News. OEM & System Integration. Industry 4.0 Reality Check Weighing Works for Quality Control. Weighing Components

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1 OEM & System Integration Weighing Components 16 News Industry 4.0 Reality Check Weighing Works for Quality Control A new Industry 4.0 demonstration machine shows individualized production with lot size 1, flexible manufacturing and future concepts for IT integration. High-resolution weigh modules proved to be the ideal solution for reliable, flexible and simple quality control of individualized products. The SmartFactory KL, which is founded by the German Research Center for Artificial Intelligence (DFKI), developed a fully functional demonstration machine for discrete manufacturing as a showcase for Industry 4.0 (or The Internet of Things). The SmartFactory KL and the institute were supported by 50 leading automation and software companies. Individualized mass production is possible To demonstrate individualized production with lot size 1, SmartFactory KL produces personalized business-card cases in various colors. The case has product memory in the form of a radio frequency identification (RFID) tag. This RFID tag stores all the necessary infor- mation for manufacturing, such as parts list, production status, the name to be engraved and quality parameters. The data stored on the RFID tag allows the cases to actively manage their own production. That allows the individual case to be made without the need for extra production control, which is the prerequisite for flexible and individualized mass production with lot size 1. Flexible manufacturing facilitates fast changeover Future manufacturing concepts have to be flexible to efficiently adapt to new products and to be moved to new locations. To do that, SmartFactory KL comprises nine mobile modules. The modules are supplied with electricity and com-

2 Industry 4.0 / Internet of Things 2 1 Layers pressed air and connection for data exchange via one loose cable. That allows the modules to be completely independent from one other and allows the production team to shift the modules in different orders as needed or to even take out modules if they are not needed. Their independence allows efficient commissioning Reference Architecture Model RAMI 4.0 The overview below shows SmartFactory KL application displayed using the RAMI 4.0 model of Industry 4.0 or Internet of Things. Life Cycle & Value Stream IEC Type 2.2 Instance and format changes for different products. The individual modules correspond to the Reference Architecture Model (RAMI 4.0), which describes Industry 4.0-compliant production equipment. They represent the element Station which include Control Devices and Field Devices. 1 Layers 1.1 Business: Giveaway for visitors at the trade show 1.2 Functional: Holding Business cards with name of owner 1.3 Information: All product data. Ensuring data integrity Hierarchy Levels IEC // IEC Absence of manufacturing execution systems SmartFactory KL doesn t require a manufacturing execution system to steer the product through the production process. Data exchange via OPC UA between modules is limited to the mutual recognition for clarification as to whether the adjacent module fits with the next manufacturing step. 1.4 Communication: Data format 1.5 Integration: RFID tag 1.6 Asset: Physical component. Business card case 2 Life Cycle & Value Stream 2.1 Type: Development and Maintenance of Product 2.2 Instance: Individualization with color and name of holder 3 Hierarchy Levels 3.1 Product: Business Card Holders 3.2 Field Device: Motors and conveyors 3.3 Control Device: Scale for quality control 3.4 Station: Module with PLC, motors, conveyors, scale and other sensors 3.5 Work Center: Production Line 3.6 Enterprise 3.7 Connected World Publisher / Production Mettler-Toledo GmbH Industrial Division Heuwinkelstrasse CH-8606 Nänikon Switzerland Subject to technical changes 02/2017 Mettler-Toledo GmbH 2 METTLER TOLEDO OEM & System Integration News 16

3 by courtesy of SmartFactory KL Weighing is the right choice A manufacturing process consisting of automatic and manual modules does not automatically guarantee perfect quality. Therefore, the cases are weighed for quality control with a high-precision WMS weigh module. Their weight value is com- pared with the specific target weight that is stored in the RFID tag. Weight detection with a high-precision weigh module makes it possible to detect faulty, missing or excess components with great certainty, even if a part is not visible from the outside of the product. Weight-Based Quality Control This white paper explains advantages and provides application hints for weight based quality control in automation. Business Card Holders Individualized business card holders in different colors and with holder s name engraved. Each card holder has an integrated RFID tag to memorize all product data. WMS Weigh Module High-precision weigh module for quality control detects deviations of one point in four millions with a capacity of 400 grams and repeatable readability of 0.1 milligram. METTLER TOLEDO OEM & System Integration News 16 3

