Tighter Control to Achieve Food Saftey with Process...
Transcript of Tighter Control to Achieve Food Saftey with Process...
Standards
Certification
Education & Training
Publishing
Conferences & Exhibits
National Symposium on
Automation & Digital Transformation of
Food & Beverage Industry26th & 27th February 2016
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Wolfgang Felber,Group VP,ABB
AG,Switzerland,[email protected]
T R Ravishankar,VP,ABB Ltd,India,
Tighter Control to Achieve Food Saftey
with Process Control, Batch, and MES
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Academic- MScEE (PowereElectronics & Biomedical Engineering), SwissFederal Insitute of
Technologies ETH, Zürich
- MBSc (Business Sciences) Swiss Federal Insitute of Technologies
- Post graduade Gene technologies, University of Zurich
Worked in:• ABB Ltd, 1997 to 2007, Process Automation Division, global head of Newspaper
production automation
• ABB Switzerland 1994 – 1997: Head of Project Management for Pharma and
Food automation
• ABB Switzerland 1991 – 1994: Sales and Project mgmt Automation for
Environmental industries.
• Roche Diagnostics 1988 – 1991: R&D project manager for DNA Diagnostics
Currently working with:
- ABB Ltd, Process Automation Division, Global Head of Systems for F&B, Pharma
and Specialty Chemicals Industries since 2008
Wolfgang Felber
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Academic- B. E. (Electronics Engineering), Bangalore University
Worked in:- Started Career in BARC Training Centre, Mumbai in 1980
- Worked in Rajasthan Atomic Power Station & Kalpakkam Atomic Power Station till
1985
- Working in Process Automation in ABB since 1985 in industries such as Sugar,
Dairy , Pharmaceuticals , Cement ,Primary Metals ,Industrial Boilers, and Chemical
Currently working with:- ABB process Automation ,Local BU manager for Control Technologies
Association:- Senior Member, International Society of Automation (ISA), Past President, ISA
Bangalore Section , Founder Member of ISA Bangalore
TR Ravishankar
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• Context Setting
• FSSAI Standards
• Technology
• ISA Manufacturing Model
• Definition of Batch
• MES for F&B applications
Agenda
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Context Setting
Maggi worth Rs 320 crore being destroyed: Nestle PTI | Jun 15, 2015, 06.04 PM IST NEW DELHI: Nestle India is in the process of destroying Maggi instant noodles worth Rs 320 crore after it was banned by central food safety regulator FSSAI due to presence of lead and taste enhancer monosodium glutamate (MSG) beyond permissible limits.
http://www.fssai.gov.in/
FSSAI demands pictorial and health warnings on junk food packetsFriday, January 29, 2016 - 08:33
New Delhi: Health experts on Thursday demanded pictorial and health
warnings on junk food packets in order to provide information to people
on health issues caused by them.
The demand was made by a panel of experts from the Food Safety
and Standards Authority of India (FSSAI), AIIMS, the Public Health
Foundation of India and the National Institute of Nutrition
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Standards
Equivalent of
USFDA 21 CFR
Supervisory Scada
& Historian ,MES
Process
Control,Batch
Training on
Automation
Solutions,Products
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© ABB Group
March 20, 2016 | Slide 7
Changes of paradigms
4th Industrial Revolution
Industry 1.0 – 1712First Steam Engine
Industry 2.0 – 1870First Assembly Line
Industry 3.0 – 1969Electronics- /
Software-based Control
Industry 4.0 – today and tomorrow
People
ServicesThings
Internet
of
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Models & Standards in Manufacturing
Level 4
IEC 61131
Fieldbus
ISA 88
(IEC 61512)
OPC
ISA 95
(IEC 62264)
Batch
Control
Discrete
Control
Continuous
Control
Levels
2,1,0
Equipment Control
Intelligent Devices
Equipment Control
Intelligent DevicesAutomation
ERP
MES
Manufacturing
Operations & ControlDispatching Production, Detailed Production
Scheduling, Reliability Assurance, ...
