Download - I40 pack ml at arla foods v8
Industry 4.0 / PackML @ Arla FoodsLenze PackML Webinar / 20th June 2016Arne Svendsen, Arla-IT MES & AutomationReferences: Dennis Brandl, Visionaire/Open StandardsBryan Griffen, Nestlé & OMAC Chair
Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. Industry 4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A
3 May 20233
Who am I ?
1957: Wendelbo1980: M.Sc. EE(P) + Computer Science1980-1991: PLC firmware and SCADA software development1990-2002: CIM-consultant (Computer Integrated Manufacturing)2002 - now: Head of Corporate MES & Automation team
(Part of Arla Global-IT)
Contact: [email protected]: https://dk.linkedin.com/in/arnesvendsen
Arla Foods Introduction
13,500+FARMER OWNERSFROM 7 COUNTRIES
70 Production Sites(EU, US,CHN)
MILK INTAKE12,5+ BILLION KILO
19,000+COLLEAGUES
10 BILLION EUROREVENUE
PRODUCTS SOLD IN100+ COUNTRIES
Our vision: Creating the future of dairy to bring health and inspiration to the world, naturally
Arla Foods Introduction1000’s of Variants - Arla Brands & Private Label
Business EnvironmentCooperative business since 1880
Cooperative dairy business - 1880 -> 2016
Business EnvironmentA global supply chain today
• 70+ Production Sites, 50+ Distribution Centers• Sales worldwide
Business EnvironmentStrategic Focus
• Networked supply chain, fast moving consumer goods/cool chain
• A history of Mergers & Acquisitions• Organic growth is the strategy now• Partnering in Manufacturing &
Distribution
• Core business: Product Innovation, Supply Chain & Distribution
• Non-core: Partnering with specialised service-providers
Agenda
1. Arla Foods - Global Dairy Foods Manufacturer2. Industry 4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A
Industry 4.0 - high levelOne (of many) views
The 1st (Steam) The 2nd (Ford T) The 3rd (www, PC) The 4th Industrial Revolution
Internet of Things (IoT)”DIGITAL”
New Business Models
INDUSTRIAL Internet of Things (IIoT)Digital / Smart ManufacturingINDUSTRY 4.0
The good old www: Internet (of People)
Industry 4.0 - high levelTechnologies – and Connectedness
• (New) Technologies• Connecting Anything• => New Business
Models• Sharing economy• “Everything” as a
service
Connectedness & New Business Models
BILLIONS AND BILLIONS OF DEVICES
• Already there are sites under construction with 500,000 devices
May 25, 2016 12
Reference: Dennis Brandl
INTEGRATION NIGHTMARES• Today the average worker in an modern plant
interacts with over 30 smart devices per day• in the near future this will be over 300 to 3,000
smart devices per worker
• Integration is already the hardest part of any new system
• Over 70% of the effort on a typical project• Just for dozens of systems and hundreds of devices
May 25, 2016 13
Reference: Dennis Brandl
UNINTENDED JOB SECURITY• Be Smart• Or integration will become a generational project
• A 100,000 device refinery takes 5-10 years to get up & running, a 1,000,000 device will take 50-100 years
• Train your kids/grandkids in automation & control
May 25, 2016 14
Reference: Dennis Brandl
BUT STANDARDS WILL SAVE US, RIGHT?
XKCD.COM
May 25, 2016 15
Reference: Dennis Brandl
Agenda
1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A
Mapping to Arla Business needsTODAY: Connected, yet still hard work.
Distribution
CenterDistributio
nCenter
Dairy
DairyDairy
SAP - Business IT system
Mapping to Arla Business needsTODAY: Connected, yet still hard work.
Technologies:- Automation- RFID, scanners- Printers- Wireless LAN
- AGVs- Robots- Inline measure- Analytical dev.
Dairy
Functions:- Prod.Orders- BOM/Recipes- Collect ”all” data
- Traceability- Quality- Reporting- Analytics
DATA
MES
- AGVs- Robots- Inline measure- Analytical dev.
Technologies & Devices- Automation- RFID, scanners- Printers- Wireless LAN
SAP - Business IT system
Mapping to Arla Business needsIn I4.0 terms, the solution is:
Functions:- Core Realtime (remain on site)- Core Non-Realtime -> Cloud- Non-Core function -> ext. Service
FACTORY
Technologies/Sensors/Devices
Arla InternalBIG Data
Arla StrategicInnovation Center
EnergyOptim.
EquipmentOptim.
