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09/06
Title : Batching & Filling – An introduction to the Market & Proposed Strategy
Manufacturing Areas : Making & Packing
Date : July 2007Presented by : Rodger Jeffery & Venus Simmons
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2 07/07
Scope of Discussion
• WHY? Motivation & Objectives
• WHAT? BCS Market & Solutions
• WHO? End Users – Environment, Business Drivers, Needs
• HOW? Proposed B&F-BA Portfolio Model • SO WHAT? Benefits for End Users & Mettler Toledo
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3 07/07
The Supply Chain
MAKE
PACK
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4 07/07
Motivation & Objectives
Top 10 Motivations for this Workgroup (not ranked)- Need a comprehensive portfolio of batch & filling solutions (MTNA)- Competitors (e.g. 920i) solutions eroding customer and distributor base (MTNA)- No current replacement for legacy product (e.g. 9215) (MTNA)- Need a PC based global batch solution (MTE)- Opportunities for growth in small to mid-sized batch and packaging market (MTNL)- Need to develop communication drivers for new terminals for manual batch (BASY) - Need to be able to capitalize on Q.i technology investment across terminals (MTWI)- Need to be able to differentiate MT’s solutions portfolio to drive SI & OEM growth (CS&S)- Need to develop common terminology glossary for batch & filling (BASY, MTWI & MO’s)- Need new sources of revenue growth (BUSI)
5 Objectives for this Workgroup- Develop B&F (Tools & Solutions) Functional Matrix - Develop B&F Positioning Matrix- Develop path forward for communication drivers for new terminals for manual batch- Develop B&F Glossary- Discuss ways to improve channel Skills/Resource challenges
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5 07/07
Scope of Discussion
• WHY? Motivation & Objectives
• WHAT? BCS Market & Solutions
• WHO? End Users – Environment, Business Drivers, Needs
• HOW? Proposed B&F-BA Portfolio Model
• SO WHAT? Benefits for End Users & Mettler Toledo
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6 07/07
Batch Control Systems Market – layers by % of units
Source: ARC Advisory Group
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7 07/07
Batch Control Systems Market – by market segment adoption
• Chemical
• Pharmaceutical
• Pulp & Paper
• Food & Beverage
47.2%
28.4%
8.3%
6.3%
Source: ARC Advisory Group
2005 Worldwide Market 3,2 M USD
“ Opportunities for Growth “
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8 07/07
Batch Control Systems Market – by hardware platforms
2005 Worldwide Market 3,2 M USD
• DCS-based = 53.8% +1%
• PLC-based = 43.3% -1%
• PC-based = 3.0% +9%
Source: ARC Advisory Group“ Potential for Partnerships “
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9 07/07
Scope of Discussion
• WHY? Motivation & Objectives
• WHAT? BCS Market & Solutions
• WHO? End Users – Environment, Business Drivers, Needs
• HOW? Proposed B&F-BA Portfolio Model
• SO WHAT? Benefits for End Users & Mettler Toledo
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10 07/07
• Fewer plants
• Complex mix of products per plant
• Demand for higher quality product & service
• More difficult to maintain brand loyalty
• Reduced time to market
• Global competition
• Margin & regulatory pressures
• Growing lack of technical resources
• Projects align to business strategies & prioritized based on ROA/EVM
End Users – Environment, Business Drivers, Requirements
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11 07/07
Orders
PC
Resource Planning
PC
Raw Material Logistics
PC
Manufacturing
PC
ProductLogistics
PC
Shipping &
Billing
PC
Delivery
PC
Produce
FAT & Start Up
Construct
Engineer
R & D
Innovate
Optimize & Maintain
Make Pack
Manufacturing
PC
PLC, DCS, Other
End Users – Environment, Business Drivers, Requirements
Sources: WBF,OMAC,ARC Advisory
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12 07/07
Manufacturing
PC
Produce
FAT & Start Up
Construct
Engineer
R & D
Innovate
Optomize
Make Pack
ERPManufacturing
MESPC
PLC, DCS, Other
A growing percentage of CEO’s view the traditional Manufacturing Supply Chain as a…
TACTICAL LIABILITY
• Complex to Install & Operate
• Time consuming to implement
• Not scalable enough, not agile enough
• Not robust enough
• Lacks Standardization
• Generates Process Data (secs, min,hr)
• Expensive to Own & Operate
Business leaders are now investing inways to return Manufacturing back to a…
STATEGIC ASSET
• Simple to Install and Operate
• Quick to Implement
• Scalable (Size, Price & Performance)
• Robust
• Use Industry Standards
• Also generate Business Intelligence
• Lowest possible Total Cost of Ownership
ISA S95 Standard
ISA S88 Standard OMAC Standard
Business leaders are reinvesting inways to return Manufacturing back to a…
STATEGIC ASSET
Simple to Install and Operate
Quick to Implement
Scalable (Size, Price & Performance)
Robust
Use Industry Standards
Also generate Business Intelligence