Level 3
Adapted from: ISA-95.00.01-2000
Business Planning & LogisticsPlant Production Scheduling,
Operational Management, etc
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Technology Enables Process Control at all Levels
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Definition of Batch Control
Some applications require that specific quantities of raw
materials be combined in specific ways for particular
duration to produce an intermediate or end result.
One example is the production of adhesives and glues,
which normally require the mixing of raw materials in a
heated vessel for a period of time to form a quantity of
end product. Other important examples are the
production of food, beverages and medicine. Batch
processes are generally used to produce a relatively low
to intermediate quantity of product per year (a few
kgs/litres to Thousands of kgs/litres).
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Definition of Batch Control
• Specific quantities >Recipe of raw materials
• Combined in specific ways >Sequence Logic Or Workflow dependent
on how-sequence/ Auto/ Manual, where-localised control ,Remote
control, Actual Control done locally ,Remote Control done Locally
• Particular duration to produce an intermediate or end result.
>Processed Food
Recipe
Noodle Meal
for 8 persons =
Ingredients
+
Processing
Steps
(Actual = Control)
Recipe
Noodle Meal for 6
persons
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Simple to Complex Batch Manufacturing
Local PID Controller
Dedicated Batch Controller
PLC with Scada
PLC with Scada & Batch Server DCS with HMI
DCS with HMI & Batch server
PLC/DCS System with MES As Batch Server
PLC/DCS System with ERP As Batch Server
Batch Algorithm
Human Interface
No Flexibility to alter productsFexibility to alter products
Fexibility to alter products as per other production /quality dataFexibility to alter products as per other production /quality & Market Demand data
No S88 Standards Compliance
Partial S88 Standards Compliance
Medium S88 Standards Compliance
Higher S88 & S95Standards Compliance
Full S88 & S95 Standards Compliance
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MES - Integrating business with plant floor
Synchronizing & integrating production
Production Order
BOM, Recipe
Routing, Operation
Material Classifications
Inventory Receipt/ Reservation
other ...
Production Yield Confirmation
Production Scrap Confirmations
Material consumption
Equipment Downtime
Equipment Utilization
Actual Labour Time
Inventory Return / Scrap
Product Characteristics
Quality Notification
other ...
Material
receptionMaterial storage
Material
preparationProcessing Dispensing Packaging Pallettizing
MES – Synchronizing and orchestrating flow across «the island of automation»Share information andexecuting timely and accurately. Vertical and horizontal integration
Enterprise Ressource Planning
(ERP)
Warehouse ScalesPLC/
SCADA / DCSHistorian CAPA LIMS
Documen
repository
Quality
management
system
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MES
Support production processes
Control of logistic flow
for materials
and products
Fulfill document
requirements
Improve traceability
for materials
and products
Improve production
performance
Customer expectationsReliable and safe manufacturing execution system
Food Safety RELEVANT
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5The MES Impact - Achieving competitive advantages
Operational Excellence powered by MES
IMPROVE RESSOURCE UTILIZATION, THROUGHPUT AND LEAD TIMES
• Machines and equipment utilization, downtime & interruptions in the context enables fast
interventions and systematic improvements
AGILE MANUFACTURING
• Ease of introducing new products and processes, integration with engineering and
design solutions, discovering and removing production constraints,
FACILITATE CONTINUOUS IMPROVEMENTS
• Systematic collection, visualization and analysis of downtimes, quality test records,
deviations and non conformances increase knowledge and enables intelligent decisions
IMPROVE QUALITY AND REDUCE VARIATIONS, ERRORS, AND WASTE
• Defined workflows, electronic work instructions & checklists, enforces processes and
specifications
REDUCE MATERIAL CONSUMPTION AND INVENTORY
• Real-time update and accurate overview of the material usage and inventories / WIP
eliminates the need for “just in case” inventories and reduces obsolete inventory
FULFILL REGULATORY COMPLIANCE
• Effectively deal with complex genealogy and traceability requirements, using
automated transactions
10-20% OEE IMPR
20-40% TPT
LINE EFFIECIENCY
ENABLED!
ENABLED!