IT-systemsSupport
NON-coreService
Offerings
ERP
<-Faster Connect
Mapping to Arla Business needsWhat to consider, implementing I4.0
PARTIAL CONCLUSION:• Decision: Which NON-core functions - to be bought as a service• Cloud solutions: Costs move from CAPEX to OPEX• INFORMATION strategy • IT Security
Agenda
1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of
PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A
PackML - A real-world example (1:8)Build faster Packaging lines
ONE Business SolutionERP
ONE Production SolutionMES/Manufacturing Operations Mgmt.
ONE Automation SolutionProcessAutomation
ProductionAutomation
PackagingAutomation
• Adopted ISA95 in 2002 for SAP/MES integrations• Corporate MES-solution, implemented on 50+ sites• ISA88 Library in place for Process Automation• Since 2013, focused on faster integration of
production and packaging lines.
PackML - A real-world example (2:8)Cheese Production Line – example
ON THIS ONE CHEESE PACKAGING LINE: 9 units, from 7 suppliers, from 4 countries
PackML - A real-world example (3:8)The PackML ”USB” connector
• Arla has no large technology center. We build packaging lines, mainly by integrating standard units from our industry
• Challenge is to integrate units into a working line• Faster, faster, faster
LINE Control
PackML
LINE Control
PackML PackML
PackML - A real-world example (4:8)Cheese Production Line – example
PackML as interface to Units
PackMLPackML
PackML - A real-world example (5:8)Making it easy for the operators !
3 May 202328
Packaging Line Implementation – IMPROVED ..
Timeline
AnalysisPhase
Implementation phase
Timeline
ContractSigned
Analysis
Implementation phase
Site Installatio
n
FATtest(s)
Site Installation
SAT test (s)
Improved Production TimeTime to Market
PackML - A real-world example (6:8)Business Value
Success items: Specification (forward to contract) much faster Works across all automation (PLC) platforms Test suitcase for remote FAT testing Data => Business information from day-1 Harmonised Operator interfaces!
OEESEE also ARC article:
PackML - A real-world example (7:8)Business Value
Machine Project Time Cost Prod.TimeSpecification -> Sign Contract ++ +Integration tests (FAT & SAT) ++Training (Operators & Maint.personnel) ++Commisioning (”burn in”) +
Operations (5-8 years ?) Time Cost Prod.TimeMaintenance (time to repair) +OEE / Optimisation +Training (Operators & Maint.personnel) + +Line changes/New units /New products + ++ ++
PackML - A real-world example (8:8)Gathering momentum for PackML
• P&G and Arla Foods offer their company standards documents on OMAC website for unrestricted use (based on OMAC membership)
• Company and platform-independent OMAC Best Practice Guide is in progress. For end-users and Machine builders to get started. Nestlé is actively supporting this as well.
Agenda
1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A
For Industry 4.0 to get successConnectedness need Protocols
Send Mail
Write English
Prequisite:Agree language
Receive Mail
Read English
”The Internet takes care of the rest ...”
For Industry 4.0 to get successWhat the Internet does for you...
An IP adress
PhysicalInfrastructure
WAN/LAN/Wireless
IP Protocol
Mail protocol
Language
An IP adress
PhysicalInfrastructure
WAN/LAN/Wireless
IP Protocol
Mail protocol
LanguageThe Internet
For Industry 4.0 to get successPackML – showing the way !
PackML is a good example of a high level ”DOMAIN” Protocol of I4.0• An agreed common language, and lower levels taken care of
PackagingLine Control
An IP adress
Machine unit
An IP adress
Physical InfrastructureWAN/LAN/Wireless
OMAC PackML
Physical InfrastructureWAN/LAN/Wireless
OPC UA OPC UA
OMAC PackMLIIoT
OPEN Standard ProtocolsPackML in this case
Copyright © 2016 OMAC. All rights reserved.
OMAC - OPC Foundation Collaboration
Bryan Griffen, OMAC Chair
The Need for Standards in Packaging Automation
Wednesday, May 25, 2016
37Copyright © 2016 OMAC. All rights reserved.
Complexity and standards: case study #1
Lack of standard brings complexityto an inherently simple system!
38Copyright © 2016 OMAC. All rights reserved.
Our automation systems are diverse, but must liaise to facilitate integration
• Inside the box certainly needs to be proprietary. Outside the box we need an open standard used by everyone. This will allow:
– Data exchange– Machine interface/coordination– Safety monitoring
• OEMs can simplify integration by eliminating proprietary architectures at the system level, and instead using open standards.
39Copyright © 2016 OMAC. All rights reserved.
PackML is our standard for packaging equipment automation
PackML
States
Execute, Held,Suspended…
PackTags
Which state?How long in state?Alarm Events?
