Plant-wide Automation

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Alice Watts
6 years ago
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1 Totally Integrated Automation in the Food & Beverage Industry Siemens AG 2016 siemens.com

Food & Beverage Industry Challenges are Growing Worldwide Strengthening our customers competitiveness Reduce Time to Market Enhance Flexibility

markets High productivity Closed loop quality processes Traceability and integrated genealogy Reliable Processes Reduce energy consumption

2 Food & Beverage Industry Challenges are Growing Worldwide Strengthening our customers competitiveness Reduce Time to Market Enhance Flexibility Increase Quality Increase Efficiency Shorter innovation cycles More complex products Larger data volumes Individualized mass production Volatile markets High productivity Closed loop quality processes Traceability and integrated genealogy Reliable Processes Reduce energy consumption Better resource utilization Higher productivity High transparency Siemens has the right answers to the challenges of the Food & Beverage industry Page 2

NX SIMATIC IT Plant Cloud Services Global

3 Totally Integrated Automation The basis for future industrial concepts Customer requirements IT Level PLM MES Services Consistent data management Teamcenter / NX SIMATIC IT Plant Cloud Services Global and open standards Uniform interfaces for hardware and Totally Integrated Automation Integrated Engineering software Industrial Data Management Industrial Communication Industrial Security Safety Integrated Page 3

TIA@F&B Plant-wide Automation Standards and Concepts for an Entire Plant

Inbound Process/Production Filling/Packaging Outbound Production solutions

Cream, Entire Production Plant Braumat Brewery Process Automation CPG OEM

Auxiliary Processes: Energy, Water, Steam, Air, HVAC, Totally Integrated

4 Plant-wide Automation Standards and Concepts for an Entire Plant Plant-wide Automation Full MES Plant Integration/Line Monitoring + SCADA Inbound Process/Production Filling/Packaging Outbound Production solutions Edible Oils OEM Animal Feed (Machines) Nahmat Sugar Solutions Dairy, Ice Cream, Entire Production Plant Braumat Brewery Process Automation CPG OEM (Process Unit 1 Machine n) WinCC SES Bakery & Confect. Auxiliary Processes: Energy, Water, Steam, Air, HVAC, Totally Integrated Automation Production Line Integration and Control OEM (Machine 1 Machine m) OEM (Machines) Page 4

A Modular Approach Standardized components: Example of

Monitoring and Control Overview Visualization

WinCC SES (Sequence Execution System) OEE Analysis

2 Architecture Power distribution Networks Level 1

5 A Modular Approach Standardized components: Example of a Chocolate Plant Level 4 Energy Management OEE Line Monitoring and Control Overview Visualization Diagnosis Energy Monitoring Central Visualization WinCC SES (Sequence Execution System) OEE Analysis Maintenance- Laptop HVAC Level 3 Data Interfaces Level 2 Architecture Power distribution Networks Level 1 Hardware Software Mixing Milling, Conching Moulding Cooling Packaging Page 5

6 Starts with Standardization Line Overview HMI????? Diversity No Data Interface Data Interface 2 HMI PLC HMI PLC PLC PLC Line integration Motion Energy I/O monitoring Line Integration I/O I/O Control I/O OEE Integration Drives Drives Drives Line overview Network Motors diagnostic Motors Motors LV Sensors LV Standard LV Sensors LV Standard Sensors Data Interface Data Interface Software Machine Toolbox 1 from OEM x Machine 2 from OEM y Machine 3 from OEM z Data Interface HMI PLC HMI PLC Application I/O I/O Machine Architecture Hardware Standardization Software Conventions Machine Topology Topology Drives Motors LV Topology Topology Data Interface n Drives Motors LV Complexity Difficult System-integration Difficult Diagnostics Standard Data Interface Asset Costs Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z Topology HMI I/O Drives Motors LV PLC Topology Page 6

7 Scalable Concept from Field up to Factory Supervisory Level MES SIMATIC IT SIMATIC B.Data Line Monitoring System (LMS) ERP connectivity Material Management Order Management Line HMI KPI/ OEE/ RCA Energy Monitoring Dataanalysis, Reporting Line Control Unit (LCU) Energy Data Mgmt. WinCC Network Industrial Ethernet Profinet PDI IF PDI IF PDI IF PDI IF PDI IF PDI IF Automation S7-300/400 SIMOTION S7 1x00 3 rd Party ET rd Party Utilities Building Page 7

to seamlessly coordinate OEM SIEMENS End User Organization E Partner community to support system integrators in performing projects

8 Step-by Step Approach Planning A B Consulting to optimize specification and accomplish standardization Provide standardized PLC data blocks, HMI libraries and LMS configurations Line Integration Implementation C D Implementation support to OEMs Project coordination to seamlessly coordinate OEM SIEMENS End User Organization E Partner community to support system integrators in performing projects Architecture Operation F G On-Site support with trained local staff during commissioning Specific training for operators Tools Page 8

