PackML Workshop Introduction & Case for PackML presented...

PackML

PackMLThe Science of Machine Software

Adal Tecleab

Procter & Gamble

Copyright © 2015 Procter & Gamble. All rights reserved.

PackML

Topics

Background

Programming Example

Going Forward

Questions / Discussion

1

2

3

4


PackML

P&G Business

Sales: $83.7B, Net Earnings: $10.8B

61% Sales Outside US

250+ of Worlds Best Known Brands

25 - $1B Brands

1,500+ Packing Lines & GrowingCopyright © 2015 Procter & Gamble. All rights reserved.

PackML

P&G Business Needs

Delight more consumers in more areas around the world

Manufacturing translation:

More sophisticated machines purchased and installed globally

Deliver the product and packages consumers desire

Manufacturing translation:

Constant machine modifications and upgrades


PackML

Manufacturing Competitiveness

Packaging

Requires:

• More equipment innovations

• Faster machine and line startups

• Production information critical to business(Overall Equipment Effectiveness data)

• To and from OEM machines

• Business information systems

• Reliable systems

• Diverse global workforce

Challenges

• Limited resources

• More complex

machines

• Global coordination

• Engineering

• Manufacturing

• Information Technologies


PackML

The Wild West of Software

Purchase machines from many suppliers around globe

and integrate them to create a packing line system

Problem:

◦ No software consistency between machines

◦ No software consistency between like machines from same OEM

◦ Horizontal and vertical Integration is difficult and time consuming

◦ Training challenges for operators and technicians.

◦ Hard to troubleshoot

Solution…Embrace & deploy industry software standards

Why doesn’t the manufacturing machine industry have software

standards like the military, IT world, financial industries, etc.?


PackML

Business Need

Wide variety of software approaches and templates used at P&G

Baby Care study – 60% of start-up issues are software related

Opportunity –

Change software execution to a SCIENCE

Converge on a single, proven industry-standard approach


PackML

Software Method Standards

Equipment Operational Methodology

Information Integration

Machine-to-Machine

Machine to/from Enterprise

Equipment Decomposition Methodology

PackML(ISA TR088.00.02)

PackTags(ISA TR088.00.02)

Make2Pack(ISA S88 Part 5)

Industry Software Standard


PackML

PackML Development Timeline

2003 2005 2006 2007 2008 2009 2010

First versions of current template are created and installed in manufacturing sites, using S88 11 state model

OMAC template available for download

Current template created using latest PackML Standard, ISA-TR88.00.02

Various revisions and executions across multiple projects…

P&G specifies PackML in equipment specifications

PackML ISA-TR88.00.02

Released

Various revisions and executions across multiple projects…

PackML v2.2Released, includes 10 state model

PackML v3.0Released, 17 state

model

2004


PackML

PackML Workshops

P&G workshops

North America (June 2010)

Asia (January 2011)

Europe (May 2011)

North America (Oct 2011)

Europe (Oct 2012)

North America (May 2013)

Europe (September 2014)*

Over 400 people trained

Working with organizations on similar industry training


PackML

PackML Benefits

Standard enables:

Simplification through standardization

One time training

Faster startups

Robustness & reliability

Operational consistency

Troubleshoot easier

Consistent tools to track and manage “line performance”

Effective use of our limited engineering resources

Reduced costs!


PackML

What’s in it for the OEM?

Faster Development Time

Greater Reapplication of Programming

Shorter Debug Times & More Robust Programming

Greater Flexibility

Fewer End-User Custom Software Requests

Less Training for both OEM & End-Users

Allows for Greater Focus on Innovation & Machine Capability

Faster

New configurations

New machine concepts

Intellectual Property Still Maintained

Great Customer Selling Point!


PackML

Topics

Background

Programming Examples

Going Forward


1

2

3

4


PackML

PackML Tools Make Software a Science

Implementation Guide Planning Project Worksheet Modular Programming Template

Data Flow Score Card


PackML

Six Simple Steps

1.

• Decompose machine into Equipment Modules and Control Modules(S88:Make2Pack)

2.• Define PackML Modes and States

3.