50% SCRAP /
WASTE
2-10 % RM /WIP
INVENTORY
REDUCTION OF
HUMAN ERRORS
Examples
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Genealogy and all Quality supporting functionsFood Safety on Level 3
Reduced product
throughput time
& raw material
storage
Availability of real-time
information from the
entire process,
significantly improved
visibility in production
Full material and
product genealogy
on lot and batch
level Reduced errors &
impact from
bottlenecks in the
production
Improved
production
performance
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Human Factor Role in Food Safety
Role Based Access & User Interface Log-in to workplace
Role based displays
- Administrator
- Production
Management
- Operator
- other
Authentication
- keyboard
- touch screen
keyboard
- badge
- barcode scanner
- USB
- integrated Windows
security
Log-in to the
station/machine
- automatic to a defined
default
- manual selection from
the list of
stations/machines
National language
support (NLS)
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© ABB Group
March 20, 2016 | Slide 18
Material Track & Trace
Genealogy
Providing comprehensive
track and traced capabilities
from raw material,
intermediates to finished
goods
Product genealogy allows
searching and analysis of
production data
Downstream and upstream
by equipment instance
person name
production period
produced and consumed lot
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© ABB Group
March 20, 2016 | Slide 19
Quality assurance and quality control
Enforcement of quality and compliance measures
Proactive enforcement of quality
and compliance measures
Approved materials are used
Appropriate equipment and
locations are used
Support for sampling and
testing requirements
Manual or logic-based
material quality status /
characterics (e.g. expiration
date)
Real time laboratory
interaction with the production
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© ABB Group
March 20, 2016 | Slide 20
Quality assurance and quality control
Non-conformity reporting
Deviation from the product, process,
procedure, or compliance
specifications.
Submitted on demand by the operator
Submitted automatically if
measurement out of tolerance
Reason, description, just for
information or need to abort product
and hand over problem to a
supervisor, information attached to
product
Configurable NCR reasons
Configurable NCR actions (abort,
resume, decide)
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© ABB Group
March 20, 2016 | Slide 21
Quality Assurance & Quality ControlElectronic Signatures / Electronic Batch Report
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Shop-floor logistics - identification, picking, packing ...
Material Management
• WorkOrder (PO)
• BOM
• Configuration
• ….
ERP
Picking Station
a)
b)
Electronic PickList
(QCCard)
input/scan SerialNumber
confirm component
real-time validation
against BOM
comments entry, when
required
Picking Packing
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Transparency of Operations
Genealogy – Progress – Status - Performance
Product genealogy
PO Progress Overview
SN Status, WIP
Plant Performance
”Today we don’t have
a proper tool to
answer where actual
manufacturing order
is in the workshop an
dbe able to give an
order
acknowledgement for
a new order in time.”
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Batch Management – Boost effincency and flexibility
Effective batch automation according to S88
Batch and Operations
in one single user
interface
Flexible recipe
handling including
version control
Automatic arbitration
of resources in
runtime
Reduce process
variability, increase
process reliability and
yield
Interface to ERP
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ABB Food and Beverage software libraries
Boost efficiency and flexibility
Easy to use and operate
A complete industry
library of ready-made
objects for the food and
beverage industry
Assuring food safety and
quality 21 CFR Part
11 compliant
High engineering
efficiency – typically
reducing your
engineering cost up to
20%
ProBase library example
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Comprehensive MES functionalities -
from loading of raw material and order
preparation to packaging and quality
control of finished goods
Control from raw material to finished productABB’s MES-ECS
Out of the box connectivity with ERP
(SAP) and PLCs
PLC
Start
Order Preparation
Deconditioning
Mixer Loading
Mixing
Packaging
Finish
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Raw material intake and Order managementRecording, monitoring and analyzing data
Start
Order Preparation
ECS manages a list of warehouses and