4 Ease of Integration Integrate Weighing into a PLC In Less Than 5 Minutes Fully engineered Device Description files for Siemens and Allan-Bradley PLC Systems allow you to simply integrate weighing devices via drag and drop in their well-known programming tools. After wiring is completed and all devices run, typically it takes less than five minutes to transfer weight values into the PLC input register. Direct Connectivity for Siemens S7 via PROFINET IO RT Direct Connectivity for Allan Bradley via EtherNet/IP Two typical network-topologies for PROFINET IO RT or EtherNet/IP including a Siemens or Allan Bradley PLC plus Computer for programing, switch, power-supply and a weighing device. The present and future of production network technologies are based on the Industrial Ethernet standard. The most common solutions using that technology are PROFINET IO RT and EtherNet/ IP. Sensors and actuators that comply with those standards can be easily integrated into PLC systems if vendors provide the right tools and design installation-friendly products. The PLC integration can easily be done with the well-known Siemens TIA portal or Allan Bradley s Studio 5000 programing tool. The fully prepared device description file can be imported into the PLC programing tool with drag and drop. All data for the PLC s input/output-image are pre-configured. The programmer doesn t have to give symbolic names for convenient programing, because it is done already. State-of-the-art connectivity METTLER TOLEDO offers a comprehensive range of transmitters, weigh modules, scales and weighing platforms, which are made for easy integration into machines and instruments. The product range covers capacities from 100 grams up to hundreds of tons with the smallest readability of 0.1 milligram. All models can be connected to PROFINET IO RT and EtherNet/ IP directly or via an optional easy-to-install gateway. 4 METTLER TOLEDO OEM & System Integration News 16

5 The present and future of network technologies in production are based on the Industrial Ethernet standard. Common solutions using this technology are PROFINET IO RT and EtherNet/IP. Sensors and actuators that comply 1.1. Check with those configuration standards of can weighing be easily device integrated into PLC systems if vendors provide the right tools and designed installation- via the webserver friendly products. The configuration of the weigh module can be checked Power from the webserver. Connect the weigh module to a Suppliy Overview computer via a Power-over-Ethernet Switch using an This document explains the key points for integrating a RJ45/M12 patch cable. Enter the weigh module s IP WMF high-precision weigh module into Allen-Bradly and address (default: ) into the computer s Siemens PLC Systems. It addresses project managers, browser. network designers and software engineers by providing WMF a brief guideline for establishing basic connectivity to Note: An IEEE 802.3af Power-over-Ethernet Switch is necessary to provide electric power to the weigh test the functionally of hardware and software. module. Power Suppliy Power over Ethernet Switch Application The examples in this document use the WMF high-precision weigh module. However, the content is not limited to that particular weighing device. It can be applied configuration including type, software version, IP-Ad- The webserver identifies the individual weigh module to many other METTLER TOLEDO products that provide dress but also specifications and weighing parameters. It is also possible to show the weight value. PROFINET IO and EtherNet/IP connectivity. Content 1. Configuring weighing device via the web 2. Connecting Siemens S7 PLC via PROFINET IO 3. Connecting Allen-Bradley PLC via EtherNet/IP 4. Programming the PLC with weighing data 5. Conclusion Network for connecting to a Siemens PLC over TIA Portal or Simatic Step 7 Manager via PROFINET IO requires an IEEE 802.3af Power-over-Ethernet switch to provide power to the weigh module. The configuration is illustrated with TIA Totally Integrated Automation. The configuration with Simatic Step 7 Manager is similar to TIA portal. After installation of the GSDML file, the WMF weigh module is available in the hardware catalog. It can be added to the project by dragging and dropping the file. The Device Description File of the weighing device includes all the needed information. There is no additional configuration needed. The configuration parameters for the WMF weigh module are available, as well as the Module Parameters, such as filter settings, stability criteria and adjustment configuration. The WMF Weigh module s IP address and device name must be configured in the project and in the HW configuration tool. Default values are WMF and If more than one weigh module is connected, the addresses of the additional modules have to be changed. For example: , , etc. The status LED on the weigh module shows installation and communication is working. The second LED blinks in red if the module is not connected to a PROFINET network. Standardized PLC-I/O image offers flexibility All METTLER TOLEDO weighing devices with incorporated connectivity to PRO- FINET IO RT and EtherNet/IP have the same data at their input/output image inside the PLC. This simplifies weighing equipment standardization for the machine manufacturer because different weighing devices may be exchanged without changing the PLC programming. That provides unlimited freedom for the machine manufacturers to always select the right weighing devices. Engineering Note Efficient Integration Weighing for Common PLC Systems Engineering Note 2. Connecting Siemens S7 PLC via PROFINET IO Engineering Note Engineering Note: Connectivity to PLC This engineering note explains and shows how easy it is to connect a comprehensive range of METTLER TOLEDO weighing devices to the most common PLC Systems. METTLER TOLEDO OEM & System Integration News 16 5

