The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.
The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.
Digital Transformation in Food and Beverage, CPG
Improving Asset Performance and Reliability
Confidential Property of AVEVA Group plc.
Presented by: Xavier Marfa, F&B Business Development Manager EURA
The Value Driver for Digital Transformation in F&B/CPGValue Propositions across the operational cycles; the production cycle, the assets cycle and the
product cycle
Energy Management & SustainabilityReduce carbon and water impacts, adopt sustainable practices
Improve Operational PerformanceImprove productivity and remove all the wastes from your processes
Improve Asset Performance & ReliabilityReduce Capital and Operation Expenditure needs
Increase Recipe AgilityMeet demands with the right products at the right time
Safety, Quality and ComplianceProtect both consumers and shareholder value. Reduce risk and costs of
compliance and non compliance
• Asset (Visibility): Strategize/Design, Monitor, Analyze, Maintain• Production (Velocity): Prepare, Operate, Inform• Product (Variety)
Improve Asset PerformanceSmart Manufacturing, Smart Supply Chain
• Provides capability for data capturing,
production delay analysis with reasons and
root cause analysis
• Reduction in unplanned outages/downtime
• Improve performance and adherence to plan
• Deliver sustained asset production
performance improvements
• Defer or eliminate capital investment in new
assets (“sweat” the assets)
Business Value:
Our solutions are designed to help to increase
plant performance and asset utilization through
manual and automatic manufacturing equipment
event data collection, efficiency monitoring and
utilization analysis
• Enterprise Asset Performance Management
(eAPM)
• Line Performance / Insight Performance
• Advanced Process Control (APC)
Asset performance: Maintenance strategy is keyPrioritize improvement opportunities and apply the right optimization strategy
Risk-based
Condition
Preventive
Predictive
Pre
sc
rip
tive
Information
The Digital Asset Vision
Looking back…
Model T Ford Toyota Production System
Mass Production
Lean Manufacturing
• Identify “muda” using Value Stream Map
• 5S, SMED, TPM, CI, Deming Cycle…
The Origins of Total Productive MaintenanceThe demands for predictable machine performance in Lean
Manufacturing led to the development of TPM.
Early on, the people at Toyota must have realized that many quality
problems and setup problems originated in poor maintenance
OEE
Overall Equiment Efficency
Targeting OEE – Overall Equipment EffectivenessMeasuring productivity – identifies the % of manufacturing time that is truly productive
Available time
Running timeAvailability
losses
Theoretical Output
Actual OutputPerformance
Losses
Actual Output
Good ProductQuality
Losses
A
B
C
D
E
F
Ava
ilab
ility
Pe
rfo
rma
nce
Qu
alit
y
OEE = Availability x Performance x Quality
= (B/A) x (D/C) x (F/E) x 100%
1. Equipment failure
2. Set up and adjustment loss
3. Reduced speed
4. Idling or minor stoppage
5. Defects in process (scrap)
6. Rework
• It measures the effectiveness of the production
operations / equipment utilization.
• 100% means full capacity
Line Performance
• Based on industry-leading Wonderware MES
• Turnkey OEE package
• Integrated Reporting & Analysis
• Whether your role in the orrganisation
provides timely, accurate & relevant
information
• Ensure peak performance, meet your
operational KPIs
• Offers reason codes, loss deployment, root
cause analysis for production losses.
Predefined User Interface
Work order management
• Accessed by Supervisor.
• Work order creation & assignment.
• Work order details – order
number, quantity, status.
Work order execution
• Work order & Event data entry.
• Start & end work order.
• Visibility of work queue and
production history.
Performance Monitoring
• Monitor over a period (hour, shift,
day).
• Utilization events of the
equipment.
• OEE, including Availability,
Performance & Quality.
Predefined reports
Reports Functions
OEE Analysis OEE performance data & trend
Utilization
Timeline
1 glance understanding of
production events
Utilization by
Entity
Details on availability &
performance events
Production by
Entity
Details on quality events
Line Production Production output data & trend
Utilization
Analysis
Root causes of production losses
MTBF Details & nature of unplanned
stops
MTTR Maintenance & repair
performance
• Derived based on Lean manufacturing / TPM practice.
• Save the time of digging and diving into the ocean of data.
• 8 predefined reports including MTBF and MTTR
Pag
e 11
User ExperienceBased on Feedbacks & Optimized by UI/UX Expert
• Line Performance standard contents are improved in look & feel and usability.
• The contents can be configured and used flexibly to form various layouts / views according to
customer requirement
Entity Overview and WO Execution
Confidential Property of Schneider Electric | Page 12
Text: according to attribute
Text: according to attribute
Good Qty
90
Rejected Qty
10Remaining Qty
90
Utilization management
Work Order
Execution
# of
Plants
Complexity/Readiness/Maturity• Assets
• Automation
• Complex process
• Scale
Deploying OEE Solutions
Not easy to Justify Cost &
Effort to Implement MES
OnPrem
Justified
Majority of plants fall
below threshold of either
value or complexity to
justify MES
These are the
companies to
embrace Cloud
solutions
Capability Maturity
Model (CMM) Levels
Deployment Options: FlexibilityOpen and flexible hybrid operating mode offers best of both worlds.
1) Full Cloud
IIoT devices are direct-connected to and
operated from the Cloud (any modules).
2) Hybrid
Some on-premise controls and sources
and some Cloud connected (mixed mode).
3) On-Premise
All controls and software are fully on-
premise. (traditional approach)
Information and Analytics
Application Development Toolkit
Visualization
System Configuration and Standards Management
Real-Time Control and Device Integration
Digital Engineering
Digital Planning and Operations
Digital Asset Performance
Control and Information Management Platform
Industry Value Chain Platform
Information and Analytics
Application Development Toolkit
Visualization
System Configuration and Standards Management
Real-Time Control and Device Integration
Digital Engineering
Digital Planning and Operations
Digital Asset Performance
Control and Information Management Platform
Industry Value Chain Platform
Information and Analytics
Application Development Toolkit
Visualization
System Configuration and Standards Management
Real-Time Control and Device Integration
Digital Engineering
Digital Planning and Operations
Digital Asset Performance
Control and Information Management Platform
Industry Value Chain Platform
Information and Analytics
Application Development Toolkit
Visualization
System Configuration and Standards Management
Real-Time Control and Device Integration
Digital Engineering
Digital Planning and Operations
Digital Asset Performance
Control and Information Management Platform
Industry Value Chain Platform
Page 16Confidential Property of Schneider Electric |
Typically used by Customers…
• Who are looking to reduce infrastructure, cost and complexity
• Who are looking for a standard approach with fast, frictionless
deployment and pay back
• Who have minimal on-site IT presence
• Whose IT department support cloud-based solutions
• Who are focused on visibility and not requiring tight
enforcement of process - looking for standalone
Utilization/OEE solution
Insight Performance - Customer Value
Insight Performance:
Automatic/manual utilization
and efficiency data collection
Real-time Dashboards:
- Equipment KPI’s
- Utilization/Downtime Events
Reporting with drill down
Analyses
- Equipment comparison
- Equipment history
Insight PerformanceBuild on the Insight platform - powered by Wonderware Online
Edge Computing Device
OEE/Performance
Management App
Historize(Process, Utilization &
Production Event Data)
Edge Device
& App Mgt.
Asset
Registry
Analysis &
Analytics(InSight &
SmartGlance)
Smart
Sensor
Automation
Controller
Smart
Sensor
…
Automation
Controller
…
On-Premise
3rd Party
Apps
Insight Performance ModuleThe Offering
Public Cloud
• Cloud-based OEE/Performance Management App
SaaS - Completely managed and maintained by SE.
• Rapid Application Provisioning
Simple onboarding and configuration process.
• Automatic and/or Manual Data Collection
Flexible data collection options.
• Equipment Monitoring
Utilization/OEE dashboard for Operations Personell
• Advanced Reporting & Analytics
Advanced analysis & analytics provided by Wonderware
InSight & SmartGlance
• Utilization & Production Event Historization
Leverages common “Historization” services as already
utilized by Wonderware Online Process Historian
• On Premise Edge Computing
Robust on premise event store/forward capability and
device/sensor connectivity.
Page 20Confidential Property of Schneider Electric |
Best practice of improving operational efficiency at lowest TCO
Benefits of Cloud hosted
Software application:
• Eliminates efforts to
create and maintain an
IT infrastructure
• Faster time to value
• Connect multiple
plants:
- best practice sharing
- makes standardization
easy
- scales from small to large
in storage and
performance
New Belgium Grows
Packaging Performance
to Meet Demand
Client:
New Belgium Brewing
Location:
Fort Collins, CO
Ashville, NC
Closing the Loop:
New Belgium is 4th largest craft
brewer supplying America’s favorite
Fat Tire Ale. Production went from
weekly peak 150K Cases to 200K to
meet growing customer demand.
