 4 5
Ability to create applications from a library of reusable software modules 5 9
Ability to access product performance data 6 3
Having a standard/consistent machine state operating model for any/all machinery OEM 8 6
*** Packaging World Magazine/OMAC Survey
What-if ?
► My PLC is not OMAC-ready▪ That’s ok, you can incrementally move from manual to automatic
data collection▪ The system supports both scenarios
► Do I need ERP integration for planned orders▪ No, planned orders can be created manually or be imported from
csv, xml
► Can the system be localized?▪ Yes
► Can I extend the system with my standards▪ Yes, the System Platform allows you to scale users and scope
independently
Excel import utility
Industry Application forPackaging
Area
Line
Equipment
Screen Example – Overview
Screen Example - Line
Screen Example – State Model
Screen Example – Performance
Summary
► Industry pressures▪ Cost, Energy, Engineering Efficiencies
► Wonderware Solution▪ Industry Application for Packaging
► Fast time to value▪ Quick deployment▪ Meets needs of Planners, Operators, Supervisors &
‘Reporters’
Software Solutions for Real-Time SuccessSM