Lowest possible Total Cost of Ownership
Sources – WBF, OMAC & ARC
End Users – Environment, Business Drivers, Requirements
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13 07/07
Orders
PC
Resource Planning
PC
Raw Material Logistics
PC
Manufacturing
PC
ProductLogistics
PC
Shipping &
Billing
PC
Delivery
PC
Produce
FAT & Start Up
Construct
Engineer
R & D
Innovate
Optimize
MakeBATCH
PackFILL
Manufacturing
PC
Maintain
STATEGIC BUSINESS ASSET
Simple to Install and Operate
Quick to Implement
Scaleable (Size, Price & Performance)
Robust
Use Industry Standards
Also generate Business Intelligence
Lowest possible Total Cost of Ownership
OEMSI
OWNER manufacturer or CONTRACT manufacturer
End Users – Environment, Business Drivers, Requirements
Optimize the Manufacturing Supply Chain
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14 07/07
2.72
2.73
2.84
2.96
2.96
3.00
3.00
3.16
3.16
3.24
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00
Improved change control
Improved material tracking module
Controller data buffering & time stamp
Enhanced data collection/historian
Common S88 data definitions
Common phase structure
Improved product traceability
Standard library of equip. modules
Better intrgrated view of the batch
Standard library of control modules
Not Important
Critically Importan
t
End Users – Environment, Business Drivers, Requirements
Prioritized Review of ALL User RequirementsSource: ARC Advisory Group
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15 07/07
Not Important
1.72
1.88
1.96
1.96
2.04
2.54
2.64
2.67
2.68
0.00 0.50 1.00 1.50 2.00 2.50 3.00 3.50 4.00
Tools to convert General/Site Recipe to MasterRecipe
Tools to convert P&IDs to User RequirementsSpecs
Increasing size of execution system
Link procedure to equip. control
Tools to convert P&IDs tocode
Common S95 data definitions
Common library of HMI objects
Distribute batch execution functions
Batch execution in the controller
Critically Important
Prioritized Review of ALL User Requirements
End Users – Environment, Business Drivers, Requirements
Source: ARC Advisory Group
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16 07/07
“ Manufacturers require more robust dock to dock batch control system to meet their business needs.
They want to be able to invest in commercial
off the shelf batch control systems”
Source: ARC Advisory Group
Business Drivers…OPTIMIZE the Enterprise Supply Chain
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17 07/07
Scope of Discussion
• WHY? Motivation & Objectives
• WHAT? BCS Market & Solutions
• WHO? End Users – Environment, Business Drivers, Needs
• HOW? Proposed B&F-BA Portfolio Model • SO WHAT? Benefits for End Users & Mettler Toledo
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18 07/07
B&F-BA Model..based on ISA 95 & ISA 88 (ANSI & IEC)International Standards
S95
S88
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19 07/07
Unit Procedure(s) Unit(s) Process
Stage
combined with a
Operation(s) Unit(s) Process Operation
combined with a
Phase(s) Unit(s) Process Action
combined with a
Phase(s) Equipment Module(s)
combined with an
Procedure(s) Process Cell(s) Process
combined with a
provides process functionality to carry out a
provides process functionality to carry out a
provides process functionality to carry out a
provides process functionality to carry out a
provides process functionality to carry out a
Resulting Process
Functionality Equipment Procedural
Elements
Procedural Control Model
Physical Model (Lower Portion)
Process Model
Process Action
B&F-BA Model …based on ISA S88/IEC 61512 International Batch Standards
Source: S88 part 1
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20 07/07
Standard Control Strategies (i.e. S88/IEC61512 & OMAC)
Standard Data Flows (i.e. SP95)
Standard Presentation
Standard Documentation (i.e. S88 e-records & recipe models)
Resources
Analysis
Scope
Start-up
Test
Configure
Design
Reusable Engineering
Proprietary API ApproachStandard API Approach
Custom One Off Implementation
Standards Facilitate PerformanceStandards Facilitate Performance
B&F-BA Model…Standards & Guidelines
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21 07/07
Modular Programming saves time & money over Conventional Programming
Conventional
Programming
Modular
Programming
Program Development 4-5 weeks 1.5 weeks
Program Testing 3-4 weeks 0.6 weeks
Machine Testing 3-4 weeks 3-4 weeks
B&F-BA Model…Standards & Guidelines
Source: WBF Make2Pack Workgroup
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22 07/07
Principles of Design
1. Product will follow all current and evolving ANSI and IEC standards on Batch Manufacturing
2. All solutions will use a TABLE BASED RECIPE STRUCTURE
3. All solutions will follow the S88 model for RECIPE TYPES (General, Site, Master, Control)
4. A recipe should be able to SIMULTANEOUSLY START & RUN MULTIPLE PROCESS ACTIONS (phases/equipment modules). However, they are not necessarily managed once started