Modes
Producing,Maintenance,Manual
• Packaging Machine Language• Industry standard (ISA TR88.00.02)
40Copyright © 2016 OMAC. All rights reserved.
Collaboration with OPC Foundation to define an open communication protocol
• OPC UA provides a vendor agnostic solution to communicate PackML states, modes and PackTags to any machine
41Copyright © 2016 OMAC. All rights reserved.
Strong, global leadership from member companies drives automation standards across industry
Visit the OMAC website here.
42Copyright © 2016 OMAC. All rights reserved.
Next gen packaging lines will be natively capable of full integration via PackML & OPC UA
PackML
PackML
PackML
PackML
PackMLPackTagsOPC UA
network
Tag Database,Historian, etc.
MES Apps
PackML
Mapping to Arla Business needsOPC-UA – Basic I4.0 Protocol
Manufacturing Execution Processes/Functions ...
MilkIntakeArea
Main ProductionAreas
Filling /PackagingAreas
Semi/FinishGoods WarehouseAreas
OPC UA Basic I 4.0 Protocol
OPC UA
PackML PackMLPackML
I4.0 I4.0 I4.0
ProcessOptimisation
OEEDetailScheduling
Track &Tracing
ProcessOptimisation
OEEProcess
OptimisationOEE
OPC UA
SAP Business SystemData Warehouse
For Industry 4.0 to get successEnd users requirements to I4.0
1. Standardisation bodies (and there are many) must cooperate closely to define generic, OPEN Standards.
2. The end user requirements are: ”any application” to “any device” communication
Wrap-upConclusions
• Industry 4.0 is less about (new) technologies and more about Connecting & New Business Models– and doing it fast, maintainable, upgradable
• PackML is a clear case of Standardisation BenefitsCost reduction, faster projects, harmonised interface, operator efficiency, higher uptime. Its ready – use it!
• I wanted to give you a background for understanding the ”Protocol challenges” of I4.0.(We, the end users, do NOT want to get caught - having to choose between proprietary platform communities in the Manufacturing space)
Q&A
Your are always welcome to contact me at:[email protected]://dk.linkedin.com/in/arnesvendsen
Further studies
47
Arla PackML interfaceOMAC - Organization for Machine Automation and Control
48
Arla PackML interfaceTR88.00.02
Machine buildersUnit control program
TR88 Model
Machine buildersUnit control program
TR88 Model
”Upper IT-system”
TR88/PackML
ISA88/Part-5(Make2Pack)
49
Arla PackML interfacePackML Statemodel
3 May 202350
Arla PackML interface PackML is a part of the Arla standard purchase contract
50
Commissi
oni
ngContract
Time
Overall Interface demandPackML
Specification
Interface details defined
PackML SDS
Specificat
i
onOffe
rHOT
OPac
kML
FAT
PackMLtest suitcase
Arla PackML interface PackML implementation as of 1st of January 2015
Delivery
and
installat
ion
SAT
Valid data from day 1
SETUP
UNIT
TEST SUITCASE• 22 mandatory tests• 3 optional tests
TEST SUITCASE UNIT
52
Arla PackML interface Test suitcase
05/03/2023
Arla PackML interfaceMachine builder training
3 May 202354
• Intro• Arla Foods• Arla Production IT• Arla PackML interface• Arla PackML OEM implementation• Next step (Industry 4.0, IoT...)
Agenda
3 May 202355
Arla PackML OEM implementation PackML State Manager
56
”Upper” IT system
Solution 3
PackML
”Upper” IT system
Solution 2
PackML
Gateway PLC
PackTagsSocket TCP/IP
Socket TCP/IP
”Upper” IT system
Solution 3
Gateway
PackML
Socket TCP/IP
Arla PackML OEM implementation Interface solutions
”Upper” IT system
Solution 1
”Upper” IT system
Solution 1
”Upper” IT system
Solution 2
PackML
PackTags
Arla PackML OEM implementation Interface requirements and Specification for Units - PackML
57
Selected Mark type
Unit type
Connection type Specification in section
☐ Type #1
PackML State model simulator
7 Configuration of PackML State model simulator
☐ Type #2
PackML State model simulator
7 Configuration of PackML State model simulator
☐ Type #3
TCP/IP Socket communication
8 Configuration of PackML unit
Arla PackML OEM implementation PackML “Lite” – type 1 & 2
58
Arla PackML OEM implementation PackML “Lite” – type 3
59
Arla PackML OEM implementation
60
TR88.00.02 specification of minimum set of PackTags
Arla PackMLLine Controller