The Journey to More Effective Packaging Automation

Transcription

1 The Journey to More Effective Packaging Automation Bryan Griffen Nestlé E&A Engineering Manager OMAC Packaging Workgroup Chair May 2012 The world s leading nutrition, health and wellness company

2 Topics we will cover Nestlé: The world s leading nutrition, health and wellness company PackML: Our packaging automation vision The packaging simulation Designing a more effective HMI A specification for everyone Our traveling salesman The value and benefits of implementing PackML Conclusions 2 May 2012

3 Nestlé: The world s leading nutrition, health and wellness company Our objective is to be recognized as the world leader in Nutrition, Health and Wellness, trusted by all our stakeholders, and to be the reference for financial performance in our industry. 3 May 2012

4 Nestlé at a glance: key figures CHF 109.7bn sales in 2010 CHF 34.2bn net profit in 2010 CHF 16.2bn Group EBIT in ,005 employees 443 factories Factories in 81 countries Products sold in more than 140 countries 4 May 2012

5 The Nestlé story how it all began Henri Nestlé s 1980s 1970s 2000s 1990s 5 May 2012

6 Nestlé products & brands: instantly recognizable 10,000 different products Around 1 billion products sold every day A product for every moment of every day, from morning to night and from birth to old age 6 May 2012

7 THE JOURNEY BEGINS PACKAGING SIMULATION LINE 7 May 2012

8 A brief history of automation and packaging at Nestlé Engineering in Nestlé is traditionally process-oriented we own and manage our process solutions We design and automate the key process units Rockwell Automation is our solution provider for process automation We typically do not own the solutions for the packaging hall We have a strong focus on materials, aspect and machine capabilities No real efforts have been placed on machine automation standards Packaging OEMs very often have their own automation platform specification Changes to their specified platform increases costs No guarantee on performance is given if they must use a different platform It is now time to set a new direction 8 May 2012

9 The Wild West of software Goal: 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.? Copyright 2010 Procter & Gamble. All rights reserved. 9 May 2012

10 Nestlé s vision for packaging automation Support sustainable financial performance through reduced total cost of ownership and increased automation Enhance manufacturing competitiveness by improving OEE Optimize the control of packaging equipment through: Implementation of international standards Realization of horizontal (line) integration Providing links to vertical MES/ERP systems Improve the operational safety of packaging equipment 10 May 2012

11 The vehicle that will help us realize our vision OMAC Organization for automation and manufacturing professionals, including endusers, machine builders, and technology providers Dedicated to advancing manufacturing capabilities and efficiencies through identifying common problems, standardization, and improvements to processes that positively impact the way companies do business PackML Industry standard programming structure that drives a common look and feel between equipment: Defines operational state of a machine (State Model) Provides for operational modes (Auto, Manual, Jog, Clean Out, etc.) Standard information to/from machines (PackTags) Modular coding for re-application libraries and diagnostics Foundation for horizontal & vertical machine integration 11 May 2012

12 What is PackML (Packaging Machine Language) Industry standard (ISA TR ) Software design methodology that leads to: Common operational look and feel between equipment Defines operational state of a machine Provides for operational modes Standard information to/from machines (PackTags) Modular coding for re-application libraries and diagnostics Applicable to other types of machine systems 12 May 2012

13 Simulation line layout Pick and place: Picks up products and arranges them on a conveyor for the case packer. Case Packer: Fills cases with products and then closes the case. Case Maker: Erects the case, then positions the case on a conveyor ready to be filled. Wrapper: Places and wraps a quantity of cartons. Case Maker Equipment Conveyor Sensor Pick and Place Case Packer Wrapper 13 May 2012

14 Three-fold target of the first prototype Validation of the Horizontal Line Integration Concept 1. Use an international standard as the solution (OMAC/PackML) 2. Make equipment coordination without a line integration PLC 3. Demonstrate that multiple automation suppliers can communicate on a single network and protocol 14 May 2012

15 Packaging strategy partners 15 May 2012

16 PackML state model 16 May 2012

17 PackML state model implementation 17 May 2012

18 Current status: Machine-to-machine communications Ethernet TCP/IP utilizing a Weihenstephan-based structure: Ethernet TCP/IP Status/Cmd PackTags Status/Cmd PackTags Status/Cmd PackTags Pick & Place Case Maker Case Packer Wrapper 18 May 2012

19 Simulation line conclusion Successful points Use of an international standard solution (OMAC/PackML) Coordinated equipment without needing a line PLC Demonstrated that Rockwell, Siemens, B&R and Schneider can communicate on the same network and protocol 19 May 2012

20 THE CONTINUING JOURNEY: HMI, SAFETY AND MES 20 May 2012

21 HMI standards are needed to improve operator efficiency Actual status of individual HMIs for one packaging line... Metal detector Coding filing bag Bag filler VFFS Check-weigher Cartoner (CAMA) Ink-Jet cartons Metal detector finish carton X-ray detector Bar code reader Bar code check Caser Ink-Jet case Elevator 21 May 2012

22 Many current machine interfaces are not userfriendly and add complexity to run machines More than 200,000 HMIs are currently used in Nestlé Factories More than 70,000 people involved in packaging operations worldwide All screens have a different aspect and this creates confusion and hinders staff flexibility A specific training is required for each equipment, this costs money and takes too much time 22 May 2012

23 A standard HMI solution has been developed Packaging and Automation have worked together to define a standard look-and-feel for operator interfaces 23 May 2012

