Leveraging Standards to Improve Productivity

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Christiana Harrell
5 years ago
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1 Leveraging Standards to Improve Productivity PackML to the Industrial Internet The Drive for Standardization Jay Joyner Controls Engineer Manager Procter & Gamble OMAC Board OMAC PACK EXPO Innovation Stage Copyright All rights reserved.

3 PackML is a standardized methodology for organizing & programming discrete machines Packaging Machine Language Industry standard (ISA TR ) Producing, Maintenance, Manual Execute, Held, Suspended Modes Which state? How long in state? Alarm Events? States PackTags PackML OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 3

We have created templates & guides to assist with PackML specification &

specifying packaging machinery The P&G programming template has been

02 The Arla Foods Unit/Machine Implementation Guide helps to simplify the

4 We have created templates & guides to assist with PackML specification & implementation The OMAC PackSpec Template provides a standardized framework specifying packaging machinery The P&G programming template has been updated to comply with the new revision of TR The Arla Foods Unit/Machine Implementation Guide helps to simplify the design and implementation of PackML OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 4

We have developed several tools to assist with PackML development

based on PLCopen XML import & export standards Light tree management

the navigation and standardizes the look-andfeel of the machine

5 We have developed several tools to assist with PackML development PackTag_Builder from Bosch-Rexroth is a configurator for PackTags based on PLCopen XML import & export standards Light tree management directly indicates the machine state The Nestlé HMI template defines the navigation and standardizes the look-andfeel of the machine interface OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 5

6 We are collaborating with OPC Foundation to define an open communication protocol OPC UA provides a vendor agnostic solution to communicate PackML states, modes and PackTags to any machine OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 6

We have shown the value and benefits of implementing PackML Machine Builders Drives common user specifications Promotes

market requirements Drives innovation Improves product and application supportability Technology Providers System

Improves speed to market Consistent data and control structure for horizontal & vertical integration Reduces integration

7 We have shown the value and benefits of implementing PackML Machine Builders Drives common user specifications Promotes modular designs Improves code reusability Improves machine supportability Protects intellectual property Facilitates market requirements Drives innovation Improves product and application supportability Technology Providers System Integrators Reduces customization Reduces integration time Improves supportability Focus on value-added tasks End Users Improves speed to market Consistent data and control structure for horizontal & vertical integration Reduces integration cost, time & variability Reduces system life-cycle cost, MTTR, etc. OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 7

Our automation systems are diverse, but must liaise to facilitate integration Inside the box certainly needs to be proprietary. Outside the box we need an open standard used by everyone.

8 Our automation systems are diverse, but must liaise to facilitate integration Inside the box certainly needs to be proprietary. Outside the box we need an open standard used by everyone. This will allow: Data exchange Machine interface/coordination Safety monitoring OEMs can simplify integration by eliminating proprietary architectures at the system level, and instead using open standards. OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 8

9 Let s Hear from an OEM and End User about their Experiences with PackML Church & Dwight Co. Inc. Andy Knerr - Senior Research Engineer Joe Giambrone - Associate Machinery Specialist Mettler Toledo Tom Dorward - Product Manager OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 9

10 Leveraging Standards to Improve Productivity PackML to the Industrial Internet End User Benefits of PackML Andy Knerr Senior Research Engineer Joe Giambrone Associate Machinery Specialist Church & Dwight Co., Inc. OMAC MEMBERS

11 It Isn t Rocket Science Pre-PackML Workshop, Chicago

12 Or is it Post-PackML Workshop

13 PACER Purpose Agenda Conduct Expectations Roles/Responsibilities

14 Agenda Church & Dwight Overview PackML Strategy PackML Use Example Recognizing Trends Next Steps

years with C&D Andy Knerr, CPP - Senior Research Engineer 8 years with C&D OMAC

15 Church & Dwight Team Doc Bullard Director 12 years with C&D Paul Redwood - Program Engineer 8 years with C&D OMAC Board of Directors Tom Barlics Program Engineer 15 years with C&D Andy Knerr, CPP - Senior Research Engineer 8 years with C&D OMAC Technical Advisory Board Joe Giambrone - Associate Machinery Specialist 7 years with C&D

16 Church & Dwight Team Packaging Machinery Group (PMG) DISCLAIMER We are NOT Controls Engineers and we will not pretend to be but feel free to if you are looking for a controls job