5. All solutions will support a LIMITED SET OF PHASE CLASSES
6. All solutions will support UNIT CONTROL MODES
7. All solutions should support CONFIGURATION CHANGE LOG IN THE TERMINAL & RECIPE CHANGE LOG IN THE PC
8. The SP88 11 state phase model will apply the states to the appropriate level of control.
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23 07/07
Batching Portfolio (15.5.07)
EN
TR
YE
NT
RY
+M
ED
IUM
HIG
HH
IGH
+
formulation
EN
TR
YE
NT
RY
+M
ED
IUM
HIG
HH
IGH
+
MANUAL
manual filling, check-weighing
AUTOMATIC
filling, dosing
batching
Sin
gle
Com
pone
ntM
ulti
Com
pone
nt
formulation
manual filling, check-weighing filling, dosing
batching
IND 690
batch
IND4...check /
R
remotebatching PLC w/o
HMI
IND 690 form
IND4...check
IND 560 fill
IND 690 fill
IND 690
fill / R
IND ???form/
batch / R
IND 560
fill / R
IND ???batch+/
R
remotebatching with HMI
at the PLC
FormXPIND690
IND ???form/R
xxx
xxx
Master data on PCplus remote work terminal
Stand-alone terminal
IND ??? Remote batching w/o HMI
FoW ID30
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24 07/07
Functional Matrix (6.7.07)
Batch Functionality based on “location” of batch control
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25 07/07
Functional Matrix (6.7.07)
1. Terminal based Material Transfer tools
2. Terminal based Batch Executive
3. Controller based Batch Executive
4. PC based Batch Executive
Four ‘location” types:
1 2 3 4
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26 07/07
Functional Matrix (6.7.07)
Terminal based Material Transfer tools:
• Terminal is used as a tool for control system’s access to weight data
• Only provides material transfer functionality (target)
• Relies on some type of communication interface
• Simplest level of functionality
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27 07/07
Functional Matrix (6.7.07)
Terminal based Batch Executive:
• Terminal is responsible for execution of recipe(s)
• Traditionally thought of as stand alone batch product
• Replacements for LynxBatch, 9215
• Limited by amount of I/O & simple manufacturing information
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28 07/07
Functional Matrix (6.7.07)
Controller based Batch Executive:
• Controller is responsible for execution of recipe(s)
• Terminal may be used for execution of material transfer phase
• Strengths lie in I/O control (logical to physical connection)
• Weakness in production scheduling, recipe management
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29 07/07
Functional Matrix (6.7.07)
PC based Batch Executive:
• PC is responsible for control execution of recipe(s)
• Usually relies on controller or terminal for execution of phases (process action)
• Weakness – I/O control
• Strengths in manufacturing information, recipe management, production scheduling (access to other PC applications), suitable for Manual & Automatic batch.
