Digitalization
in Food & Beverage
Istanbul, May 24th 2017
Heiko Söhner, Siemens AG
siemens.com © Siemens AG 2016
Unrestricted © Siemens AG 2016
Digitalization changes everything Page 2
Unrestricted © Siemens AG 2016
Digitalization in Food & Beverage Industries - 2017 DF FA AS F&B Page 3
New business models in the internet age
are disrupting complete markets
From taxi
to ride sharing
From record store
to streaming
From book store
to e-book
From Yellow Pages
to marketplace
Unrestricted © Siemens AG 2016
Digitalization drives evolution in the Food & Beverage market
and is key to develop new business models
Digitalization in Food & Beverage Industries - 2017 DF FA AS F&B Page 4
Sources: 3) Barclays report, Nov. 2015
• Natural processing vs heavily processed foods
(increasing consumer focus on health and nutrition)
• Fresh products: $600 billion business,
with 30% waste
• Robotics: improve productivity of 25% by 2025(3)
• Huge losses because of product recalls
(~10’ per recall)
F&B market
Consumer driven
innovations
“Free from” for all
Individualization
Fresh, organic, local
Social and demographical structures
E-commerce
New food processing technologies
Technology driven
innovations
“Freshurety”-sensors in process & packaging
Robotics
In-Line quality control & Traceability
• Gluten-free products growing 20%/a since 2014
• Broad market products are becoming rare, large
companies bulking up portfolios with smaller brands
• major packaged-food companies lost $4 billion
market share in 2014
• Table for one
• E-revolution from carts to clicks
Unrestricted © Siemens AG 2016
Ensuring competitiveness in the Food & Beverage industry
requires enormous improvements in all processes
Digitalization in Food & Beverage Industries - 2017 DF FA AS F&B Page 5
Reducing
the time to
market
• Individualization: high
product variety, small
campaigns
• Seasonal demand
Enhancing
flexibility
• Energy efficiency and
resource efficiency
as key competitive
factors
Increasing
efficiency
Increasing
Quality
• Closed loop quality
processes
• Traceability and
integrated genealogy
• Shorter
innovation cycles
• More complex products
• Wider product portfolios
Product and production
integrated
Flexible
production
Full process
transparency
Optimized
production resources
Security
Unrestricted © Siemens AG 2016
Digitalizing the entire enterprise
drive continuous
improvement
optimize
products and
processes
Our holistic approach in Food & Beverage -
A concept addressing the entire enterprise
Digitalization in Food & Beverage Industries - 2017 DF FA AS F&B Page 6
Production
engineering
Production
execution
Services 3 4 5 Product
design
Production
planning
1 2
eliminate silos
drive a tighter
intra-company
collaboration
reuse existing
data
Unrestricted © Siemens AG 2016
Digital Enterprise Suite –
Siemens’ answer to customer requirements
Totally Integrated
Automation
MindSphere
Product Lifecycle
Management
Manufacturing
Operations Management
Teamcenter
Driving the Digital Enterprise for discrete industries
Unrestricted © Siemens AG 2016
Process Simulate
Product design in Food & Beverage Industries
DF FA AS F&B Page 8
Package design
Label design and compliance check Simulation & digital prototyping
SIMATIC IT
R&D Suite
Teamcenter
NX
Product design
Digitalization in Food & Beverage Industries - 2017
Product and formula design
Unrestricted © Siemens AG 2016
Production planning in Food & Beverage Industries
DF FA AS F&B Page 9
Collaborative line design
Capacity simulation and bottleneck elimination
Modeling the production facility
Simulation of critical process steps
Production planning
Comos
Tecnomatix
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Production engineering in Food & Beverage Industries
DF FA AS F&B Page 10
Virtual commissioning
Machine design
Automation engineering
Plant Simulation Process Simulate
Automation Electrical Mechanical
PLCSIM Advanced
Mechatronics
Concept Designer
Automation
Designer
TIA Portal
Production engineering
Mechatronics integration In work
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Virtual Commissioning
DF FA AS F&B Page 11
PLCSim Advanced &
simulation tools
Verify PLC program against
digital twin of the process
Consider “What if”
scenarios
Reduce on site
commissioning time by
commissioning in the office
Safe testing of control
concepts using the model
Prevention of damage to
the real plant
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Production execution in Food & Beverage Industries
DF FA AS F&B Page 12
Process Simulate Reporting & quality execution
Energy efficiency
Order download & scheduling
Line monitoring & optimization
SIMATIC IT
SIMATIC
Production execution
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Line monitoring & optimization
DF FA AS F&B Page 13
Plant wide automation
Standardized interfaces (PDI)
based on Weihenstephan and
OMAC for fast and easy
machine connectivity
Line Visualization (HMI) -
a template-based approach
for immediate line overview
Line Monitoring System
brings transparency through
data analysis tools and
reports KPI calculations e.g.
