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WW OPS-08 : Wonderware ExecutionSolutions for the Food and BeverageIndustry

Tom TroyBill SchielTom Giunta

@InvensysOpsMgmt / #SoftwareRevolution

/Wonderware

/InvensysVideos

social.invensys.com

© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.

Tom TroyBill SchielTom Giunta /Wonderware

/Invensys Operations Management

Introduction of Speakers

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Tom Troy•Director, Operations andExecution Portfolio

Bill Schiel•Director, Global BusinessDevelopment

Tom Giunta•Manager, Food & BeverageBusiness Development

Session Overview

1. Common F&B Initiatives

2. Focus on Packaging

3. Focus on Energy

4. Solution Components

5. How to get started

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*FMCG Companies have many Initiatives!

• Plant Wide OperationalImprovement

• "Make" OperationalImprovement

• "Pack" OperationalImprovement

• TPM- Total ProductiveMaintenance

• Material ManagementImprovement

• PLM to MES Execution

• Utilities/Sustainability/Energy

• Compliance/Food Safety/EHS&S

• Quality Program automation

• Continual Improvement

• ERP Integration

• Business Process Automation

• Multi-Plant Reporting andAnalytics

• Peer System Integration

• LIMS, WMS, CMMS

• Workforce Mobile Enablement

* Fast Moving Consumer Goods includes Food, Beverage, CPG, and many other product categories

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• Plant Wide OperationalImprovement

• "Make" OperationalImprovement

• "Pack" OperationalImprovement

• TPM- Total ProductiveMaintenance

• Material ManagementImprovement

• PLM to MES Execution

• Utilities/Sustainability/Energy

• Compliance/Food Safety/EHS&S

• Quality Program automation

• Continual Improvement

• ERP Integration

• Business Process Automation

• Multi-Plant Reporting andAnalytics

• Peer System Integration

• LIMS, WMS, CMMS

• Workforce Mobile Enablement

Customer Initiative Customer Goal Our Offering- Solution Components NotePlant Wide OperationalImprovement

Improve performance of existing plant assets and capacity.Reduce shrinkage and wasteReduce COGS

Real-time KPIs using IntelligenceMES (all)CEM

Likely need a step-wise approach

"Make" OperationalImprovement

Focus operational improvements in make area includingbatching, mixing, blending, cooking, baking, fermenting

Real-time KPIs using IntelligenceMESBatch ManagementRecipe ManagementFixed and Mobile accessWorkflow

"Pack" OperationalImprovement

Focus operational improvements on fill, pack, and palletize Real-time KPIs using IntelligenceMES

TPM- Total ProductiveMaintenance

The objective of TPM is to maintain the plant or equipmentin good condition without interfering with the daily process.To achieve this objective, preventive and predictivemaintenance is required. By following the philosophy of TPMwe can minimize the unexpected failure of the equipment.

Real-time KPIs using IntelligenceOEECondition Based MonitoringIntegration with CMMSWorkflow

Material ManagementImprovement

Reduce waste and shrink forbulk material receiving, material storage, bi-product bulkload-out, WIP material storage, finished goods.

MES-WorkflowHMI/SCADA

Implement receiving,load-out, internaltransfers inOperations

Corporate Initiatives and Solution Offerings for FMCG

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Implement receiving,load-out, internaltransfers inOperations

PLM to MES Execution Automate the NPI and change management processes Workflow Combination ofEAI for data andhuman workflow forapprovals

Utilities/Sustainability/Energy Reduce energy intensity, water intensity, effluent, solidwaste and emissions. Integrate Co-Gen, solar, wind,biomass

Real-time KPIs using IntelligenceCEM

Compliance/FoodSafety/EHS&S

Automate and integrate SOPs for compliance to internal andexternal regulations

Workflow, IntelaTrac

Quality Program automation Automate and integrate the quality program MES QualityWorkflow, IntelaTrac

Continual Improvement Tools and procedures for Lean, Six-sigma, TPM WorkflowERP Integration Automate interfaces to/from ERP from plant systems

Business ContinuityWEI

Business Process Automation Automate any and all SOPs for any aspect of the operation Workflow, IntelaTrac, MES Operations

Multi-Plant Reporting andAnalytics

Compare KPIs across plants for any measure EMI Intelligence

Peer System IntegrationLIMS, WMS, CMMS

Automate interfaces between systems, including manualactivities

WEI

Workforce Mobile Enablement Provide information access to workers any time and place SmartGlance, IntelaTrac, Intelligenceclient on mobile device, AWF client

Plant Initiatives

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Focus: Packaging OperationsManagement

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What is it?