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30 07/07
Functional Matrix (6.7.07)
Batch Executive functions:
• Manufacturing information: scheduling, recipe management, tracking/tracing, production analysis
• Manufacturing operations: recipe execution, arbitration, execution at unit and/or phase level
• Manufacturing process control: phase control, interlocks, exception handling
• Process Instrumentation: material feed control, process measurement, special operations (user interface, custom)
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31 07/07
Scope of Discussion
• WHY? Motivation & Objectives
• WHAT? BCS Market & Solutions
• WHO? End Users – Environment, Business Drivers, Needs
• HOW? Proposed B&F-BA Portfolio Model • SO WHAT? Benefits for End Users & Mettler Toledo
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32 07/07
4 Primary Benefits for End Users
2.91
3.14
3.23
3.36
4.18
1.00 1.50 2.00 2.50 3.00 3.50 4.00 4.50 5.00
Reduced Maintenance& Operations Costs
IncreasedManufacturing
Efficiency
Reduced EngineeringCosts
More ConsistentProduct Quality
IncreasedManufacturing
Flexibility
NotImportant
CriticallyImportant
“ Customer Investment Drivers/Benefits “
Source: ARC Advisory Group
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33 07/07
9 Benefits for Mettler Toledo
Delivers a comprehensive portfolio of batch & filling tools and solutions to the channel
Defends existing customer and distributor base from attack by competitors
Allows the channel to go after small to mid-sized batch and packaging opportunities
Globally harmonizes MT’s manual/automatic batch & filling solutions for the first time
Capitalizes on existing Q.i technology investment (exclusivity last for ~12 more years)
Differentiates MT’s solutions portfolio to drive SI & OEM growth
Delivers a common terminology glossary for batch & filling applications
Provides opportunities for MO’s to increase existing, or access new revenue growth
May eventually deliver a PC based small to mid size global batch solution
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34 07/07
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35 07/07
DRAFT ONLY
TOOLS & SOLUTIONS …completing the batch and filling range”
GMP (Standards Based e.g. S88) Batch / FillIntegrated Solution
Traditional Batch / FillManual
Stand Alone Solutions
OEM / SIIntegration Tools
MT Channel Solutions
IND560
IND780 Fill
Fill
Q.i Batch Compact +
Q.i Batch +
$1,500
$3,800
$10,900 >
Q.i pro + (12chn & Network )Q.i lite + (12chn) Q.I compact + (2chn)IND780 IND690IND560 Panther
C710/750T600
$750
$500
$6,211 >$3,988 >$3,200 >$2,300 >$2,100 >$1100 >$795 >
$27,500 >
T600 C710/750 Q.bATCHcompactIND780IND560 Q.bATCH
Full Q.i material transfer capability +Limited Q.i material transfer capability ~
IND690 SysFill
$?$?
Traditional (Non Standards Based) Batch / FillIntegrated Solution
Traditional (Standards / Non Standards Based) Batch / FillAutomatic or Semi-Auto Stand Alone Solutions
IND690 Q.iMPACT
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36 07/07
DRAFT ONLY
TOOLS & SOLUTIONS …completing the batch and filling range”
Traditional (Non Standards Based) Batch / FillIntegrated Solution
Traditional Batch / FillManual
Stand Alone Solutions
OEM / SIIntegration Tools
MT Channel Solutions
IND560 ~
IND780 ~ XXX XXXXXX
XXX XXXXXX
Q.i Batch Compact +
Q.i Batch +
$?$2,000$1,500
$?$4,300$3,800
$10,900 >
XXXXXX XXXIND780 XXXIND560 IND331IND131
XXXXXX
$750
$500
$6,211 >$3,988 >$3,200 >$2,100 >$1 600 >$1100 >$695 >$495 >
$27,500 >
T600 C710/750 Q.bATCHcompactIND780IND560 Q.bATCH
Full Q.i material transfer capability +Limited Q.i material transfer capability ~
GMP (Standards Based e.g. S88) Batch / FillIntegrated Solution
Traditional (Standards / Non Standards Based) Batch / FillAutomatic or Semi-Auto Stand Alone Solutions
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37 07/07
DRAFT ONLY
TOOLS & SOLUTIONS …completing the batch and filling range”
Traditional (Non Standards Based) Batch / FillIntegrated Solution
Traditional (Standards / Non Standards Based) Batch / FillAutomatic or Semi-Auto Stand Alone Solutions
Traditional Batch / FillManual
Stand Alone Solutions
OEM / SIIntegration Tools
MT Channel Solutions
IND560 ~
IND780 ~ Formweigh?RecipeFill
Formweigh?RecipeFill
Q.i Batch Compact +
Q.i Batch +
$?$2,000$1,500
$?$4,300$3,800
$10,900 >
IND780 + (Q.i pro 12Network )IND780 + (Q.i lite 12) IND780 + (Q.i compact 2)IND780 ~IND560 + (Q.i compact 1)IND560 ~IND331IND131
C710/750 Repl ~T600 Repl ~
$750
$500
$6,211 >$3,988 >$3,200 >$2,100 >$1 600 >$1100 >$695 >$495 >
$27,500 >
T600 C710/750 Q.bATCHcompactIND780IND560 Q.bATCH
Full Q.i material transfer capability +Limited Q.i material transfer capability ~
GMP (Standards Based e.g. S88) Batch / FillIntegrated Solution