Line Monitoring System The right functionality for all different

interface Engineering/System-Integration Only one system house for

up to MES integration Machine and Line Operator Higher visibility

improvement within the line Line Supervisor/Maintenance

analysis to understand machine behavior Top Management Multi-line

9 Line Monitoring System The right functionality for all different users OEM Weihenstephan and OMAC integration Easy-to-use data interface Engineering/System-Integration Only one system house for Line Integration projects From shop floor components through SCADA up to MES integration Machine and Line Operator Higher visibility of performance issues Optimized system support to localize areas of improvement within the line Line Supervisor/Maintenance Standardized KPI system for high transparency Online and offline analysis to understand machine behavior Top Management Multi-line performance analysis and benchmarking Business reporting to support management decisions Page 9

and pictures 3 Support through standard Siemens channels Plant-Wide Automation offers Quick and easy engineering of data interface without changes in the machine program

10 for OEMs How can I simplify the PLC data interface? How can I reuse programs in other machines? 1 Well-defined interface data blocks for OMAC and Weihenstephan (including Documentation, Guidelines and examples for HW and SW) 2 Templates for Operator Panel objects and pictures 3 Support through standard Siemens channels Plant-Wide Automation offers Quick and easy engineering of data interface without changes in the machine program Implementation with examples and interface data blocks downloaded from Siemens Online Support Internet Reduction of test- and commissioning times Support available 24/7 TIA@F&B reduces time and risk to integrate machines data interfaces Page 10

Plant-Wide Automation for System Integrators Project delivery with clearly defined value and fixed costs How can I lower the engineering costs?

11 Plant-Wide Automation for System Integrators Project delivery with clearly defined value and fixed costs How can I lower the engineering costs? How can I meet my end customer s cost and performance targets? 1 Libraries for HMI objects can be re-used other projects 2 Easy-to-use configuration tools for Line Monitoring System (LMS) 3 Standard data interface ensures correct, consistent data Plant-Wide Automation offers Configuration tools with import/export capabilities allow to reuse configurations Libraries with predefined objects can be used as templates for now or other projects Standardization reduces risk and implementation costs TIA@F&B supports cost-efficient and reliable implementation Page 11

with detailed KPI s Plant-Wide Automation offers Optimized usage of machines by real-time monitoring of line and machine status Full integration of

12 for Line Operators What is the status of my machines? Am I on target with production demands? 1 Detailed real-time information about machine downtimes 2 Online information about production quantity and quality 3 Machine information screens with detailed KPI s Plant-Wide Automation offers Optimized usage of machines by real-time monitoring of line and machine status Full integration of all data in one system enables operators and saves HW costs User-friendly interface with standardized objects Fast access to all information TIA@F&B makes machine and line operators more efficient Page 12

for Line Supervisors and Maintenance How can I analyze data from different points of view?

1 Asset Performance Analysis 2 Root Cause Analysis to find the real reason for downtimes 3 Monitoring and

all relevant data for fast decisions Easy visualization and less time-consuming analysis of KPI s Reduction of

13 for Line Supervisors and Maintenance How can I analyze data from different points of view? How can I find the real reason for performance deviations? 1 Asset Performance Analysis 2 Root Cause Analysis to find the real reason for downtimes 3 Monitoring and extensive Reporting for further data analysis Plant-Wide Automation offers Supports the responsible people with all relevant data for fast decisions Easy visualization and less time-consuming analysis of KPI s Reduction of downtimes by identifying root causes and scheduling preventive maintenance Predefined and easily to configure reports for detailed analysis LMS supports efficient and fast analysis of data Page 13

management decisions Plant-Wide Automation offers Business Reporting (integrating data from shop floor up to business systems) Cost control and identification

14 for Top Management How can I compare different lines with each other? How can I find material-related issues? 1 Multi-Line Analysis based on customized Scorecards and Dashboards 2 Detailed Analysis of KPI s and production parameters 3 Business Reporting to support management decisions Plant-Wide Automation offers Business Reporting (integrating data from shop floor up to business systems) Cost control and identification of cost savings by continuous monitoring (also in multiple plants) Current data also supports the investment decision process With SIMATIC IT you can prepare the right decisions and support continuous improvement Page 14

15 Support and Deliverables Selected HW & SW Specification templates Guidelines and documents Reduces diversity and complexity in production process, filling and packaging Supports optimization and standardization of the automation equipment Network design, Interface descriptions, etc. simplify implementation Standardization Online support Training Ensures interoperability according to international standards Free of charge downloads for PLC and HMI templates and data interface block Enables fast, easy and reliable implementation Page 15

16 Benefits at a Glance reduced life cycle costs more transparency increasing productivity Reduced diversity in hardware and software Less spare parts variety Lower assets costs Less training for operational and service staff Less energy consumption Better resource utilization Integration of machines/lines in proper network topologies Using international standards Harmonized, OEM-independent line visualization High degree of diagnostics Calculation of KPI/OEE values to analyze line efficiency Foundation for MES systems to support management decisions MIS/MES Limited effort and risk of integration (commissioning phase) Lowering of efficiency drop effect Production efficiency Time Easy and fast service and maintenance Reduced downtimes $ Field Level Decreasing life cycle costs, while increasing line efficiency! Page 16

17 Thank you for your attention! Joachim Roesler Industry Development DF FA AS Food & Beverage Page 17