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Industry Application for Packaging

Industry Application for Packaging. Alex Chia Solution Sales Manager. Industry Application for Packaging – Top 3 Values. Top 3 Values: Increase Line Efficiency/Productivity Faster Changeovers Greater visibility into performance, downtime, problems, state Higher throughput Reduce Costs

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Industry Application for Packaging

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  1. Industry Application for Packaging Alex Chia Solution Sales Manager

  2. Industry Application for Packaging – Top 3 Values • Top 3 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 (1 week) • Quick deployment • Meets needs of Planners, