02 plant it_line management systems for filling and packaging plants_michael sembenotti_20140402_ism_2014

certified by experience

© 2013 ProLeiT AG

Line Management Systems

for filling and packaging plants

Plant iT LMS


2

Plant Acquis iT

Extract from our reference list

Customer Activities

Weser Gold – Plant-wide production data management.

Use of Plant Acquis iT directly by the customer.

Danone – Production data management via Intranet.

HTML-supported efficiency analysis.

Warsteiner – Production data management for four bottling lines, incoming order

processing via Microsoft Excel, Filler Stop Tracker, reporting via interfacing to the

customer's bottling database.

Coca-Cola Germany – Plant-wide production data management for one PET and

one bottling line (new plants) respectively, system retrofit on existing bottling plants.

Grolsch – Production data management for 7 bottling lines, integrated incoming order

processing via SAP, diagnosis (Filler Stop Tracker) and optimization via OEE,

order-related material identification for raw materials and supplies.

Bauer – Production data acquisition for a milk bottling line, with interfacing to the ERP

system. Batch tracking from production and material identification in the line.

Bad Dürrheimer Mineralbrunnen GmbH & Co. KG Heilbrunnen,

Plant-wide use of Plant Acquis iT for bottling lines.

Line Management Systems, 2013


3

Plant Acquis iT

Extract from our reference list

Customer Activities

Friesland Campina – Use of Plant Acquis iT as a Production Management System;

current integration of 13 packaging and 4 preparation lines.

Monitoring of the "Availability", "Performance" and "Quality" indicators, productivity

comparison of the lines via KPIs.

Ur-Krostitzer – Use of Plant Acquis iT as a Production Management System in glass

filling. Fault cause allocation via the Filler Stop Tracker. Plant output evaluation via the

STANLY Status Analyzer. Generation of an order list, including item management with

integrated reporting.

KHS – Worldwide use of Plant Acquis iT as an OEM solution for production data

acquisition in bottling plants.



4

Plant iT LMS

System overview



55

Production data acquisition

Plant Acquis iT - system parameterization

Configuration Manager

Central engineering environment for

the complete system

General administrative information

Archiving and data removal cycles

User administration

Hardware structure of subordinated

control

systems

Messaging structures

Plant specific communication formats

Physical plant structure

Mapping of physical plant structure

by hierarchical arrangement of

location keys

Parameterization of the data points to

be acquired by using a variety of

object types

and allocation to the location keysLine Management Systems, 2013


6

Weihenstephan Standards

History of the ‘WeihenstephanerStandards’ (WS)

WS 2005

General part

WS 2005, Teil 1Physical interface

specifications

WS 2005, Teil 2Specification of the

Interface Content

WS 2005, Teil 3Data Evaluation and

Reporting

WS 2005, Teil 4Approval and Safe

OperationWS 2000

Specifications


2007 extensions with

packaging lines

(during LineMod

research-project)

2010 WS Food interface

contents for meat

processing companies


7

Weihenstephan Standards

Development

Food Production/Bottling Lines, Packaging

Standard interface

• Ethernet network

• Communication instructions

• Testtool

Data evaluation

• Quality assurance

• Batch tracking

• Efficiency analysis

Data points

• Tagname/

number

• Data types

• XML device

description

Machine Controller



88

Detailed view of a filling line with current information on machine states, active

filling orders and production counters

Line visualization

Detail screen filling lines



99

Overview of all lines with current information on machine states, filling orders and

production counters

Line visualization

Overview states and filling orders



10

Analysis of faults

Machine operating states



11

Analysis of faults

State analysis filling line



12

Analysis of faults

Fault analysis

full day

restrict time range

Pasteur valve failure

Time selection



13

Analysis of faults

Detailed downtime analysis

Time range

three days

Line state

Operating: „Filling“

Failure

labellerdowntime



14

Analysis of faults

Detailed downtime analysis

Equipment

failure

line/filler

Bottle washer

Filler stop all

error causes

Filler

Time range

three days



1515

Production reports

Daily report

Quantities (movements of raw material, counter values), limit violations, standard