• Define machine, equipment, and control module Actions during each mode and state

4.• Define PackTags for line integration and MES functionality

5.• Define Events (and Recipe Setpoints)

6.• Program machine: keep it simple


PackML

Step #1 - Equipment and Control Modules

PLC 1 PLC 2


PackML

Step #2 - PackML Modes and States

Everything needed to make good

product will be automatically

enabled/started. The machine

should automatically start up without

having to manually move or start any

of the modules. Only in this Execute

state will the machine report uptime.

Everything will run like the

producing mode, but the

operators have the ability to

disable any module

manually and force most

solenoids.

For purging the fluids. Will

also have automatic control

of flushing tanks for

changeovers.

For homing the axes

that you select


PackML

Step #3 - Actions

Documentation translates directly into PLC code

Basis for training of operations, technicians, process engineers, etc.


PackML

Step #4 – PackTags Setup


PackML

Step #5 – Events and Recipe Setpoints

Define Alarms, Warnings, and PackML Status Events (can be broken

into categories)

Define Recipe Setpoints


PackML

Step #6 – Program the Machine


Old Software New Software % Improvement

# of PLC’s 3 2 33%

# of Programs 48 21 56%

# of Routines 355 117 67%

# of Rungs 4877 2206 55%

# of Tags 5525 2415 56%

# of

Produced/Consumed

Tags

76 35 54%

Memory 2.85MB 5.37MB -89%

PLC #1 CPU Utilization

(L63)99% (task overlaps) 81% (no task overlaps) 18%

PLC #2 CPU Utilization

(L61)65% 53% 18%

PackML

Step #6 – Program the Machine


# of Alarms 586 325 45%

# of Warnings 264 68 74%

# of Recipe Setpoints 256 113 56%

# of HMI Screens 44 34 23%

# of clicks to change

setpoint aaa from Run

Screen

22 4 82%

# of clicks to change

setpoint bbb6 3 50%

# of clicks to perform

function xxx7 4 43%


PackML

Other Examples

Machine B Before and After

Machine C Before and After


# of Rungs ~8000 ~1100 86%

# of User Setpoints ~300 33 89%

Memory 3.2MB 1.8MB 44%


PLC Utilization 90% 30% 67%


# of Rungs 461 383 17%

# of Tags 518 389 25%

Memory 170kB 453kB -166%


PackML

Other Examples



# of Routines 198 92 54%

# of Rungs 2089 1884 10%

# of UDTs 88 14 84%

# of Alarms 136 217 -60%1

# of Warnings 0 5 -

# of Recipe Setpoints 271 157 42%

# of HMI Screens 52 33 37%

Memory 3.15MB 2.60MB 17%

1Added additional alarms for situations that were never accounted for in old software

Machine D Before and After


PackML

Topics

Background

Programming Examples

Going Forward


1

2

3

4


PackML

P&G PackML Template Future

Continue to maintain and improve current template

Feedback to design through steering team meetings and website

(packml.pg.com)

Operator and maintenance/troubleshooting training

Continued harmonization with ISA standards (waiting for approval)

Common tool for software development and code creation (PackML Planner)

Education through key networks and tools

OEM, system integrator, and vendor training/support*

Interactive web based training

Studio 5000 v22 and beyond

More object definition beyond typical AOI

Objects better link PLC code with HMI


PackML

P&G PackML Planner


PackML

Machine Control Software Masterplan

Business Need

Majority of machine functions realized through software

Links mechanical and electrical components with process/product performance and quality

Development and support strategies must enable improved productivity, faster speed to market, higher reliability

Vision

Enables flow of resources, training, code, and IP

Reduces software lifecycle costs

Improves reliability and robustness of software

Principles

We manage machine software and capability as a competitive advantage.

P&G and Connect&Develop Partners will maintain software mastery for design of key product transformations.

We standardize software where it makes business sense to increase reliability and reduce costs.

Existing software standards served us well, we only change them based on business need.

We will actively work to improve our templates and library blocks versus deviating to meet project preferences.


PackML

Needs from OMAC

P&G needs and wants PackML to succeed in industry

Let’s work together to improve the standard and drive it into

industry.


PackML

Question / Discussion


PackML Workshop Introduction & Case for PackML presented...

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