Designing the production of tomorrow today. Your path to the Smart FOOD Factory with CSB

Transcription

1 Designing the production of tomorrow today Your path to the Smart FOOD Factory with CSB

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3 IoT (Internet of things) = Things communicating with one another via the Internet. CSB-System AG

4 IoT in the food industry: Data can flow along the value chain much faster. Producer Raw material provider Pre-producer Production 1 to n Smart logistics Trade Consumer CSB-System AG

5 The IIoT (Industrial Internet of things) is the path to the production of tomorrow. I. Mechanization 2. Electrification 3. Automation 4. Networking Industry Today 4.0 stands for the intelligent networking of product development, production, logistics and customers. CSB-System AG

6 The IIoT has many benefits: e.g. agility, quality and maintenance. Agile Supply Chain: Production becomes needs based. Customer needs are actively integrated into the production process. In the event of demand fluctuations, production and logistics are directly adjusted. Increase of OEE from 73.6 % to 85.5 % Reduction of quality defects from 4.9 % to 2.5 % Traceability & Quality: The role of the consumer is changing. Online consumers can actively take part in the traceability & quality of products. Maintenance: Machines automatically report their maintenance needs. Complex tasks are guided by the machine. Reduction of unplanned machine downtimes from 11 % to 5.8 % CSB-System AG

7 Business software, consulting and services, automation solutions and industrial image processing is a requirement for the IIoT. Consulting and Services Business process consulting Automation consulting & planning Realization User training Support 24/7 Cloud services Software for Management & Planning Software for process control Software for execution & manufacturing Automation solutions Control station Material flow system Inventory management system Labeling & identification Picking Machine & system control CSB-Vision Image processing CSB Grading Systems CSB-Vision-Robotics CSB-Eyedentifier CSB-Vision-Quality Usage Optimization CSB Image Documentation Hardware CSB Rack CSB I/O-Controller CSB Hang & Move CSB Sorters Server & IT Hardware CSB Cloud Center CSB-System AG

8 A complete solution offers all modules for your Smart Food Factory. Software for Management & Planning Company Performance Center Business Intelligence Certification Management Quality Management Human Resources Accounting and Finances Document Management Customer Relationship Management Software for Process Control Supply Chain Management Procurement Inventory Production Coverage Planning Sales Traceability Quality Assurance Labeling Electronic Data Interchange Software for Execution & Manufacturing MES PPS CSB linecontrol CIM Maintenance management Corporate data capture Mobile data capture CSB-System AG

9 A factory level system is the central answer to the requirements of IIoT: From the function pyramid to the process pyramid. BI CRM AF Group ERP Forecasting data Sales orders ERP MES CSB FACTORY ERP Production planning Production orders CIM / OEE Corporate data capture online and realtime (all integration levels) SPS / SCADA Machines & Systems SPS + SCADA Machines & Systems CSB-System AG

10 Better control, more transparency and homogeneous IT is achieved with a shop floor solution supplementing the group ERP at the individual factories. Standardized interfaces Group of companies / corporate group Group ERP Meat production CSB Factory ERP MEAT Machine production Bread and baked goods production CSB Factory ERP FOOD AND BEVERAGES Chemicals production CSB Factory ERP Chemicals Logistics Pharmaceuticals production CSB Factory ERP Pharmaceuticals Construction company Requirement: More stability and security for your IT landscape Factory ERP : Homogeneous IT landscape ensures stability and security at all factories Requirement: More transparency and low cost Factory ERP : Homogeneous processes create transparency and reduce costs Requirement: Enhanced process optimization and ideal control of the individual factories Factory ERP : Industry-specific processes and best practices enable successful factory management and optimal processes

11 Your technology partner should use standardized interfaces to group ERP to establish a homogeneous IT landscape in your group of companies. Group ERP Items, addresses & prices Procurement orders* Long-term planning* Sales orders* FACTORY ERP Standard interface 1: Master Data Standard interface 2: Procurement & Goods Receiving Standard interface 3: Planning & Production Standard interface 4: Inventory & Traceability Standard interface 5: Sales & Dispatch Standard interface 6: Accounting & Calculation Quantities Goods Receiving Current quantities & product cost Stock on hand Detailed delivery note & invoice data Calculation margins & invoice books (optional) Group ERP *Also possible in FACTORY ERP Alternative 1: Data Web Service Alternative 2: File-based CSB-System AG

12 Machines & equipment are controlled directly via the standardized interfaces eliminating the need for a separate MES. FACTORY ERP Orders for raw material, production, labeling, inventory movements, picking Machines & equipment Production machines & equipment, scales and lab equipment, inventory systems and dispatch logistics Production quantities and times, quality indicators, defective goods, inventory postings, malfunction reasons etc. CSB linecontrol CSB-Control Station Standard-Schnittstelle: interface: CSB-System AG

13 The technology partner establishes the basis for optimal factory management and more profitability. Material Man Machine With the Factory ERP, you plan, control and optimize the utilization of all critical resources at your facilities: Material, machines and staff. In brief, you have full control of your factories and can manage them down to the last detail. With Factory ERP, you are able to enhance the profitability at your factories and thus lay the foundation for growth. CSB-System AG

14 The nervous system of the Smart FOOD Factory is the ERP system. A true system connects the shop floor & the top floor. Traceability 4.0: All information seamlessly verticalized from original production to the consumer High delivery availability, lowest stocks with integrated coverage and production planning for an agile supply chain Quick and reliable decisions based directly on available figures this is how you control big data Cross-location coordination of production and logistics in the cloud CSB-System AG