6 Compliance Services ISO 9001 Regulation Revision due 2018 New Business Opportunity for Machine Builders Compliance with the ISO 9001:2015 revision requires a risk-based approach. To comply with the revised standard, your customers must evaluate weighing equipment installed in machines that you have supplied. We support machine manufacturers in consulting their customers and we also perform the necessary on-site calibrations. Many of your customers are likely ISO 9001 certified. Due to the recent revision of the standard, they will have to evaluate their performance verification processes for their measuring equipment by That evaluation is required for weighing equipment incorporated into machines and instruments. Turn new requirements into business As a result, customers might contact you to evaluate the calibration of the weighing equipment you installed a while ago. Such consulting can trigger new service business for you, as recalibration services are an enhancement to your existing preventative maintenance services. Partnering to create a win-win situation Our experts use Good Weighing Practice (GWP ) methodology to evaluate and recommend calibration processes based on a risk-based thinking approach. With GWP, you receive a document with all the necessary information, including results of our risk assessment and the rec- Experts to Consult Machine Manufacturers and Customers Experts from METTLER TOLEDO can consult machine manufacturer and customer in performing a risk analysis, determining the right test weights and calibration intervals including documentation. Availability of Certified Test Weights in the Right Class All METTLER TOLEDO Service Organizations are in possession of certified test weights in the accuracy class that suits to the process tolerances of your customer s application. Good Weighing Practice TM Includes Risk Analysis Good Weighing Practice TM is applicable to new and existing equipment from any manufacturer for selection, calibration and operation of weighing equipment including risk based thinking. 6 METTLER TOLEDO OEM & System Integration News 16

7 ommended intervals for recalibration for compliance with the new requirements. We can provide weighing-equipment verification with a GWP Verification at your customers sites. In addition, we are able to perform the calibration on your behalf. This partnership offers you incremental business when your own service technicians and the necessary test weights are not available. New ISO 9001 Requirements are due 2018 Risk Consideration OK METTLER TOLEDO serves global customers with one of the largest sales and service networks in our industry over 5,000 sales and service specialists strong. Machine manufacturers can benefit from this organization by cooperating with our experts and service technicians for better serving their own customers. The 2015 revision of ISO9001 has brought some major changes. The combination of the process approach with risk-based thinking, and employing the Plan-Do-Check- Act Cycle at all levels in the organization is relevant for weighing applications with relevance for product quality. Companies have to update their processes until September METTLER TOLEDO OEM & System Integration News 16 7