A turn key solution composed of Wonderware Software, Invensysand Partner Services, Ongoing support, hardware as needed

A highly configurable and modular solution that is designed to bereplicated and sustained in multiple plants

Packaging Operation KPIs for equipment, lines, and plants.

Centralized KPIs for multiple plants

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A turn key solution composed of Wonderware Software, Invensysand Partner Services, Ongoing support, hardware as needed

A highly configurable and modular solution that is designed to bereplicated and sustained in multiple plants

Packaging Operation KPIs for equipment, lines, and plants.

Centralized KPIs for multiple plants

What does it do?

Gives Packaging Operation Managers the tools to continuously

improve the performance of their packaging operations

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What kind of results can I expect?

Categories of Quantifiable Improvement• Improved throughput of xx%

• Reduced Packaging material waste

• Reduced use of Cleaning chemicals

• Reduced Lost product or shrinkage

• Increased Energy efficiency

• Reduced Water waste

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Categories of Quantifiable Improvement• Improved throughput of xx%

• Reduced Packaging material waste

• Reduced use of Cleaning chemicals

• Reduced Lost product or shrinkage

• Increased Energy efficiency

• Reduced Water waste

How does it do this?

Connects to key equipment to measure automatically

• Production counts

• Rejects (by type)

• Error codes

• Operating variables

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Connects to key equipment to measure automatically

• Production counts

• Rejects (by type)

• Error codes

• Operating variables

And then…..• Provides information to Baseline current performance and spot opportunities

to improve

• Real-time view of Performance KPIs including OEE

• Monitor for problems and alert those who need to know

Prevent Mistakes by guiding line operators through procedures

including:

• Changeovers

• Replenishment

• Line Startup

• Line Shutdown

Manages Production Problems through Workflows defined by you

• Equipment breakdown

• Process out of control limits

• Quality out of control

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• Provides information to Baseline current performance and spot opportunitiesto improve

• Real-time view of Performance KPIs including OEE

• Monitor for problems and alert those who need to know

Prevent Mistakes by guiding line operators through procedures

including:

• Changeovers

• Replenishment

• Line Startup

• Line Shutdown

Manages Production Problems through Workflows defined by you

• Equipment breakdown

• Process out of control limits

• Quality out of control

Who Uses this solution?

Plant leadership team

Production Manager

Scheduler

Shift Lead

Area operators

Utilities manager

Accounting

Maintenance

Process Engineering

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Plant leadership team

Production Manager

Scheduler

Shift Lead

Area operators

Utilities manager

Accounting

Maintenance

Process Engineering

How do you get started?

Send an email to marc.vermette@invensys.com to schedule aconversation with one of our solution specialists.

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Focus: Energy Management

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What is it?

A turn key solution composed of Wonderware Software, Invensysand Partner Services, and Ongoing support

A highly configurable and modular solution that is designed to bereplicated in multiple plants

Energy Performance Indicators for:• Level 1: Primary Utilities at Plant Level: Electricity, Gas, Water, Fuel

• Level 2: Conversion of Level 1 to plant services: steam, compressed air,refrigeration, vacuum, purified water

• Level 3: Consumers of services. Make process, packaging, sanitation

• Level 4: Waste streams. Effluent, emissions, solid waste

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A turn key solution composed of Wonderware Software, Invensysand Partner Services, and Ongoing support

A highly configurable and modular solution that is designed to bereplicated in multiple plants

Energy Performance Indicators for:• Level 1: Primary Utilities at Plant Level: Electricity, Gas, Water, Fuel

• Level 2: Conversion of Level 1 to plant services: steam, compressed air,refrigeration, vacuum, purified water

• Level 3: Consumers of services. Make process, packaging, sanitation

• Level 4: Waste streams. Effluent, emissions, solid waste

What does it do?

