Integrated Manufacturing Operations for CPG & Process

Transcription

1 Integrated Manufacturing Operations for CPG & Process Filip Schiettecat Siemens Industry Software PLM Europe 2017 Berlin Estrel Hall C1 I October 24, h00 Unrestricted Realize innovation.

2 Digitalization changes everything

3 Digital is transforming the CPG Industry Personalizing products Mondelez enables personalized packaging Coca-Cola enables custom formulations from your smartphone Master Chef in NYC 3D-print vacation memories in chocolate Page 3

4 Today s challenges in the CPG & Process industry High quality demand High cost pressure Fast changing consumer demands Global and regional regulatory compliancy Increasing variety of products and recipes Global setup Distributed plants Page 4

5 Our customers have essential requirements throughout the CPG & Process industry Speed Flexibility Quality Efficiency Security Page 5

6 Integrating and digitalizing the entire value chain is key to staying competitive in the future Page 6

7 Creating a Powerful Digital Twin of the entire value chain Page 7

8 Our holistic approach in the CPG Industry Specific for process and discrete part of the digital enterprise Producing, filling and packaging a hybrid CPG product requires specific technologies and processes 1 2 planning Process value Product chain design Product Processand plant 1 design 2 design 3 engineering 4 execution Services Engineering Operation Services Discrete value chain Product 1 design 2 planning 3 engineering 4 execution 5 Services Page 8

9 Digitalization in the CPG industry Product Design Product 1 design 2 planning 3 engineering 4 execution 5 Services Formula Design Package Design Product and formula design Artwork development Regulatory compliance Supplier collaboration Trials, sampling & testing Package design Simulation & digital prototyping Label design and compliance Page 9

10 Digitalization in the CPG industry Planning Product 1 design 2 planning 3 engineering 4 execution 5 Services Modeling & simulating the production facility Planning the filling & packaging line Creation of general recipe Creation of the bill of process Trial runs Modeling the production facility Capacity simulation of the plant Collaborative line design Simulation of critical process steps Simulation and bottleneck elimination Page 10

11 Digitalization in the CPG industry Engineering Product 1 design 2 planning 3 engineering 4 execution 5 Services Automation design of the process Automation design of the filling & packaging line Plant design Machine design Electrical design Mechatronics integration Automation engineering Automation engineering Virtual Commissioning Page 11

12 Planning Line Layout Your Digital Plant is ready for use! Page 12

13 Digitalization in the CPG industry Execution Product 1 design 2 planning 3 engineering 4 execution 5 Services Order execution & integrated quality control Order download & scheduling Order download & scheduling Reporting & quality execution Order execution Energy efficiency Order download & scheduling Reporting & quality execution Line management & execution Energy efficiency Page 13

14 Digitalization in the CPG industry Services Product 1 design 2 planning 3 engineering 4 execution 5 Services Mindsphere Energy Analytics Mindsphere Smart Condition Monitoring Energy Analytics Smart Condition Monitoring Security Services Energy Analytics Smart Condition Monitoring Security Services Drive Train Analytics Drive Train Analytics Page 14

15 Summary The Vision Comes to Life Key Advantages of Digitalization Use Simulation to achieve foresight in the Virtual World Product 1 2 design planning Use Big Data Analytics to gain insight and drive continuous improvement engineering execution Services Seamlessly coordinate and control resources in the real world Page 15

16 Role of Manufacturing Operations within the Digital Enterprise Realize Innovation Teamcenter Visualization/Graphics Bus (JT + Atlas + Augmented Reality) Product Lifecycle Mgmt. Manufacturing Operations Management Design Engineering Execution Automation / SCADA Simulation and Test Manufacturing Engineering Teamcenter Run-Time Manufacturing Operations Service Bus Lifecycle Analytics SLM Manufacturing Execution System Quality Execution System Advanced Planning & Scheduling Enterprise Manufacturing Intelligence Page 16

17 Siemens Platform Approach for Execution Monolithic MES/MOM approach Custom Data integration Custom KPIs Custom functionality Custom Historian Custom User Interface Custom functionality Custom functionality Custom Reporting Custom Alarm/Alert Management Custom Data Management Run-Time Manufacturing Operations Service Bus Custom functionality 3 rd party functionality Custom functionality Custom functionality Implementation An integrated unified of MOM system requires responds consideration with significant of existing legacy improvements systems in to Speed, protect Flexibility customer s and investments Efficiency Page 17

18 Siemens Platform Approach for Execution Shared services Composed applications Mobility Run-Time Manufacturing Operations Service Bus Custom functionality Quality 3 rd party Custom Custom functionality APS functionality MES functionality EMI An integrated unified system responds with significant and increases the value adding the standard Siemens MOM Portfolio improvements in Speed, Flexibility and Efficiency Page 18