15 Line control provides all data on capacity and performance of your machines in real time, directly in your ERP system. CSB linecontrol CSB-control station Reporting (OEE) Visualization Connection Connection of all machines from various makes Goods receiving Preproduction Production Packaging Intralogistics

16 OEE at a consistently high level OEE Availability x Performance x Quality = OEE Line/department overview The big picture under control Machine overview Every machine under control Product overview Every production order a success The retooling process Every action fits CSB-System AG

17 It is possible to enable the evaluation of the OEE ratio even without line connection in a great solution. Entry of data directly in the CSB FACTORY ERP Quality management Monitoring of all quality parameters directly at the line Optimization of process control Execution of quality- and quantity-based test instructions Maintenance management Simple planning and execution of maintenance tasks Integration of manufacturer-specific spare parts databases and maintenance plans Inventory, finished products Rework and rejects Man, machine, material CSB linecontrol and Order Management QM Maintenance Inventory, raw materials, packaging CSB-System AG

18 The Line Control system must work in synergy with other IT systems. CSB linecontrol FACTORY ERP Scada Linecontrol Visualization OEE basic data XML configuration SOA-Que Database OEE calculation OEE controlling Dashboard Evaluation Linecontrol Servers Quality management Maintenance management IO-Server TCP/IP Modbus Profibus Database Rs232 etc. Inventory management Machine 1 Machine 2 Machine 3 CSB-System AG

19 With IIoT you design the production of tomorrow today. An overview of the most important benefits. With IIoT you reduce your costs Processes become faster, your supply chain more agile and your resources more efficient. IIoT increases productivity Utilization and performance of production systems are optimized and the OEE is significantly increased. More security and stability with IIoT Production and logistics are coordinated across all locations. More quality for your products Automated quality control delivers precise measuring results and reduces the error rate. IIoT provides more transparency and lean business processes All areas are networked in a system with a uniform data basis. CSB-System AG

20 EDEKA Südwest Fleisch GmbH How the CSB-System automates and flexibly organizes Europe s most advanced meat processing plant

21 EDEKA is Germany s largest food company. Approx. 11,300 stores, 4,000 independent EDEKA retailers Largest marketer of regional products > 347,000 employees 16,800 apprentices EDEKA 25,3 % Rewe 15 % Lidl 14,7 % Aldi 11,5 % Market share in Germany

22 EDEKA Südwest Fleisch GmbH in Rheinstetten is the largest and most advanced meat processing plant of the group. Started in July 2011 Turnover 635 million Annual tonnage 125,000 tons Customer base approx Sales items approx Employees approx. 800

23 EDEKA Südwest Fleisch GmbH in Rheinstetten is the largest and most advanced meat processing plant of the group.

24 EDEKA s project goal. A fully-automated meat processing plant and logistics center. CSB-System AG

25 From the start, EDEKA has used CSB FACTORY ERP for planning, controlling and optimizing all resources at the facility in Rheinstetten Highlights of the solution Control centers Grading Production planning Inventory management Perfect interplay of ERP & MES: Two CSB control stations permanently monitor 800 individual processes Fully automatic no-contact & absolutely hygienic grading of pork sides in Receiving Best-practice cutting & production planning for more than 20 lines Automated management & control of inventory technology, weigh labeling & picking

26 The CSB-System fully integrates the material and information flows at the meat processing plant in Rheinstetten. Planning Delivery Sorting & chilling Primal cutting Retail cutting Procurement planning Goods receiving for hanging goods (beef, pork), retail goods, fresh meat, packaging material and crossdocking items Fully automatic grading, sorting & stock putaway Cutting entry Dismantlling output

27 The CSB-System fully integrates the material and information flows at the meat processing plant in Rheinstetten. Packaging & labeling of meat parts Production Production Production Production Shipping unit boxes & crates Production planning Batch processing Production exit Quality assurance

28 The material and information flow in the Fleischwerk Rheinstetten is fully integrated with the COD system. Production Inventory Picking Dispatch Labeling of finished goods Stock entry and removal of finished goods Dynamic & static picking Trolley loading & route set-up

29 Interaction of CSB FACTORY ERP with SAP as Group ERP. Order process in Rheinstetten Transfer of order data SAP-System Transfer of delivery notice Customer orders Transfer of delivery data Order entry with MDC CSB-System EDEKA Rheinstetten Delivery Incoming goods inspection with MDC EDEKA store EDEKA store

30 With CSB Factory ERP, EDEKA increases profitability in all areas at its facility in Rheinstetten. CSB Factory ERP provides more flexibility for the supply chain EDEKA reduces costs with CSB Factory ERP It speeds up EDEKA s processes while reducing costs and error rates in picking. +22 % customer deliveries CSB Factory ERP secures standardized product quality Automatic grading ensures accurate quality assessments. CSB Factory ERP increases the productivity of the meat facility +34 % Production volumes CSB Factory ERP ensures transparency All factory units are linked in a network with a single system and a consistent data basis. CSB-System AG

31 EDEKA Südwest Fleisch GmbH Without the use of industryspecific information technology, it is not possible to manage a meat facility of this size efficiently. When we designed the facility, we have choose the CSB-System as end-to-end solution. We control the entire value chain with the CSB solutions. Jürgen Sinn, Managing Director of EDEKA Südwest Fleisch GmbH

32 CSB-System won the 2016 ERP-System of the Year award because of the benefits it provides its customers and the Smart FOOD Factory concept

33 Designing the production of tomorrow today Your path to the Smart FOOD Factory with CSB CSB-System North America 3223 South Cherokee Drive, Suite 1530 Woodstock, Georgia Telephone:

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