Gives Energy Managers the tools to continuously improve the

energy performance of their operation

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What kind of results can I expect?

Categories of Quantifiable Improvement• Reduced energy/water spend per unit of output 5-25%

• Reduced demand charges/penalties

• Reduced effluent charges/penalties

• Direct rebates from energy suppliers and energy service companiesfor demand-response programs and/or peak avoidance

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Categories of Quantifiable Improvement• Reduced energy/water spend per unit of output 5-25%

• Reduced demand charges/penalties

• Reduced effluent charges/penalties

• Direct rebates from energy suppliers and energy service companiesfor demand-response programs and/or peak avoidance

System PlatformSystem Platform

IAS Historian WIS

DAS-PLC

DAS-Modbus

DAS-BACnet

CEMCEM

EnergyUsage

Database

EnergyUsage

Database

CEMObjectsCEMObjects

InTouchfor real-timeview of energyusage

Information ServerClient for usagereports and analysis

Advanced Analytics Clientfor KPIs

How does it do this?

CEMEnergyBrowserPlugin

CEMEnergyBrowserPlugin

CEMEnergyReports

CEMEnergyReports

CEM EnergyAnalyticsWorkbook

CEM EnergyAnalyticsWorkbook

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System Platform

DAS-PLC

DAS-Modbus

DAS-BACnet

BuildingManagement

System

BuildingManagement

System

Meters for:•Electric Power•Compressed Air•Steam•Water•Gas•Chilled Medium

Meters for:•Electric Power•Compressed Air•Steam•Water•Gas•Chilled Medium

CEM

BACnetLonWorks

PLCDCSPLCDCS

PlantInfrastructure

And then…..

• Provides information on baseline energy usage and cost to spotopportunities to improve

• Real-time view of Performance KPIs including EnPIs (energyperformance indicators)

• Monitor for problems and alert those who need to know

• Allocate true energy usage by department, cost center, etc.

• Manages Energy through Workflows defined by you:• Energy use targets exceeded

• Demand Response

• Peak avoidance

• Staged startups of energy intensive equipment

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• Provides information on baseline energy usage and cost to spotopportunities to improve

• Real-time view of Performance KPIs including EnPIs (energyperformance indicators)

• Monitor for problems and alert those who need to know

• Allocate true energy usage by department, cost center, etc.

• Manages Energy through Workflows defined by you:• Energy use targets exceeded

• Demand Response

• Peak avoidance

• Staged startups of energy intensive equipment

Who Uses this solution?

Plant leadership team

Energy Manager

Sustainability team

Cost Accounting (treat energy as a variable cost)

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How do you get started?

Send an email to marc.vermette@invensys.com to schedule aconversation with one of our solution specialists.

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Solution Components

Products

SupportProductSolution

Infrastructure

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SupportProductSolution

Infrastructure

ServicesCollaborate Delivery

Wonderware MES Software: Operations,Performance, Quality

What it does:• Executes Production Orders at each operation• Directs Operators during the operation• Collects production results, material use, process data• Maintains genealogy of materials, operators, equipment• Executes the Quality plan for a production order

Who Uses it:• Production Operations• Quality• CI teams to meet corporate improvement goals

How it adds value to your operation:• Maximum utilization of plant assets to produce to schedule• Maintains quality and product safety• Produces real-time KPIs to support initiatives

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What it does:• Executes Production Orders at each operation• Directs Operators during the operation• Collects production results, material use, process data• Maintains genealogy of materials, operators, equipment• Executes the Quality plan for a production order

Who Uses it:• Production Operations• Quality• CI teams to meet corporate improvement goals

How it adds value to your operation:• Maximum utilization of plant assets to produce to schedule• Maintains quality and product safety• Produces real-time KPIs to support initiatives

Wonderware Corporate EnergyManagement (aka CEM)

What it does:• CEM reads meters for electricity, gas, air, steam, water, chill, and

effluent• CEM relates energy usage to production output to create Energy

Intensity KPIs• CEM provides cost of energy usage for products, processes,

orders, utilities, cost centers….