8 Continuous Manufacturing A Leap in Process Efficiency Expert Advice: Continuous Solids Dosing Continuous manufacturing of oral solid dosage (OSD) forms provides significant efficiency and quality benefits but it can also pose substantial process-development challenges. Dr. Ralf Weinekötter, an expert on continuous dosing and mixing, provides insights on the capabilities and limitations of such systems. How does a tablet manufacturer benefit from a continuous approach? A tablet press can be considered a continuous system already. However, the tablet mixture has historically been prepared in a batch mode. Making the entire process continuous provides significant efficiency gains and contributes to better product quality. What is the role of dosing and mixing in this process? The continuous dosing-mixing module is an essential element of continuous OSD production. It typically consists of gravimetric feeders for APIs and excipients, as well as a mixing module that feeds directly into the tablet press, granulator or extruder. Such a system requires much less floor space and substantially reduces development and validation time because scale-up is no longer needed. Current systems can process between 50 grams and 250 kilograms per hour. What needs to be considered when switching to a continuous process? Product quality is substantially determined by the accuracy and consistency of upstream gravimetric dosing processes. Any error will result in a deviation from target quality. Additionally, mix homogeneity is influenced by mixing chamber and paddle design, rotational frequency Dr. Ralf Weinekötter General Manager, Gericke AG, Switzerland Dr. Weinekötter studied Chemical Engineering at University Karlsruhe, Germany and ENSIC Nancy, France. He was awarded his Ph.D. at the ETH-Zürich, Switzerland on the topic of Continuous mixing of fine solids. Weinekötter is a respected author of articles, papers and books, including Mixing of Solids, published by Springer Verlag, Germany. 8 METTLER TOLEDO OEM & System Integration News 16

9 (shear rate) and residence time distribution. Continuous processes have a reduced segregation risk compared to batch mixers because the product is directly fed into the next process without the use of intermediate bins with a high segregation risk. Material properties can also pose challenges. Cohesive materials, for example, require extensive engineering to ensure accurate dosing and mixing. Why is weighing technology a critical part of continuous dosing systems? Dosing of micro-components, such as APIs, requires a level of accuracy that only can be achieved with gravimetric dosing feeders. Other technologies for powder dosing, such as flow meters, are significantly less accurate. What are important specifications for weighing sensors in these systems? Precise feeding requires advanced weighing, optimal design of the screw feeder and a sophisticated controller that analyzes weighing-sensor data and selects the optimal settings to ensure a constant feed rate. The weighing sensor must combine high accuracy with a large capacity. The capacity is essential because the sensor has to carry the screw feeder with the feed hopper, which contains the dosing material. Not many weighing technology companies, apart from METTLER TOLEDO, can provide sensors that master this challenge of high capacity with pristine accuracy. In addition, the weighing sensor must provide a high measurement update rate and fast transmission of weighing data to the controller. This is necessary to accurately control the screw feeder and ensure constant material throughput. Are continuous processes the future of pharma preparation? Continuous processes provide significant benefits in terms of efficiency, quality and process safety. We have reached a point where suitable systems are available to help companies transition to the continuous method, and we believe the coming years will generate many more exciting developments. Key Benefits: Continuous Solids Processing Better quality: Easy integration with downstream processes, such as tablet compression, reduces segregation risk. Improved efficiency: Continuous manufacturing is an automated process with integrated sophisticated online measuring devices and control technologies to ensure accurate formulations. Faster time to market: Scale-up from lab to pilot to production is no longer necessary. Extending the operating time of the pilot module to reach normal production output is sufficient. Less space: A continuous dosing-mixing-module s footprint is just 2 x 2 x 2 meters. METTLER TOLEDO OEM & System Integration News 16 9

