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Plant-wide AutomationTotally Integrated Automation in the Food & Beverage Industry
siemens.comUnrestricted @ Siemens AG 2016
Unrestricted © Siemens AG 2016June 2016Page 2 Joachim Roesler| DF FA AS F&B
Food & Beverage IndustryChallenges are Growing Worldwide
Strengtheningour customers’ competitiveness
Enhance FlexibilityReduce Time to Market Increase Efficiency
• Shorter innovation cycles• More complex products• Larger data volumes
• Reduce energy consumption• Better resource utilization• Higher productivity• High transparency
• Individualizedmass production
• Volatile markets• High productivity
Siemens has the right answers to the challenges of the Food & Beverage industry
Increase Quality
• Closed loopquality processes
• Traceability andintegrated genealogy
• Reliable Processes
Unrestricted © Siemens AG 2016June 2016Page 3 Joachim Roesler| DF FA AS F&B
Totally Integrated Automation –The basis for future industrial concepts
ƒ Consistent datamanagement
ƒ Global and openstandards
ƒ Uniform interfacesfor hardware andsoftware
Customerrequirements
TotallyIntegrated
Automation
IT Level
IndustrialData Management
IndustrialSecurity
SafetyIntegrated
IndustrialCommunication
Integrated Engineering
PLM
Teamcenter / NX
MES
SIMATIC IT
Services
Plant Cloud Services
Unrestricted © Siemens AG 2016June 2016Page 4 Joachim Roesler| DF FA AS F&B
TIA@F&B – Plant-wide AutomationStandards and Concepts for an Entire Plant
Plant-wide Automation
Inbound Process/Production Filling/Packaging Outbound
OEM(Machines)
OEM(Process Unit 1…Machine n)
OEM(Machine 1 … Machine m)
OEM(Machines)
Auxiliary Processes: Energy, Water, Steam, Air, HVAC, …
Plant Integration/Line Monitoring + SCADA
Full MES
Production Line Integrationand Control
Dairy,Ice Cream,
CPG
BraumatBreweryProcess
Automation
NahmatSugar
Solutions
Productionsolutions
Edible OilsAnimal Feed
WinCC SESBakery &Confect.
Entire Production Plant
Tota
llyIn
tegr
ated
Auto
mat
ion
Unrestricted © Siemens AG 2016June 2016Page 5 Joachim Roesler| DF FA AS F&B
Plant-wide AutomationA Modular Approach
Standardized components: Example of a Chocolate PlantMaintenance-Laptop
Power distribution
HVAC
Mixing Milling, Conching Moulding Cooling Packaging
CentralVisualization
WinCC SES(Sequence Execution System)
OEEAnalysis
EnergyMonitoring
Level 4• Energy Management• OEE• Line Monitoring
and Control• Overview Visualization• Diagnosis
Level 1• Hardware• Software
Level 3• Data Interfaces
Level 2• Architecture• Networks
Unrestricted © Siemens AG 2016June 2016Page 6 Joachim Roesler| DF FA AS F&B
Data Interface 2
Machine 1 from OEM x Machine 2 from OEM y Machine 3 from OEM z
PLCHMI
I/O I/ODrivesMotors
LV Sensors
Topo
logy
Topo
logy
PLCHMI
I/ODrivesMotors
LV LV Sensors
PLC PLC
I/O
MotorsDrives
LV Sensors
Data Interface n
Line Overview HMI?????
MotionControl
No Data Interface
• Diversity
• Complexity
• DifficultSystem-integration
• Difficult Diagnostics
• Asset Costs
Plant-wide AutomationStarts with Standardization
Line integration• Energy monitoring• OEE• Line overview• Network diagnostic
Software Toolbox• Data Interface• Application
Machine Architecture• Hardware Standardization• Software Conventions• Machine Topology Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z
Integration
Topo
logy
PLCHMI
I/ODrivesMotors
LV
StandardData Interface
StandardData Interface
StandardData Interface
Topo
logy
PLCHMI
I/ODrivesMotors
LV
Topo
logy
PLCHMI
I/ODrivesMotors
LV
Line Integration
Unrestricted © Siemens AG 2016June 2016Page 7 Joachim Roesler| DF FA AS F&B
ET 200
Plant-wide AutomationScalable Concept from Field up to Factory Supervisory Level
Automation
Network Industrial Ethernet Profinet
MES
LineMonitoringSystem(LMS)
LineControl
Unit(LCU)
S7-300/400
PDI IF
SIMOTION
PDI IF
S7 1x00
PDI IF
3rd Party
PDI IF
3rd Party
PDI IF
UtilitiesBuilding
PDI IF
LineHMI
KPI/OEE/RCA
EnergyMonito-
ring
Data-analysis,Repor-
ting
SIMATIC B.Data
EnergyData
Mgmt.
OrderMana-gement
MaterialMana-gement
ERPconnec-
tivity
SIMATIC IT
WinCC
Unrestricted © Siemens AG 2016June 2016Page 8 Joachim Roesler| DF FA AS F&B
Plant-wide AutomationStep-by Step Approach
Planning
Implementation
Operation
Line Integration
Organization
Architecture
Tools
Consulting to optimize specificationand accomplish standardization
Provide standardized PLC data blocks,HMI libraries and LMS configurations
Implementation support to OEMs
Partner community to support systemintegrators in performing projects
Specific training for operators
Project coordination to seamlessly coordinateOEM – SIEMENS – End User
On-Site support with trained local staffduring commissioning
A |
B |
C |
D |
E |
F |
G |
Unrestricted © Siemens AG 2016June 2016Page 9 Joachim Roesler| DF FA AS F&B
Plant-wide Automation – Line Monitoring SystemThe right functionality for all different users
OEM• Weihenstephan and OMAC integration• Easy-to-use data interface
Engineering/System-Integration• Only one system house for Line Integration projects• From shop floor components through SCADA up to MES integration
Machine and Line Operator• Higher visibility of performance issues• Optimized system support to localize areas of improvement within the line
Line Supervisor/Maintenance• Standardized KPI system for high transparency• Online and offline analysis to understand machine behavior
Top Management• Multi-line performance analysis and benchmarking• Business reporting to support management decisions
Unrestricted © Siemens AG 2016June 2016Page 10 Joachim Roesler| DF FA AS F&B
Plant-WideAutomationoffers
1 | Well-defined interface data blocksfor OMAC and Weihenstephan(including Documentation, Guidelinesand examples for HW and SW)
2 | Templates for Operator Panelobjects and pictures
3 | Support through standardSiemens channels
Plant-wide Automationfor OEMs
How can I simplify the PLC data interface?How can I reuse programs in other machines?
• Quick and easy engineeringof data interface withoutchanges in the machine program
• Implementation with examplesand interface data blocks down-loaded from Siemens’Online Support Internet
• Reduction of test- andcommissioning times
• Support available 24/7
TIA@F&B reduces time and risk tointegrate machines data interfaces
Unrestricted © Siemens AG 2016June 2016Page 11 Joachim Roesler| DF FA AS F&B
1 | Libraries for HMI objectscan be re-used other projects
2 | Easy-to-use configuration toolsfor Line Monitoring System (LMS)
3 | Standard data interfaceensures correct, consistent data
Plant-Wide Automation for System IntegratorsProject delivery with clearly defined value and fixed costs
How can I lower the engineering costs?How can I meet my end customer’s cost and performance targets?
• Configuration tools withimport/export capabilitiesallow to reuse configurations
• Libraries with predefined objectscan be used as templatesfor now or other projects
• Standardization reduces risk andimplementation costs
TIA@F&B supports cost-efficientand reliable implementation
Plant-WideAutomationoffers
Unrestricted © Siemens AG 2016June 2016Page 12 Joachim Roesler| DF FA AS F&B
1 | Detailed real-time informationabout machine downtimes
2 | Online information about pro-duction quantity and quality
3 | Machine information screenswith detailed KPI’s
Plant-wide Automationfor Line Operators
What is the status of my machines?Am I on target with production demands?
Plant-WideAutomationoffers
• Optimized usage of machinesby real-time monitoring ofline and machine status
• Full integration of all datain one system enables operatorsand saves HW costs
• User-friendly interface withstandardized objects
• Fast access to all information
TIA@F&B makes machine and lineoperators more efficient
Unrestricted © Siemens AG 2016June 2016Page 13 Joachim Roesler| DF FA AS F&B
1 | Asset Performance Analysis
2 | Root Cause Analysisto find the real reason for downtimes
3 | Monitoring and extensiveReporting for further data analysis
• Supports the responsible peoplewith all relevant data for fastdecisions
• Easy visualization and lesstime-consuming analysis of KPI’s
• Reduction of downtimes byidentifying root causes andscheduling preventive maintenance
• Predefined and easily to configurereports for detailed analysis
LMS supports efficient and fastanalysis of data
Plant-wide Automationfor Line Supervisors and Maintenance
How can I analyze data from different points of view?How can I find the real reason for performance deviations?
Plant-WideAutomationoffers
Unrestricted © Siemens AG 2016June 2016Page 14 Joachim Roesler| DF FA AS F&B
1 | Multi-Line Analysisbased on customizedScorecards and Dashboards
2 | Detailed Analysisof KPI’s andproduction parameters
3 | Business Reportingto support management decisions
• Business Reporting(integrating data fromshop floor up to business systems)
• Cost control and identificationof cost savings by continuousmonitoring (also in multiple plants)
• Current data also supportsthe investment decision process
With SIMATIC IT you canprepare the right decisions andsupport continuous improvement
Plant-wide Automationfor Top Management
How can I compare different lines with each other?How can I find material-related issues?
Plant-WideAutomationoffers
Unrestricted © Siemens AG 2016June 2016Page 15 Joachim Roesler| DF FA AS F&B
Selected HW & SW Specification templates Guidelines and documents
Plant-wide AutomationSupport and Deliverables
Reduces diversity and complexity inproduction process, filling and packaging
Supports optimization and standardizationof the automation equipment
Network design, Interface descriptions, etc.simplify implementation
Ensures interoperability accordingto international standards
Free of charge downloads for PLC andHMI templates and data interface block
Enables fast, easy andreliable implementation
Standardization Online support Training
Unrestricted © Siemens AG 2016June 2016Page 16 Joachim Roesler| DF FA AS F&B
Plant-wide AutomationBenefits at a Glance
• Reduced diversity inhardware and software
• Less spare parts variety• Lower assets costs• Less training for
operational and service staff• Less energy consumption• Better resource utilization
• Integration of machines/linesin proper network topologies
• Using international standards• Harmonized, OEM-independent
line visualization• High degree of diagnostics• Calculation of KPI/OEE values
to analyze line efficiency• Foundation for MES systems
to support management decisions
• Limited effort and risk of integration(commissioning phase)
• Lowering of “efficiency drop” effect
• Easy and fast service and maintenance• Reduced downtimes
Time
Pro
duct
ion
effic
ienc
y
Field Level
MIS/MES
$Decreasing life cycle costs, while increasing line efficiency!
… reduced life cycle costs … more transparency … increasing productivity
Unrestricted © Siemens AG 2016June 2016Page 17 Joachim Roesler| DF FA AS F&B
Thank you for your attention!
www.siemens.com/food-beverage
Joachim RoeslerIndustry DevelopmentDF FA AS Food & Beverage
siemens.com