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PBWW224 IntelaTrac Industry Applications Integrating IntelaTrac with TPM. Presented at OpsManage‘11 Presented by Tom Braydich – Campbell’s Engineering Sam Bethea – Campbell’s Reliability November 9, 2011. Invensys Enterprise Control Offerings. Corporate Systems. Industry Solutions
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PBWW224 IntelaTrac Industry ApplicationsIntegrating IntelaTrac with TPM Presented at OpsManage‘11 Presented by Tom Braydich – Campbell’s Engineering Sam Bethea – Campbell’s Reliability November 9, 2011 Invensys proprietary & confidential
Invensys Enterprise Control Offerings Corporate Systems Industry Solutions Services: Consulting, Project Execution, Learning, Operational Improvement, Maintenance & Support Partner Ecosystem Corporate Software Applications Invensys and Third Party Manufacturing / Production Operations Automation Invensys and Third Party Enterprise Control System IT Platform Integration and Collaboration Platform
Where The Offerings We Will Discuss Fit Within TheInFusion Enterprise Control System Execution Integration & Collaboration Platform Enterprise Asset Management Mobile Workforce Management Manufacturing Execution Systems Batch Performance Software Applications Enterprise Manufacturing Intelligence Asset Performance Performance Measurement and Reporting Enterprise Integration Visualization Quality Optimization Workflow Advanced Process Control Simulation / Optimization Design Operator Training Third-Party Offerings Open Device Integration Web Portal Control Automation Software Applications DCS PAC SCADA HMI Application Toolkit Safety Turbomachinery Control Safety Instrumented Systems General Purpose Safety Historian Measurement & Instrumentation Recorders Instrumentation Controllers
Pillars of Operational Excellence and Focus of This Discussion Operational Excellence Level 3 (Multi-plant/Multi-site) Environment And Safety People Level 2 (Plant Floor/Area) Asset Level 1 (Resource/Asset) Control
Introduction page • TPM initiative started in 2005 • Implementing a Centerline Program & a Planned Maintenance Program • Setup and Adjustments • Static and Dynamic Measurement Points • Mechanical Rounds and Operational Rounds • TPM initiative is installed at all Campbell’s Plants World Wide • Intelatrac is used to sustain the gains and to create Trend Capability
Global manufacturer/marketer of: • Simple meals • Baked snacks • Healthy beverages • Nearly $8 billion in sales • Approximately 18,000 employees • 140 year history • Products marketed in over 100 countries 7
Campbell – Key points #1 Soup manufacturer in the world #3 Cookie and Cracker manufacturer in the world More than 18,000 employees around the world #1 Vegetable Juice brand in the world (V8) 94% of U.S. Households have at least one Campbell product #1 Children's Cracker in the world (Goldfish) #1 in Core Categories and segments in core countries
Business Units and Products North America Soup, Sauces, and Beverages
Business Units and Products North America Foodservice
Business Units and Products Pepperidge Farm
OEE Campbell's Reliability Planned Maintenance Focused Improvement Training Early Equipment Management Safety / Health / Environment Autonomous Maintenance 5S Daily Direction Setting and Process Control Systems Process Improvement At Campbell's 2nd Step in the Journey Current Focus Area Process Control - Centerline Autonomous Maintenance Planned Maintenance Focused Improvement 1st Step in the Journey Foundation Initiatives
TPM – IntelaTrac Pilot Why IntelaTrac Short Term Long Term • Centerline is Paper Intensive • Operators need clarity to make decisions • Trend Capability provides opportunity to reduce the grind • Points can be evaluated and eliminated • System could be used for Maintenance Rounds, Steam Traps • Standard Work For Operators • Quality Checks
The Pilot • The Pilot was conducted on Line “A” • Sterilizer • Filler • Bottle Labeler • Case Packer • Palletizer • 5 User System • Out of the Box Functionality was tested • No customization of reports, etc.
Paper Centerline Sample Centerline Sheet
Napoleon Plant Feedback • “Management Visibility; enforce Consistent Performance” • “CL Rounds are Faster, Cleaner, Easier” • “Speed up the feedback Mechanism; Out of tolerance……showing the red flag” • “Process management, already more effective” • “Data can be trended and correlated to improve…”why are we spending more time on one shift than another” • “Users really took to the system, simpler than paper, leads you thru the process, mistakes seen immediately, people will act on it”. • “Using the web reports has provided us good compliance (or in this case lack of) data that we didn't previously have.”
Next Steps • Expanding System to all 5 lines in the West Plant by end of fiscal year • Second Pilot at the Sacramento Plant • Interest in using IntelaTrac for Autonomous Maintenance • Interest from Quality in leveraging IntelaTrac
Example Integration Scenarios • Demand Driven Plant Floor Inspections – Leverage the ability to schedule new procedures as needed for your mobile workforce. • Coordinated HACCP Inspections – Coordinate appropriate resources, enforce the decision making process, communicate the decision back to the stakeholders, update the target applications (e.g. PLM and MES).
Example Integration Scenarios • Lean Manufacturing Procedure Enforcement/Operator Driven Reliability Support – Perform Preventative Maintenance (PM’s) tasks on all types of equipment, and communicate back to the appropriate target applications and stakeholders. • Coordinated Equipment Startup/Shutdown Procedures - Enforce sequencing of work tasks with location verification and access to digital copies of equipment drawings and procedures based on situational awareness. • Etc.
IntelaTrac Future • Schedule a procedure from Workflow • Workflow drives execution of procedures in a sequence • Workflow can suspend, cancel a procedure • Workflow can schedule procedure status change (overdue, etc.) • IntelaTrac can trigger workflow steps