17 C&D Overview Most may know us by the brand name Arm & Hammer Our FLAGSHIP Power Brand - 1 of 10 11

19 Church & Dwight PackML Strategy simplicity.

20 Programming PackML Clarity Code Soup Execute

21 Recent Install Example York, PA 17 machines 11 OEMs 1 Integrator Only 3 PackML machines

22 Church & Dwight Product Acquisition Best Tube Filling Start-Up Ever Mike Boyer

23 Church & Dwight PackML Strategy

24 Current PackML Install Base

25 PackML Installed Example

26 RFQ Assessment Current RFQ 60% 30% 10%

27 RFQ Assessment

28 RFQ Assessment 33% 33% 33% 60% 30% 10% Update RFQ - leverage PackSpec

29 Next Steps Continue Controls Development Training RFQ Update Identify Potential Partners, such as Demonstrate benefits Gain alignment and establish momentum Roll-out retrofits and upgrades Present, Promote and Educate

30 THANK YOU

31 Leveraging Standards for the Future PackML Bridge to Industrial Internet Harmonizing Data Tom Dorward Product Manager Mettler Toledo OMAC TAB OMAC PACK EXPO Innovation Stage Copyright All rights reserved.

32 Mettler Toledo Product Inspection Division CI-VISION Chicago IL, USA PCE Zwingenberg Germany SAFELINE X-ray Royston UK SAFELINE EAGLE Tampa, FL USA SAFELINE Manchester UK HI-SPEED Ithaca, NY USA GARVENS Giesen Germany Vision Inspection & Serialization X-ray & Metal Contaminant Detection Checkweighing & Product Handling

produce data..lots of data. Part of a packaging line that is also producing data.

33 Preparing for Industry 4.0, IoT and IIoT The Challenge: Getting Data ready for the Product Inspection devices produce data..lots of data. Part of a packaging line that is also producing data. Cloud PackML provides common definitions for machine and process data OMAC PACK EXPO Innovation Stage Copyright All rights reserved. 33

The PackML Progression A Path to Industry 4.

Expo 2014-17 The evolution was largely driven by customer requirements for Checkweighing, a

For the others, as a requirement for continued customer support Checkweighing X-Ray Metal

34 The PackML Progression A Path to Industry 4.0 Recv'd customer guides Attend OMAC meeting First State Model Demo Joined OMAC Demo's at Pack Expo The evolution was largely driven by customer requirements for Checkweighing, a general need for a method to communicate line status. For the others, as a requirement for continued customer support Checkweighing X-Ray Metal Detection Vision Inspection As part of the X-series development At the request of a major customer At the request of a major customer At the request of major customers

Harmonizing Integration Consistent connection to an MTPI product PackML as the backbone of PI device logic Nearly

Driving the state Changing modes Changing parameters Monitoring events Requesting production stats A device specific

Production Data Excerpt from above "The intent was to make every packaging machine report its operational status the

35 Harmonizing Integration Consistent connection to an MTPI product PackML as the backbone of PI device logic Nearly identical interfaces Combination of defined PackML structure and PI Structure An identical common section of data Driving the state Changing modes Changing parameters Monitoring events Requesting production stats A device specific section Common look, individual data Structure of production stats Metal Detection Production Data Checkweigher Production Data Excerpt from above "The intent was to make every packaging machine report its operational status the same way, independent of the machine type. As an analogy, PackML is for packaging equipment what Morse code was for the telegraph."

Evaluation of our products Four solutions, for four inspection disciplines, developed in

solution, are we compliant with ISA TR88.00.02?

do the solutions vary within the set? Is there a best practice within the solutions?

36 Evaluation of our products Four solutions, for four inspection disciplines, developed in four organizations, in three countries - what are the chances that the solutions are all designed and look the same? Standard Interpretation and implementation Assess the state of the products - For each solution, are we compliant with ISA TR ? MTPI Checkweighing, Metal Detection, X-Ray and Vision Where there are gaps, fill them How do the solutions vary within the set? Is there a best practice within the solutions? Write a guide for best practices Evaluate the instruction sets for all solution Can integration be done with the instructions? Exercise the instructions by constructing a physical model Test the theoretical model

PackML - a basis for future development, IoT, and Industry 4.

products with machinestate data Use common fundamental inputs to identify States in a consistent manner

interest to the industry Why Standardized Customer Interface for MTPI products reuse of code Less

37 PackML - a basis for future development, IoT, and Industry 4.0 PackML as a common "spine" for all machine communications Applies to Fieldbus, OPC, ProdX any future products with machinestate data Use common fundamental inputs to identify States in a consistent manner Establish common definitions for shared Modes and Tags Propose inspection-specific Modes and Tags of interest to the industry Why Standardized Customer Interface for MTPI products reuse of code Less "unnecessary invention" Less training required engineers, service personnel, support personnel, Integrators and Customers Faster development time and greater reliability