weihenstephan standards for brewing · pdf filein a tree diagram based on ansi/isa-s88 (batch...
TRANSCRIPT
Chair of Food Packaging Technology
TUM School of Life Sciences Weihenstephan
Technical University of Munich
Contact: Raik Bär, M.Sc.
+49 8161 71 3580
www.lvt.wzw.tum.de
www.weihenstephaner-standards.de
Chair of Food Packaging Technology
TUM School of Life Sciences Weihenstephan
Technical University of Munich
R. Bär, T. Voigt
A standardized MES interface for process areas of breweries
Introduction
Breweries have to produce high-quality products at acceptable market prices. In order to
remain competitive, they rely on effective IT assistance for their in-company processes. They
are increasingly using process-orientated production management systems, so-called
Manufacturing Execution Systems (MES). MES closes the gap between the production
level (Process Control System) and the enterprise management level (Enterprise Resource
Planning) and thus enables a vertical data continuity. Exemplary tasks of MES are shown in
Figure 1.
For effective use of MES functions, a data exchange network between all relevant production
facilities and the involved IT systems is essential. However, the connection of the machines,
process control and computer systems is complex. Automation companies use different
communication mechanisms. The availability of data of relevance for the MES varies. In
many cases, no data are available. Therefore, time-consuming definition work and expensive
engineering and programming is required to connect the different systems.
Standard definitions for the communication interfaces, especially the contents of the provided
and acquired data, help to reduce integration problems and save time. This has been proved
for the bottling and packing area – WS Pack (also meat processing - WS Food and baking
industry – WS Bake) by the Weihenstephan Standard concept. In the mentioned application
domains, Weihenstephan Standards provide detailed definitions of the most relevant
production data tags needed for MES implementation. Together with recommendations about
the communication protocol and explanations about data processing to gain MES
information, food and beverage producers, OEMs and IT system providers use them in a
uniform way.
Approach
For the process part of a brewery, standards are missing. The new MES interface will cover
the most relevant process areas, in particular brewhouse, fermentation cellar, filtration and
the related utilities like steam generator or compressed air supply. In order to figure out the
needed data tags a bottom up approach is followed (see Figure 2):
1. MES function description
2. Modelling based upon three founding pillars
• Equipment
• Process
• MES functions
3. Derivation and definition of the relevant data tags
Methods
Within the scope of a research project a representative survey in the form of expert interviews
was conducted. The requirements and needs of the three industry sectors were considered.
Based on the results, relevant MES functions can be derived and an optimal MES for
breweries can be described.
The modelling tool is based on already existing standards. The brewery equipment is pictured
in a tree diagram based on ANSI/ISA-S88 (Batch Control). The process is modeled using
Business Process Modeling Notation (BPMN) and can be divided in a granularity of three
levels. The process can be linked to the equipment and by using standard (mathematical)
templates, KPIs like the brewhouse yield and consumptions (related e. g. on a batch) can be
calculated.
First Results
In cooperation with the project partners relevant MES functions have already been worked
out and are currently formulated and modeled.
One of the most important functions of a MES is the interface between the production and the
enterprise management, in order to enable a transparent and effective production. In
combination with an appropriate communication protocol such as OPC UA, the MES is the
leading IT system to manage and evaluate the production, where all relevant data are
merged.
Project partners
Weihenstephan Standards for brewing processes
Figure 2: Used method to determine MES relevant data tagsFigure 1: Automation pyramid: MES functions in breweries based on [VDI 5600] and [ANSI-ISA S-95]
Tracking and Tracing Process- and product quality Long-term evaluation
Key Performance Indicator (KPI) Energy and media consumption Capacity and states
Detailed scheduling Information management Maintenance
Table 1: Most relevant MES functions in a brewery
Breweries OEMsIT systemproviders