10 Efficiency and Compliance Trust Your Old Weighing Equipment? You Could Have False Sense of Security Process tolerances in your manufacturing process could have changed a while ago. Old measuring equipment which, despite frequent recalibration, might not comply with today s accuracy requirements. We can get you compliant with a professional verification. Most machine manufacturers use weighing in their own production for logistics, formulation or quality control. Their scales were often procured long ago and they are no longer accurate enough because process tolerances have changed. That can happen even when scales are regularly verified with test weights as part of the quality-control process. New regulations might require action The new ISO9001:2015 revision requires a risk-based evaluation of measuring equipment. It could also require a reevaluation of existing equipment. Auditing an installed base Our service technicians can help you comply with the ISO revision using our Good Weighing Practice (GWP ) method. It includes risk evaluation and provides a statement regarding whether the scale is suitable for the particular application for which it is used. Efficient Weighing and Piece Counting Compact bench scales for simple weighing or piece counting with printer and scanner provide features for efficient printing of customized labels. Connectivity to ERP System support state of the art data management. Portable Scales Provide Flexibility Factory layouts change often to make manufacturing processes more efficient or adapt quickly to new products. Portable scales or mobile pallet truck scales provide flexibility to adapt fast and easy to new situations in the future. Floor Scales for Simple Weighing in Production and Logistics Different platforms sizes including ramps and pit frames made of painted carbon steel up to 316 stainless steel with IP69k protection offer the right solution for any environment and application. 10 METTLER TOLEDO OEM & System Integration News 16

11 Company ABC Machine Manufacturer Contact john Sampleman Department / Position Production Manager Building Machine Assembly Street Road to Success Zip code / City 1234 Moderntown Date Monday, 15. August 2016 Scale Maximum capacity 30 kg Readability (d) 0.1 g Hazardous approval no Wet application ( IP 65) yes Terminal type name ICS429 Maximum weight 30 kg Smallest net weight 50 g Weighing accuracy 1 % Safety factor required 2 Standards and Regulations Expansion Factor k 2 Minimum weight typical 10 1) g Weighing accuracy 1 % Safety factor* 5 * Based on typical minimum weight The specified device meets the user requirements for accuracy procedures, test frequencies and weights to maintain reliable weighing accuracy of the device over time. GWP Verification can be issued for all weighing equipment of any manufacturer. Additionally, the user receives a recommendation for calibration intervals and suitable test weights for calibration. Scientific selection method GWP is applicable to new and existing equipment from any manufacturer. It supports you with a standardized scientific methodology for secure selection, calibration and operation of weighing equipment. It also provides documented evidence for reproducible weighing results in harmony with all current quality standards in laboratory and manufacturing, including a risk evaluation. Good Weighing Practice TM Certificate Specified Scale PBK989-AB30 (300'000d) User Requirements Value Unit Achievements GWP Recommendation In addition to a GWP Recommendation, METTLER TOLEDO recommends GWP Verification to determine the actual minimum weight and safety factor of this device on site. Furthermore, GWP Verification provides all necessary information on test Ask for a GWP Verification of your installed base to reduce costs and risks. Plus, receive complete audit-proof documentation at one glance. Weighing Terminals for a Multitude of Applications Windows-based weighing terminals combine PC based standard applications or customer-specific software with weighing. Their IP69k protection, including rugged cable connectors allow use in harsh environment. Documenting proper evaluation of existing and new equipment. A certificate documents the performance of each balance versus process requirements based on a calibration. The safe weighing range displayed in the certificate visualizes the specific weighing security and risk of each scale. METTLER TOLEDO OEM & System Integration News 16 11

12 Predictive Maintenance Remote Performance Monitoring InTouch SM Remote Services is a cloud-based, off-the-shelf solution that is making maintenance easy and downtime a thing of the past for businesses large and small. Machine manufacturers can pass on the benefits of InTouch predictive maintenance and monitoring to their customers. Alarm Alarm I'm OK Pharma Workflow Event I'm OK I'm OK Alarm I'm OK I'm OK Event I'm OK Besides gaining a competitive advantage with InTouch, you can receive valuable information about the performance of your equipment during warranty and later as paid service. For more information about Remote Performance Monitoring visit: For more information Mettler-Toledo, LLC 1900 Polaris Parkway Columbus, OH Mettler-Toledo Hi-Speed 5 Barr Road Ithaca, NY Mettler-Toledo Safeline 6005 Benjamin Road Tampa, FL Mettler-Toledo CI-Vision 2640 White Oak Circle, Unit A Aurora, IL Mettler-Toledo, Inc Argentia Road, Unit 6 Mississauga, Ontario L5N 8G6 Local contact: