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Digital Transformation in Food and Beverage, CPG
Improving Operational Performance
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 Utilization & 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)
Improving Operational Performance
• Reduces production order lead time, Supply Chain
Performance, TTM and adherence to plan (velocity)
• Lowers variance in production results
• Improves compliance and governance
• Improves manufacturing cost drivers:
• Productivity
• Inventory
• Waste
• Enable standardization of global best practices
• Business wide scorecards and KPI’s
Business Value:
Our model-driven software approach reduces
cost and complexity and enables deployment of
standards-based operations across multiple sites
Helps manufacturers manage, execute and
document production operations
• Model Driven MES/MOM
Physical Object Define in detail, various attributes of the object….
Operational Improvement: our approach
Alarms & Events
Logic/Scripting Graphics/Faceplates
Security Historical Data
Metrics/KPIs Operations
Inputs/Outputs Maintenance
Energy
Object
Derive new (multi-level) instances…Object
Library
Equipment
Type A
Equipment
Type B
Equipment
Type A1
Equipment
Type B1
Equipment
Type A2
Equipment
Type B2
Build more complex definitions…
Equipment
Line
Area
Site
Simple
Process
Complex
Process
What kind of a “driver” do I need on the frontlines of execution?
Automation-centric view:
Minimize / eliminate
the human role?
Human-centric view:
Invest / augment
the human role?
Process & People: A culture of empowermentEfficiency & Agility: problem-solving “at-the-source”
Systemic
Problem-Solving
Situational
Problem-Solving
Plan Do Check Act
Detect Understand Decide Act
1
Strategic
Problem-Solving
Now Seconds Minutes Hours Days
Process & People: Operational Excellence Culture of empowerment aligned with company strategy
Filling The Gap Between Plant Systems
Decision to
HOLD
production
Records Downtime
N
Y
MES Maintenance Tech
Notified via SMS
Performs Inspection
and submits report
Supervisor
Notified via SMS
MES
Production Continues
EAM
Maintenance Order
created
PLAN
Planner notified
to update plan
Maintenance Order
sent to tablet
Maintenance Order
completed
Maintenance Order
closed
MES
Operator notified to
restart production
Machine
breakdown
As a business adopts a
more demand driven
approach to production,
and starts to use OTIF
and OEE as measures of
performance, the
synchronization of
maintenance, planning
and operational activities
becomes a driver of
success
The Model Driven Framework: what is different?
Page 9Confidential Property of Schneider Electric |
1. Before the advent of object-oriented design (in the 90s),
software development was time-consuming and its
modeling power was limited.
2. This area represents how Corporate IT systems are
typically bought: a preference for “out-of-the-box” business process
functionality. Flexibility isn’t a priority since standardization meant all
users interacted with the system the same way, with minor variations
addressed via configuration.
3. In contrast, flexibility is paramount on the shop floor since
uniqueness is potentially everywhere: Consider the
combinations of (equipment versions + process recipes + raw material
variations) that they must deal with. Most MES offerings represent a
compromise between the two ends of the spectrum – part packaged
apps, part toolkit (but not fully both.)
4. Model-Driven MES/MOM represents a breakthrough is
because it offers the best of both worlds: The ability to reduce
deployment time by “packaging” client-specific process knowledge and
innovation into reusable templates that can be quickly deployed - and
the flexibility to adapt those templates to accommodate site-specific
needs.Time to Deploy
Development
Environment/Toolkit
Slow Fast
Low
High
Flexibility
Packaged Apps
“Out-of-the-Box”
Pre-
Object-Oriented
Software
Model-Driven
MES/MOM
MES
HMI/ SCADA
ERPCloud-based
ERP12
43
A Model Driven Approach MES
• Cheklist before starting
a WO
• Quality checks
• TPM tasks
Model-Driven Concept supports
• Standardization - provide a single, comprehensive framework for modeling and sustaining operational work processes
• Change Management – facilitate and guide the change management process in a consistent and governed manner
• Innovation – promote operational innovation through continued evolution of work processes
• Total Cost of Ownership (TCO) - reduce the cost and effort to capture and evolve operational work processes
Comprehensive
framework for
modeling &
executing
operational
activities
Operational Activities Framework:
Legacy or 3rd Party
Applications
Events, Data &
Parameters
Plant Model with
superior data
collection &
automation device
integration
Highly accessible
from multiple
computing platforms
iPad Surface iPhoneDesktop
Computing
Devices
Business RulesUser Interfaces
Pro
ce
ss
Mo
de
lP
hys
ica
l M
od
el
Physical ModelUser Interfaces
The Model Driven FrameworkAn approach, not a technology
The Model Driven Approach
1. Digitize
• Assess and document current processes in place along
with touch points to other systems (automation, lab etc.)