19 Manufacturing Operations Management for CPG/Process Industry Common Process Model Manufacturing Operation Management System Supplier IT Systems Material Reception & Tank Farm Primary (Continuous & Batch) Secondary (Packaging/Bottling, Palletizing) Warehouse & Distribution Supplier Incoming Materials Transformation into Semi Finished Goods Finished Goods Delivery to Warehouse Logistics Storage Page 19

20 Integrated Manufacturing Operations The 6 Pillars of our Configurable MOM Solution Portfolio Integrated Manufacturing Operations Order Download and Scheduling Order Execution Quality Execution Reporting Product Tracking & Genealogy Manufacturing Intelligence Page 20

21 Order Download and Scheduling Optimization by detailed scheduling Order Download and Scheduling Orders download from ERP Order scheduling by standard or specific algorithms Manual update of scheduling data Scheduled orders ready to be dispatched in production Page 21

22 Order Execution Process Integration and synchronization Order Execution Coordination of automatic and manual tasks Batch engine integration Quality enforcement during production Synchronization of Batch execution with quality Page 22

23 Execution Integration and synchronization of & Quality Process Execution operations and quality operations go hand in hand. Coordination of automatic and manual tasks Batch engine integration Orchestrated Quality operations during production Alignment on quality specifications and processes is key Page 23

24 Quality Execution Orchestrated testing to ensure proper product quality Quality Execution Manage the quality data & workflow in laboratories and plants, optimizing data collection, analysis and reporting Support off-line and at-line testing in laboratory and on manufacturing floor Support for complex test plans/methods definition and execution in different contexts Deviation Management Quality Reporting Page 24

25 Reporting Visibility on all the operational details Reporting Order Tracking (times, material quantities, equipment units) Actual production data compared with Estimated scheduling data Electronic Batch Report Page 25

26 Product Tracking & Genealogy Ensure Compliance through full product tracking Product Tracking & Genealogy Backward genealogy : Raw Materials used for one Finished or Semi Finished Lots Forward genealogy : Finished or Semi Finished Lots produced using one Raw Material Lot Full Product recall capability to rapidly assess the impact of a contaminated material Page 26

27 Manufacturing Intelligence Efficient analysis of KPIs Manufacturing Intelligence Deliver KPIs based on real data collection Analysis and drilldown into OEE KPIs MES data contextualization Platform independent visualization Easy and intuitive configuration of new dashboards Page 27

28 Siemens Manufacturing Operations Management Platform Enables standardization across plants SIMATIC IT UA Page 28

29 Configure your operator screens and manufacturing processes A key differentiator for our platform CONFIGURATION RUNTIME Engineering of end-user screen through Mash-Up Editor Using the configured operator screen to see materials and the track & trace info Page 29

30 Configure your tasks and manufacturing processes Graphical Work Orchestration to link task and processes together Work Orchestration Configure tasks for your specific processes Define the sequence of tasks Easily orchestrate individual tasks or task sequences by means of a graphical workflow Establish Manufacturing Operations Catalogs for your company Platform independent visualization Easy to maintain Easy to upgrade Page 30

31 Manufacturing Operations Management for CPG & Process Industry From Points of Pain to Business Benefits Vertical integration to connect ERP and Automation Systems Implement ERP Orders Optimized use of available resources Optimize production time Timely and proper execution for both automatic and manual tasks Increase efficiency Integrate Quality and Increase Product Quality Product and Traceability Compliance to regulations Process raw data into Key Performance Indicators (KPIs) Realtime asset and production monitoring KPIs analysis for stakeholders Process Visibility for Continuous improvement Page 31

32 What is our Special Sauce? Digital Twin Gain foresight by simulating products, people, processes and resources interacting in the virtual world Gain insight by matching real-world performance to your designs so you can drive continuous improvement Holistic Digital Twin Page 32

33 This is what you gain Speed Flexibility Quality Efficiency Security Page 33

34 Proof from Practice Great Wall Wine Yantai Co Ltd Consistently highest quality with MES Business benefits Data availability for responsiveness and informed decisions Aggregation of data on all aspects affecting the end product Standardization of the entire production process Improved efficiency and quality Fewer process errors Traceable production information execution SIMATIC IT Grupo Campari - Key steps towards the Digital Enterprise Business benefits Unified repository for all (approximately 21,000) product specifications, accessible via Web to internal stakeholders Standardization of contents, collection and validation processes. Integrated management of analysis on products, incoming goods acceptance process and release to production Acquisition and management of plant efficiency and performance data with real-time reporting tools execution SIMATIC IT R&D Suite Page 34

35 Digital Enterprise Suite Realize your digital transformation Page 35

36 Make the future yours.

37 Thank you! Danke! Filip Schiettecat Head of Industry Management CPG / Process Siemens Digital Factory Product Lifecycle Management Filip.Schiettecat@siemens.com siemens.com/mom siemens.com/industrysoftware Page 37