inventory level of liquid and dry material,
adjust quantities and monitor material
locationECS generates pick lists
ECS covers workflow
and recipe management
with production order
flow definition and order
sequence
Calculating material lot
correction factors from
theoretical content of active
substance and humidity in raw
materials
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Weighing and scale management Optimization of material usage in mixer loading
Weighing
Mixer Loading
Managing weighing
orders for dry and liquid
material that are not
supplied in whole
packages
Listing bags to be loaded
to what mixer
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Full contrl mixing, quality sampling and packaging Automated and smooth processes
Equipment maintenance
management for cleaning
orders, scale calibration
and metal detectors orders
Mixing
Packaging
Finish
Check of calibration of
equipment used, batch id
verification to avoid errors
Integration to scales,
scanners and printers
along the production line
Packaging control and sample
sequence definition and
notification
Forward and backward
genealogy on lot and
batch level
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“We now have reliable and transparent real-time data from the entire process and are very pleased with the ECS-MES functionalities“
- Gilles Nodot, Chief Production Manager, DSM in Village Neuf, France
Voice of the customer
|
Sli
© ABB
Switzerland
Ltd, File_Ve
rsion-
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© ABB Group
March 20, 2016 | Slide 31
Simple Batch :Flash Pasteurisation (HTST)
Dairy, Fruit juices and brewing
Control/Recording of Heat Exchanger exit
temperatures, flow and valve status
Heated to 72 - 75ºC for 15-30 sec
Cooled prior to packaging
Similar process for UHT but at higher
temperature for a shorter time
T
Cold Product
Hot Product
IP
Steam Inlet
Heat Exchanger
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© ABB Group
March 20, 2016 | Slide 32
Customer Reference
Owner & Market Position
Amul is the largest food brand in India and world's Largest Pouched Milk Brand with an annual turnover of US $1050 million .
Managed by an apex cooperative organization GCMMF. Its milk processing capacity 10-12 millions liters per day.
ABB System800xA
Products
Includes milk powders, milk, butter, ghee, cheese, curd, chocolate, ice cream, cream, shrikhand, paneer, gulabjamuns, basundi, Nutramulbrand and others.
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Client: DSM Nutritional Products
Sites: Grenzach-Wyhlen, GermanyVillage-Neuf, FranceSisseln, SwitzerlandLalden, SwitzerlandDalry, Scotland
Application: Control system for a vitamin plant
Automation from ABB –over 20 years of serviceMES-ECS in VillageNeufSystem 800xA in VillageNeuf, Dalry, GrenzachMelody in LaldenSattline in Sisseln
DSM Nutritional ProductsCH, DE, FR & UK
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Wander AG
Switzerland
Client: Wander AG
Site: Neuenegg, Switzerland
The Ovomaltine manufacturer Wander
combines the production control with the
systems for controlling and planning.
The project put highest demands on all
contributors. There was only one solution that
could be considered in terms of assuring the
connection of complex data and processes
ranging from easy applications to existing
production control systems.
During the evaluation phase of different
providers, Wander AG chose the Enterprise
Connectivity Solution (ECS) from ABB.
MES in operation: Go live 2019. Upgrade
2014
For information: Matilda Steiner Arvidsson
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Client: Heineken Brewery.
Sites: Araraquara, Brazil
Application: Plant wide control systems
Automation from ABB: System 800xA SV 4.2
AC 800M controllers per brewery
Integrated Batch mgmt
Wide range of ABB drives
Why ABB: Reliable technology,
In operation: 2009
Heineken BreweryAraraquara Brazil
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Client: Royal Friesland Foods Via SI, Tetra Pak Processing Systems
Site: Leeuwarden, the Netherlands
Application: New Milk Plant
Automation from ABB: System 800xA SV3.1 comprised of:
o AC800M, PM864o System 800xA Operations: 5 clientso S800 I/O (about 1500)o Profibus DP/PA communicationo Integrated with PlantMaster from TetraPak
Why ABB: Probase Library & TetraPak as Global Solution Provider
In operation: February 2005
For information: Aad Fokker
Royal Friesland FoodsThe Netherlands
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ABB Control Technologies
Annual Partner Conference 2015 ● Sep 23-24 ● Berlin, Germany
Food & Beverage in ABB web site
http://www.abb.com/food&beverage
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