deviations

Batch report

Article-/ product data, start and end time, filled product (saleable units), QM-relevant

data

Shift report

Filled products per shift, change over times, downtimes, line efficiencies and KPIs,

faults

Filling report

Filled articles per week, accumulated view, comparison week/month/year

Inspection report

Number of test runs/test bottles, detected, sum of ejected goods



16

PDA Krostitzer brewery

Manual input shift report



17


Shift report



18


Report sorting empty goods



19


Inspection report



2020

Management of filling orders

Overview filling orders, grouped by filling line and calendar week

Manual input and corrections

Bill of material

Job list

Example



2121

Start filling order in different order areas

Detailed information e.g. for material provision

Job list

Start filling order



2222

Start filling order in different order areas

Detailed information,

e.g. “Best before”, production counter

Job list

Start filling order on touch panels in the line



2323

Management of Bill Of

Materials based on

Material Master Data

received from SAP

Groupable views of

BOM

Usage of BOM in order

management with

adjustment of

component quantities

Materials management

Parameterization of Bill of Material



2424

1. Scan location (where)

2. Scan material-ID (what)

3. Optional display process

instruction

4. Verify, release and log


Identification - Verification if right material is used?

Example:

Labels

W-LAN

Scanner

Display product-relevant

data (e.g. EAN 128) LMS

Server



2525


Verify packaging material per filling order according to BOM

Confirmation material provision

Display material info for operator



2626

Machine-Stop-Tracker

OEE = Overall Equipment Effectiveness

OEE is a method to understand and improve the behaviour of a process by

evaluation of production stops

Basic OEE formula:

OEE = Availability rate x Performance rate x Quality rate

Process of OEE data evaluation

Define production times in the shift planning

Evaluation of heartbeat signals of the main machine to identify production stops

Assignment of error source and error cause to production stops by manual input in the

Machine Stop Tracker tool

User input of rework amounts as well as changeover timing in the dashboard overview

Store information in the database to calculate OEE rates

Establish statistical OEE – reports and analyses with the web based reporting tool,

order related view of OEE rates in the dashboard overview

OEE



27


OEE calculation overview


Calendar time = 365 days of 24 hours

Company open time

Available time for production

Operational time

Production time

Running time

Nett

running time

Nett

operational time

Useful

operational time

Commercial

stops

Company

closed

Planned

stand still

Routine

losses

Organi-

sational

Failures

Speed

losses

Quality

losses

Rework

Start up losses & rejects

Lower speed

Underutilization / short stops

Technical failures / errors

Starving of basic material / packaging material

Blocking of finished product, no personnel

Change over

Cleaning

Planned maintenance / test

Discussion of progress / training

No orders

No night shift

Weekends / bank holidays

No utilities

Availability

rate

Performance

rate

Quality

rate


28


OEE definition




29


Example: ProLeiT OEE process picture




3030

Classification plant down-times

Assignment error source (aggregate) and error cause

Optional input comments


Assignment



31

OEE Reports

Example: SAB Miller Ulyanovsk



3232

Interfaces to Domino and Videojet printers available

Printer control

Control of printer data in visualization



33

Summary

Vertical Integration – Filling Area

E R P

Filling line

Consumptions 100%

Order data per

batch area

Bill Of Material

Label information

with Start SSCCPLC

BBT cellar

Material Master Data

Bill Of Material

Order data

Pack

Order confirmations

Additional consumptions 100+x%)

Order data

Batch tracking

Actual Quantities (val.)

Machine state

Per batch area

Order state

Cons. counters

Prod. counter

SSCC per pallet

Validation Pack

PLC



ProLeiT AG

Einsteinstr. 8

91074 Herzogenaurach

Germany

Phone +49 91 32 777 0

Fax +49 91 32 777 150

E-Mail [email protected]

Internet www.proleit.com

ProLeiT Group

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Kiev/UA – Mexico City/MX –

Moscow/RU – Piracicaba/BR –

Seville/ES – Shanghai /CN –

Vienna/AT


Presentations & Public Speaking

02 plant it_line management systems for filling and packaging plants_michael sembenotti_20140402_ism_2014