Industry Application for Packaging

Andrea SartoriSolution Architect EMEA

Agenda

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Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging

SummarySummarySummarySummary

Agenda

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Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging

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Industry Challenges

► Cost Controls (Energy, Commodity)

► Demand for New Products

► Global Supply Chain

► Customer Satisfaction

► Quality – Safety, Compliance

Packaging Line Business Case

Source: Packaging World Magazine

Current Situation

1. According to Packaging World Magazine Survey

2. 50 %+ of Packaging lines are not Networked3. 50 %+ of Packaging lines have 2-4 control vendors4. 50 %+ of Packaging lines have between 2-7 machines5. 50 %+ of Packaging lines don’t use standards

6. Many Packaging lines have no data collection

7. Less then 25% of machines are designed for Supervisory systems▪ Data for Supervisory systems is mostly production-related▪ Machine reliability data is available but under-exploited▪ It’s ‘difficult/costly’ for Machine builders to use different control vendors

Current SituationLine

1

OEM1

OEM2

OEM3

OEM4

Control A

Control B

SCADA/HMI

Current Situation cont.

Agenda

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Industry Application for PackagingIndustry Application for PackagingIndustry Application for PackagingIndustry Application for Packaging

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► Targets Packaging Area► OMAC/PackML ready

1.0 Manufacturing Value Chain

1.1Receive 1.2 Preparation 1.3 Batching 1.4 Make Unit 1.5 Packaging Unit 1.6 Ship

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Inventory

Inventory

Inventory

Inventory

Inventory

Stage

Deliver

Deliver

Test

DeliverDeliver

Deliver

Deliver

Pack

Inventory

Batch Mix

Test

Make Unit

Test

Label

Quality Production

Transform

Manufacturing CycleProcurement CycleReplenishment

Cycle

Packaging CycleBatching Cycle Make Unit CyclePreparation Cycle

Days Inventory + Days Payables

Industry Application for Packaging

Industry Application for Packaging Top Values

► Increase Line Efficiency/Productivity▪ Faster Changeovers▪ Greater visibility into performance, downtime, problems, state▪ Higher throughput

► Reduce Costs▪ Less material waste▪ Increased quality, product consistency▪ Greater flexibility (manage many SKUs)

► Fast time to value▪ Quick deployment▪ Meets needs of Planners, Operators, Supervisors & ‘Reporters’

Industry Applications Approach for Rapid Time to Value

► Standard Products▪ System Platform and InTouch Clients▪ Performance & Operations MES▪ Wonderware Information Server

► Pre-defined objects, graphics and tags▪ OMAC-ready▪ Objects Setup Utility▪ Demo (on VMWare)

► Packaged Services (required)▪ Delivered by Endorsed SI▪ Finite scope

Introducing ‘Industry Application for Packaging 1.0’

► Enables Supervisory/MES functions

▪ Basic State Model, • Trending and Visualization

▪ Downtime Tracking, • Visualization and Reporting

▪ Order Management, • Visualization and Reporting

▪ Overall Equipment Effectiveness, • Visualization and Reporting

▪ Product Parameter Download (Premium Ed.)• to Control Systems

▪ On-Line Quality (Premium Ed.) • Visualization and Reporting

► Connects to Line and Equipment PLC-level information through PackML standard tags

“Standard Edition” Features

► Pre-Configured for ▪ PLC PackML tags (or PLC Alias names)▪ OMAC reason codes (or array if non-OMAC)▪ OMAC State Model (or custom model)

► Pre-Configured Line/Equip. User Windows▪ Adding InTouch graphics dynamically

► Data collection automatically detects IO▪ If No IO, Manual entry UI fields auto-enabled

Entry-level Features cont.

► Customer can extend Equipment Classes▪ Extend with specific UDAs

► Planned Orders can be imported/ISA 95▪ From CSV or XML files

► Planned orders can be sequenced▪ With simple priority rules (due date, FIFO, etc.)

► Equipment Mode of Operation tracking▪ Auto, Semi-auto, Manual

► Validated Manual production counts entries▪ Against elapsed time, current count, rates

Entry-level Features cont.

► Support Line Configuration▪ With Parallel processing (like Labelers)▪ Line Shared Equipment (like Palletizers)

► Pre-configured for three (3) roles▪ Production Planner▪ Line Supervisor▪ Line Operator

► Exception management workflows▪ Email planner if WO done out of sequence

► Leading Indicator▪ Signaling if packaging is falling behind plan

Addressing bothCustomer and OEM needs

OEMRank

Buyer Rank

Industry Application

Ability for maintenance to maintain/diagnose any controls systems 1 1

Ability to access machine diagnostic data 2 2

Ability to have a consistent software structure in all packaging machines regardless of the OEM 3 4

Ability to connect all sensors actuators/controllers within a packaging machine by using an industry-standard network 4 5

Ability to create applications from a library of reusable software modules 5 9

Ability to access product performance data 6 3

Having a standard/consistent machine state operating model for any/all machinery OEM 8 6

*** Packaging World Magazine/OMAC Survey

What-if ?

► My PLC is not OMAC-ready▪ That’s ok, you can incrementally move from manual to automatic

data collection▪ The system supports both scenarios

► Do I need ERP integration for planned orders▪ No, planned orders can be created manually or be imported from

csv, xml

► Can the system be localized?▪ Yes

► Can I extend the system with my standards▪ Yes, the System Platform allows you to scale users and scope

independently

Excel import utility

Industry Application forPackaging

Area

Line

Equipment

Screen Example – Overview

Screen Example - Line

Screen Example – State Model

Screen Example – Performance

Summary

► Industry pressures▪ Cost, Energy, Engineering Efficiencies

► Wonderware Solution▪ Industry Application for Packaging

► Fast time to value▪ Quick deployment▪ Meets needs of Planners, Operators, Supervisors &

‘Reporters’

Software Solutions for Real-Time SuccessSM