OEE
Line Control Unit (LCU)
coordination of machines for
optimized line operation
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Plant-wide Automation
Highlights at a glance
Plant Data Interface (PDI) for standardized machine
connection +
Line Control Unit (LCU) balancing machine speeds within a line
for an optimized usage of your line +
ERP connectivity Connects shopfloor
to topfloor +
Line Monitoring System (LMS) brings transparency through data analysis
tools and reports
+
Selected HW & SW Specification template Docu, Whitepaper Standardization Software toolbox
Line Visualization a template-based approach for optimized visibility
+
Energy mgmt. connectivity integrated energy monitoring solution
from machine to ERP level
+
Unrestricted © Siemens AG 2016
Predefined structures created on base of OMAC and
Weihenstephan standards
Enhanced KPI calculations for OEE, energy and
counter/status
The PWA concept was extended with current standards and additional
features to satisfy customer demands.
Easy test of interfaces of connected machines. Open
connection interfaces
Modern and flexible Line HMI based on WinCC
Enhanced KPI calculations for OEE, energy and
counter/status
Unrestricted © Siemens AG 2016
Brownfield Connection Box - installation
No adaption of machine automation systems needed
Adding additional sensors in existing machine or
existing concepts:
No need to access, change/adapt existing automation
solution
Example: light barriers connected to digital inputs to
count total and rejected pieces and calculate the
machine speed
Signal acquisition from existing machine
wiring:
Signals can be retrieved from existing machine
wiring in the control cabinet
Example: light stacks connected with 24V can be
used to detect machine states (e.g. running, stop,
failure…)
Unrestricted © Siemens AG 2016
Process Simulate
Service in Food & Beverage Industries
DF FA AS F&B Page 18
Smart Condition Monitoring
Drive Train Analytics
Energy Analytics
Plant Security Services
Mindsphere
OEM
applications
Service
+
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Mindsphere – Customer example of Cloud Applications
DF FA AS F&B Page 19
Smart Condition
Monitoring (IoT)
150+ embedded IoT
sensors are installed in the
customer plant
The sensors monitor
temperature, vibration and
other telemetrics
Mindsphere collects,
analyzes and reports the
data in dashboards which
allow to detect possible
failures of drives in
advance
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
Industrial Security
Offering from Siemens
Siemens Plant Security Services
Assess
Security
Implement
Security
Manage
Security
Siemens products and systems offer integrated security
Know how and
copy protection
Firewall and
VPN (Virtual
Private Network)
Authentication
and user
management
System
“hardening”
The Siemens security concept –
“Defense in Depth”
VSS Food & Beverage Page 20
Unrestricted © Siemens AG 2016
Only Siemens has solutions across the entire value chain
Digital Production
DF FA AS F&B Page 21
Product
design
1
Production
planning
2
Production
engineering
3
Production
execution
4
Services
5
Digitalization in Food & Beverage Industries - 2017
Unrestricted © Siemens AG 2016
We are driving the
Digital Enterprise together with our customers
Page 22