Value proposition of standardized Automation

Transcription

1 Value proposition of standardized Automation

2 Agenda PackML & Line Controller Benefits in CAPEX Benefits in OPEX The Line Controller HMI PackML is a strategic Management decision Hidden Integration cost What has been achieved Questions

3 PackML & Line Controller PackML - TR a standardised way to communicate with machines on the factory floor. - a common interface description for all machines. Possibilities - makes it possible to standardize the overall control of machines in a production line. Arla Foods experiences - Arla Foods PackML Implementation Guide is based on standard ANSI/ISA TR Developed a standardized Line Controller - uses the standarised PackML interface to the machines. - build-in use case scenaries for - prepare production, - start production, - quality control, - stop production - OEE measurement for all machines. - Machines are from now on ordered with a standardized PackML interface.

4 Machine-level OMAC Line-level Line Controller OMAC Line Integration Strategy Open protocol for PackML tag exchange PackTags PackTags PackTags PackTags OMAC State Model OMAC State Model OMAC State Model OMAC State Model I/O Machine Network I/O Machine Network I/O Machine Network I/O Machine Network Intellectual Properties Machine Builder A Intellectual Properties Machine Builder B Intellectual Properties Machine Builder C Intellectual Properties Machine Builder D

5 Benefits in CAPEX The following benefits have been achieved: Reduced the integration cost with a factor 4. The reason is a technical and organisational standardized model. Easy to integrate and test. Reduced the specification cost with a factor 5. The reason is the reuse of use case scenaries and technical specifications. The interface test is standardized and the interface can be evaluated by the machine builder itself using a test suitcase before commissioning. Training of operators can be standardized and reused across the company.

6 Benefits in CAPEX The yellow line indicates until 2014 the development in integrations costs. The white line is the estimated result after standardization. The yellow line indicates the integration cost for one unit during 5 packaging projects based on a standaridised application platform based on PackML and Line Controller. The PackML and Line Controller concept and modules are even developed during the projects. Figures are in Euro.

7 Benefits for OPEX The OPEX benefits are not really obtained yet, but there are clear indications that the following is to be fulfilled: The same OEE calulations for all machines from commissioning. Energy data can be logged. Data quality related to production and products. Reducing labelling errors, packaging material errors. The visualisation of the performance on the line and the individual units, is expected to give 5-20% increased productivity.

8 The Line Controller HMI The Line Controller HMI, that shows the status of the line and the individual machine.

9 PackML is a strategic management decision To introduce a standardised PackML interface to machines is a strategic decision for an enduser company. The reason is the whole standardization process require ressources and will take time before the results are visible. Therefore, a single project with PackML will be more expensive, because of the following reasons: Machine builders needs to understand and implement PackML The System integrators needs to understand and implement PackML There is no reuse of the interface, it is just another interface. The real benefits comes when PackML and the Line Controller is a common standard for an enduser company. This requires that the following organisational parts are involved: Technical department Purchasing department Project department Maintenance department Cooperative companies (system integrators, solution providers) Machine builders. In fact PackML can be a common standard not just for one end-user but for entire industry segments

10 Hidden integration costs Hidden integration costs Be aware of cost related to integration of data from the factory floor. Often these integration costs for machinery and equipment are hidden in the businesses, since the costs are distributed in many different departments. Example: Lack of standard integrations does not always show up in projects, but will hit the maintenance department with more costly support and upgrades.

11 What has been achieved? Standard integration cost reduced 4 times Standard specifications cost reduced 5 times. Commisioning time reduced by 50% Expectations for OPEX OEE on all machines during commissioning Increased productivity with 5-20% Quality in production data

12 Tilgængelig efter 10. novermber 2016 Arla Foods VELUX COLOPLAST SESAM + OMAC organisation Part 1: PackML Interface State Manager Part 2: PackML Machine software code structure Part 3: PackML network connections Part 4: PackML and Safety Part 5: PackML and Line integration Part 6: PackML User interface - HMI

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