• Created needed workflows and user interfaces. Integrate
with MES, System Platform and other systems Digitize
1 2 3Digitize Standardize Improve
Operational processes and
information to enable
efficiency and transparency
Global best practices for a
consistent approach to
compliance and operations
Continuously improve
operational processes and
adapt to changing
requirments
2. Standardize
• Account for needed variations between sites
• Create library of practices that are centrally governed
• Define Performance metrics to be measured
• Build deployable packages and push to the sites
Package of
processes & UIs
V5.1 V2.3
V7.2 Current
Site
Repository
The Model Driven Approach
1 2 3Digitize Standardize Improve
Operational processes and
information to enable
efficiency and transparency
Global best practices for a
consistent approach to
compliance and operations
Continuously improve
operational processes and
adapt to changing
requirments
The Model Driven Approach
3. Improve
• Manage governance of the solution centrally with
remote deployment and support of packages of
process and Uis
• Continuous improvement of processes based on
rich data collection
Change Control
Board
3 Central Baselines
Process & UIs
MES & Master Data
ArchestrA Templates
& Objects
Center of Excellence
Application &
Technical Support
1 2 3Digitize Standardize Improve
Operational processes and
information to enable
efficiency and transparency
Global best practices for a
consistent approach to
compliance and operations
Continuously improve
operational processes and
adapt to changing
requirments
Why Model Driven MES
Model-Driven MES approach mission
1. To extend standard MES operational practices to coordinate people and/or other
applications to deliver broader, more comprehensive manufacturing work process
management.
2. To deliver adaptable commercial MES application models that provide more flexibility in
aligning with customer business practices.
3. To enable corporate entities to digitize plant operational business practices with greater
efficiency, speed and ease.
Almarai Enables Smart
Manufacturing with
Schneider Electric
Page 16Confidential Property of Schneider Electric |
Client:Almarai
Location:Saudi Arabia
Closing the Loop:Schneider Electric supports the world’s
largest vertically integrated dairy
company by adding real-time
intelligence to over 100 packaging lines
to increase performance, efficiency and
agility.
The Manufacturing Execution System
(MES) delivers end-to-end workflow
management to improve operational
excellence as part of a Smart
Manufacturing initiative.
Expected benefits:
• Improved asset utilization and
operational performance
• Enhanced process and product
quality
• Improved productivity and
process efficiency with
increased flexibility
• Standardized best practices
across over 100 production lines
• Platform for data driven
continuous improvement
World’s LargestVertically Integrated Dairy
Company
Increased
Visibility Into operational processes
…model-driven approach helps
accelerate deployment by
standardizing processes with
reusable templates and
integrated workflow”“
Traditional OEE Solution Line Performance
Solution
Definition
Installation & Commissioning
Report Building
Application Engineering of
MES and App Model
MES - Performance
System Platform
InT
ouch
UI
Develo
pm
ent
Definition
Commissioning
Application Engineering of
MES and App Model
MES - Performance
System Platform
Skelta
Model D
riven
Pre
-defin
ed
Config
ura
tion,
Dashboard
s &
UI
Intelligence Server
Pre-defined Reports
Maste
r In
sta
llation
WW Products Customized items Pre-defined/standardized items
• Offering Industrial Solution (Bundle)
• Model-Driven MES solution templates
• User Interface & Business Logic – Workflow
• Web-based application
Why did Almarai Select Line Performance
• Manages and executes production
work orders
• Real-time production & utilization
data collection – manual & automatic
• Provides standard reporting &
analysis capabilities for equipment
performance evaluation
• Integrates & interfaces with other 3rd
party offerings (PLCs, ERP, etc.)
• Rich root cause analysis capabilities
(e.g. data drill-down)
• Handles large volumes of data for
reporting/analysis
• Standard solution package with pre-
defined application content – reduced
engineering
• Extensible application content – can
tailor UI & business rules to meet their
project needs
• Extensible with other Schneider
products
• Easy to install, configure & maintain
• Multi-plant standardization
Page 19Confidential Property of Schneider Electric |
Almarai Project Achievements
Project Rationale:
Improving Overall Equipment
Efficiency (OEE) and Monitoring
of Downtimes
Achievements:
• Online and hourly OEE monitoring helped
improve focus and performance
• Downtime analysis and visibility helped
accelerate root cause identification, corrective
actions and scheduling of maintenance activities
• Provided data and analysis for micro stops
Page 20Confidential Property of Schneider Electric |
Almarai Project Achievements
Project Rationale:
Simplifying Plant Analytics,
KPIs & Reducing Time/Effort to
Access Information
Achievements:
• Key information is readily available to all users
for detailed analysis
• All reports are produced and circulated
automatically - based on lean concepts and
approaches
• Manual data collection has been eliminated –
achieved goal of paperless plant floor
Page 21Confidential Property of Schneider Electric |
Almarai Project Achievements
Project Rationale:
Empowering the Supply Chain
by Integrating with SAP
Achievements:
• Plan Attainment report provides clear visibility of
the hourly run rate against required rate for each
area
• PO production, consumption, waste and sample
quantity count information posted directly into
SAP
Page 22Confidential Property of Schneider Electric |
Downtime Reports
Page 23Confidential Property of Schneider Electric |
MES Reports
Questions?
Page 24Confidential Property of Schneider Electric |