24 HMI harmonization will simplify machine operations Advantages of using an HMI template: 1. The users interface will be more friendly 2. The operators will be more mobile 3. Gives more diagnostics on equipment Current status: Initial HMI specifications is completed Currently under internal validation Pilot applications are being executed Next Steps: Integration with PackSpec initiatives from OMAC Inclusion in the general URS for packaging equipment sold to Nestlé 24 May 2012

25 Next steps: On screen diagnostics will reduce downtime and improve efficiency 25 May 2012

26 Next steps: One safety standard for the entire production plant Creating an open safety protocol (similar to the PackML concept) enables increased productivity for the plant Cost reduction Less down-time Higher productivity Easy maintenance Concept under review 26 May 2012

27 Next steps: Vertical integration into the MES layer Provide real-time data for: Machine/line configuration parameters First-fault determination OEE calculations 27 May 2012

28 THE PACKAGING USER REQUIREMENTS SPECIFICATION 28 May 2012

29 A general URS with eight modules covers Nestlé s packaging requirements 1. Procurement module 2. Line integration module 3. Equipment module 4. Safety, health and environment module 5. Hygienic module 6. General design module 7. Quality module 8. E&A module - Checklists 29 May 2012

30 A packaging Equipment is composed of 6 important modules Fully Integrated Packaging Line Integration MES Electrical PLC HMI Software & Hardware Safety 30 May 2012

31 Electrical specifications were the basis to start the standardization Content Labeling Grounding and shielding Wiring Buttons and alarms management Documentation Status Delivered in September 2011, currently in use for all new machine specifications Used as a check-list during the FAT 31 May 2012

32 Safety is a key module for us Working group : Safety, Health and Environment Manufacturing Operations Packaging Engineering Two tools have been developed : Safety specifications Safety check-list Status: Safety specifications delivered in November 2011 Training material currently under development 32 May 2012

33 OUR TRAVELING SALESMAN PROOF POSITIVE FOR PACKML 33 May 2012

34 A physical prototype will help us to validate the line integration model This platform will be composed of : - Festo modules - Staubli robot - 4 vendors PLCs and HMIs (Siemens, Rockwell, Schneider and B&R) - 1 SCADA (Wonderware) Goal of the prototype : - Communicate M2M - Implement line supervision - Fully implement OMAC state model - Evaluate the HMI template - Implement stoppage reason codes for MES Timing : - Commissioning in week 21 (this week) - OMAC line integration implementation guide (addition to P&G guideline) planned for September 34 May 2012

35 Screen examples of the line SCADA: 35 May 2012

36 VALUE & BENEFITS OF PACKML 36 May 2012

37 OPW directly addresses business drivers 37 May 2012

38 Benefits of PackML for end users Benefits of implementing a standard PackML & PackTags are part of an international standard Consistent data and control structure to share information both horizontally (machine to machine) or vertically (machine to SCADA/MES) Easier line integration and startup Enhanced operations A consistent state model enables common engineering platform for all machines within a packaging line Common look and feel for HMI requires less training Standardized interface and predefined PackTags enables easy integration with factory standard HMI/MES Business benefits Promotes best-in-class solutions focused on innovation Reduced total cost of ownership (TCO) 38 May 2012

39 Benefits of PackML for OEMs Improved development cycle Control platform independent, allowing the OEM to select the technology platform that will best suit their needs Greater reapplication of reusable, modular programming modules that work for a variety of End User Less customized code to test Improved customer delivery Reusability of proven software reduces time to market Easy integration and startup at customer site, especially when working with other OEMs and Systems Integrators Simplified post-sale support due to consistency from End User to End User Business implications Allows for greater focus on innovation & machine capability Intellectual Property still maintained 39 May 2012

40 Benefits for Systems Integrators Reduced engineering effort Consistent data and control structure for bringing in information from multiple OEMs and serving it up to End User SCADA/MES systems Consistency when working with multiple automation platforms and OEMs Consistent structure enables concurrent engineering Reusable, modular programming modules applied for a variety of End Users Enhanced offerings Focus on value-added activities such as MES, maintenance tools, etc. instead of integration concerns Ability to develop standardized integration packages that result in reapplication of code and bigger margins Improved delivery A single protocol means less worry about start-ups, faster commissioning, etc. Less service calls for integration concerns that may not have been discovered during start-up 40 May 2012

41 Benefits for Technology Providers Development strategies Wider range of discrete machine applications by using an industry standard (ISA TR plus S88 Part 5) instead of a propriety solution Easy integration of control systems into an existing environment Reduce the efforts in developing multiple networks and protocols Concentrate on innovative technologies Business implications PackML standards are becoming widely accepted by End Users, Technology Providers and OEMs Show competitive advantages instead of discussing integration issues over and over again Open the global market of packaging machines to all Technology Providers (get rid of the hard specification of one single supplier) Internal efficiency and consistency when training engineering and customer support teams, as well as for on boarding of new engineers 41 May 2012

42 What we have learned in our journey We believe that we have found a solution to improving the overall effectiveness of our packaging lines PackML We have shown that horizontal communications can be achieved with disparate control platforms using PackML standards We are building a platform for testing the vertical integration to the MES systems using PackML standards We are fully committed to the PackML strategy, and we are moving towards specifying this as a required standard from our packaging vendors It s good to use a common language. Now we can all understand each other. Christian Chatel, Schneider Electric 42 May 2012

43 Thank you for your attention