Online Remote Monitoring (Internet of Things IoT) and enterprise software

Transcription

1 F&B CUSTOMER DAY SURABAYA, SEPTEMBER 5, Digitalizing F&B processes Online Remote Monitoring (Internet of Things IoT) and enterprise software Ronald Lim, Control Technology business unit, Industrial Automation division

2 Digitalization Key Drivers Internet of Things Wireless Communication Information & Big Data Analytics Visualization Cloud Mobility Artificial intelligence, machine learning Processing power Price Collaborative Robots Anything Can Be Connected, Will Be Connected

3 What can we do with LOTS of Digital Data? There is basically unlimited amount of data available, some digitally collected, but it is useless if they make no sense How to create knowledge from the unknown: Digitally collect data into Unified Data Storage Visualization of information Closing the loop of manufacturing operations Algorithms approach (predictive analysis, machine learning, advanced statistics etc) Prioritize data collection with domain knowledge Prioritize action items using newly acquired knowledge!

4 ABB Ability Powered Data Analytics Analytics Enhanced by ABB Knowledge Less data to process saves cost and improves accuracy. MES Plant Unified Data Set Filter Out: Processes Control Programs known by ABB Faster Big Data Analytics Find New Insights Like customer demands and production trends Slide 5

5 Global Multi Site Operations Dashboard Slide 7

6 Global Multi Site Operations Energy Monitoring Dashboard Slide 8

7 Global Multi Site Operations Interactive instant reports and analysis Slide 10

8 Manufacturing Operations Management Remote Monitoring on your mobile Operator OEE Material Consumption Slide 11

9 Platform ABB Ability TM Manufacturing Operations Management Overview Scalable and modular suite: Process intelligence Manufacturing execution Production intelligence Production optimization Enables the various stakeholders effective decision-making and production execution with fully integrated operations Platform Independent encompassing core common services Slide 13

10 Digitally Enabled Automation Systems Enabling new values through Digital Level 4 Enterprise Resource Management IT / OfficeFloor Service Center Level 3 Production Planning & Optimization Maintenance Management Historical data MES ABB IoTSP platform IT Security 3 rd party condition monitoring Installed data data base data Level 2 Control & Operation Level 1 Instrumentation System server DCS SCADA Production data IoTSP enabled Local I/O IoTSP enabled Controller IoTSP enabled Control & Protectio n Common object models and communication protocols targeting Industrie 4.0 compliance IoTSP enabled Condition monitoring data OT / Shop Floor Remote I/O Intelligent devices Cloud/Off Site Slide 14

11 ABB Ability TM Manufacturing Operations Management ABB Ability System 800xA Operator Effectiveness Full scope and features set including optimal collaborative environment through control room design based on human factors best practices Electrical Integration Combines process and power automation in a common infrastructure for improved operations, maintenance and collaboration Enterprise Asset Management Full scope asset monitoring that helps operators, maintenance and manufacturing operations management streamline procedures and become more predictive Integrated Safety Combines basic process control and high integrity applications for improved control strategies and improved safety Plant-wide consolidation, collaboration, and optimization! Slide 15 3BSE en L

12 ABB Ability TM Manufacturing Operations Management Improve operating procedures, integrate existing plant equipment and control end-to-end production process Slide 17

13 ABB Ability TM Manufacturing Operations Management Sugar process example Goods Received Cane Preparation Mill and Pressure Feed Biomass Power Plant Track & Trace Process and Production Intelligence, Energy Monitoring Cane Juice holding Tanks Vacuum Pans Syrup Tank Control and Operation Quality Management (in-line) Process and Production Intelligence, Energy Monitoring Storage Molasses Centrifuges Raw Sugar Picking, Packing, Palletizing OEE, Track & Trace OEE, Weigh & Dispense Slide 18

14 ABB Ability TM Manufacturing Operations Management Ensuring the correct material is used at the right place Verification of manually infed material using scanners or counting scales Creation of non conformity if deviation detected FOR 48,000 BOTTLES /HR Reduction of 3 MINUTES 800 BOTTLES/MIN 9/12/ 19

15 Example: Wander AG, Switzerland (ABF) Production of Ovomaltine, Caotina, Isostar Slide 24

16 Example: Wander AG, Switzerland (ABF) Production of Ovomaltine, Caotina, Isostar Wander AG, Neuenegg: 175 Recipies 175 inter./end products ca. 500 raw materials 100 packing material 600 Containers 12 Bulksilos ca. 750 packing variants Horizontal integration of all involved physical equipment, systems and application along the production flow, from material delivery throughout production steps to material dispatching.

17 Effective production in Biscuits company Improved execution with connectivity solution Customer needs ABB and Göteborg Kex has a longstanding collaboration from the process to automate Göteborgs Kex production with 800xA Batch, PLC-connect and Information Manager. The company now wanted to extend the level of automation further by connecting the business system to the control level. Göteborg Kex, Göteborg, Sweden: Scandinavia's leading manufacturer of cookies/biscuits Around 50 products on the market 24/7 production Solution Automatically transfer of production related data between ERP (SAP PPPI) and DCS (ABB 800xA). Real-time transfer and retrieval of production orders and process information, material consumption and produced goods. Customer value Paperless production that contributes to a smooth and efficient production process and reduced time for manual data entry. Improved planning for raw material delivery and production based on inventory level. Slide 27

18 Embarking the Digital Journey Case Studies

19 MoM Value Study: Equipment Manufacturer Discrete Manufacturing. High Mix, Low Volume Background: Home grown MES for order and labor tracking. Integrate to SAP. No integration to shop machines. Challenges: Need to shorten manufacturing lead time. 0% Inventorize Equipment & Tools +1% Electronic Work Instructions Clean Start -8% -1% -2% Non- Conformity Mgmt Digital Quality Record -3% Farm Out Integration 13% Gain in Lead Time BONUS Digital Manufacturing Record Book Slide 29

20 ABB Ability TM Manufacturing Operations Management Case Study: MOM execution for a sugar plant = Phase 1 = Phase 2 or beyond Station Manufacturing Execution (MES) Process Intelligence Production Intelligence Production Mgmt. ERP Interface Workflow Mgmt. Equipment Maintenance Mgmt. Downtime Mgmt. Material Mgmt. (Goods Received) Material Mgmt. (Weigh & Dispense) Integration (Label Printing) Warehouse Mgmt. Material Mgmt. (Genealogy) Electronic Work Instructions Workforce Mgmt. Quality Mgmt. (Lab. Entry) Reporting Dashboard Trends & Events Excel Analyze OEE Energy Monitor Batch View / Investigate Weighing Crushing Juicer Boiler Clarification Filtration Evaporation Crystallization Centrifugation Drying Packaging Weighing Slide 31

21 So let s talk

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