Results:
We’re Closing the Loop to
help New Belgium Brewing:
• Increase Efficiency
• Improve Maintenance
• Expand Packaging
Capacity
• Avoid New Capital
Investment
Production Volume
33% MorePer week (50K Cases)
20% Increase OEEin 2 yrs
50% LessUnscheduled Downtime
%
• Optimising process operation with conventional control is challenging:
• Time delays prevent accurate adjustment
• Control actions interact with each other
• Disturbances are frequent
• Optimum conditions are unknown
• Lots of manual operation, operator’s experience dependent
• Product quality measurements are infrequent
• Conventional Control works to ensure in-specification product, yet in-specification does not equal to
optimization
• Due to the Conventional Control we need to sacrifice other KPIs to make sure it is in-specification
F&B Industry Pain Points in Process Optimization
APC for F&B – Comparison with Conventional Control
To make it simple:
Takes into account every kind of variables and
parameters which can influence an equipment or
an installation…
in order to understand/modelize process
behavior
And based on this, it is able to anticipate
process reaction due to any perturbation we
can deliver updated signal
Signal is always managed/based on the
difference between measured variable
and setting.
Powder Moisture %
Atomiser current
Air heater steam valve position
Exhaust fan speed
Dynamic Model
of Dryer
Outlet air temperature
Outlet air RH%
Dryer Feed Rate
Inlet Air Temperature
Inlet Air Fan Speed
Fluid Bed Temperature
Fluid Bed Air Flow
These are manipulated
automatically by APC
Controlled Variables (measured)Manipulated Variables
Ambient Air
Humidity
These are monitored and
controlled by Advanced
Process Control, in closed-loopDry Matter
contents
Feedforward Variables
Page 24Confidential Property of Schneider Electric |
APC - Automated Closed Loop Control
• Moves the operating process closer to multiple constraints at the same time
• Allows operation to be closer to operating limits by reducing variations
• Improves quality
• Increases operating profit
Advanced Process Control has two primary
functions:
1. Minimize process variability
2. Consistently push the operating point
towards optimum operating point without
violating product quality
E.g. Dryer:
Maximum product
moisture limit
E.g. Dryer:
Minimum outlet
air temperature
limit
“Normal”
process
variability
Optimum
operating point
Page 25Confidential Property of Schneider Electric |
Advanced Process Control
Maximum unit throughput:
determined by ambient
conditions, feed dry matter,
etc
Favourable swing in ambient
temperature
Operator-preferred
operating point (infrequent
changes, significant
margin)
“Lost opportunity” captured by
Advanced Process Control
Advanced Process Control
operating point (frequent
changes, reduced margin)
Page 26Confidential Property of Schneider Electric |
APC - Challenging the Constraints
Applicable on any process / equipment that has some or all
of the following characteristics:
• Prolonged time delays between action and response
• Slow dynamic response
• Multivariable interaction or constraints
Apply at: milk powder, coffee, tea, eggs, cereal, spices,
flavorings, starch and starch derivatives, vitamins, enzymes,
stevia, nutraceutical, colorings, etc.
All complex regulating
processes with significant
energy consumption
Industrial Oven Industrial Autoclave Grain Drying
Evaporator and Dryers
Pasteurizer
Equipment
Liquid Processing
Solid Processing
Page 27Confidential Property of Schneider Electric |
APC Application in F&B
FrieslandCampina
Optimizes Spray Dryer
Operations
Client:
Friesland Campina
Location:
Netherlands
Closing the Loop:
FrieslandCampina is the world’s sixth
largest dairy company, with an annual
revenue of 11.3 billion euros. With
facilities in 32 different countries,
FrieslandCampina’s products find
themselves in 100 different countries.
They are partnering with us for spray
dryer optimization utilizing our
predictive process control.
Results:
We’re Closing the Loop to
help the FrieslandCampina:
• Improve throughput and
quality
• Maximize production by
minimizing downtime
• Achieve significant year
on year savings
Dryer produces
8 Tonnes/HrOf Product
10% ThroughputAverage increase with zero product
quality violation
Achieved ROI in
< 2 months€
%
Questions?
Page 29Confidential Property of Schneider Electric |