Who Uses it:• Plant Controller to allocated the utility bills to departments,

products, cost centers, etc.• Plant engineer to detect energy waste• CI teams and Energy Manager to meet corporate reduction goals

How it adds value to your operation:• Reduce energy component of COGS• Reduce overall energy spend• Avoid demand charges

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What it does:• CEM reads meters for electricity, gas, air, steam, water, chill, and

effluent• CEM relates energy usage to production output to create Energy

Intensity KPIs• CEM provides cost of energy usage for products, processes,

orders, utilities, cost centers….

Who Uses it:• Plant Controller to allocated the utility bills to departments,

products, cost centers, etc.• Plant engineer to detect energy waste• CI teams and Energy Manager to meet corporate reduction goals

How it adds value to your operation:• Reduce energy component of COGS• Reduce overall energy spend• Avoid demand charges

Wonderware WorkflowWhat it does:

• Creates and Executes SOPs and cGMPs that link people,equipment and systems

• Guides the manual activities in your operation with a completeaudit trail- e.g. manual cleaning, line changeover

• Notifies, escalates, gathers feedback, shows instructions andguidance,

• Reports when, who, and what was done

Who Uses it:• Operations to ensure procedures and policies are followed• EHS&S for safety, regulatory compliance, HACCP• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Capture operation best practices and duplicate shift to shift• Measure procedural productivity to identify and remove bottlenecks• Avoid penalties for energy overuse, effluent or emissions,

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What it does:• Creates and Executes SOPs and cGMPs that link people,

equipment and systems• Guides the manual activities in your operation with a complete

audit trail- e.g. manual cleaning, line changeover• Notifies, escalates, gathers feedback, shows instructions and

guidance,• Reports when, who, and what was done

Who Uses it:• Operations to ensure procedures and policies are followed• EHS&S for safety, regulatory compliance, HACCP• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Capture operation best practices and duplicate shift to shift• Measure procedural productivity to identify and remove bottlenecks• Avoid penalties for energy overuse, effluent or emissions,

Intelligence SoftwareWhat it does:

• Pulls data from any data store: Historian, alarms, productionrecords, batch records, energy database, LIMS

• Uses data to compute and display KPIs across all systems• Highlights deviations to standards for materials, labor, quality,

productivity, energy• Allows drill-down for root-cause analysis

Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Unlocks islands of data and creates actionable information• Automated data collection for team meetings, ops reviews• Fast visibility of deviations to enable fast corrective actions

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What it does:• Pulls data from any data store: Historian, alarms, production

records, batch records, energy database, LIMS• Uses data to compute and display KPIs across all systems• Highlights deviations to standards for materials, labor, quality,

productivity, energy• Allows drill-down for root-cause analysis

Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Unlocks islands of data and creates actionable information• Automated data collection for team meetings, ops reviews• Fast visibility of deviations to enable fast corrective actions

SmartGlanceWhat it does:

• Pulls data from any data store: Historian, alarms, productionrecords, batch records, energy database, LIMS

• Stores extracted data in a secure cloud• Displays information in clear, concise reports and charts• Allows sharing of reports and charts through email

Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Authorized users see operational information anywhere, anytime,

on convenient hand-help devices• See deviations soon after they occur when action can be taken to

mitigate• One interface to all data sources

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What it does:• Pulls data from any data store: Historian, alarms, production

records, batch records, energy database, LIMS• Stores extracted data in a secure cloud• Displays information in clear, concise reports and charts• Allows sharing of reports and charts through email

Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain

How it adds value to your operation:• Authorized users see operational information anywhere, anytime,

on convenient hand-help devices• See deviations soon after they occur when action can be taken to

mitigate• One interface to all data sources

Conclusion

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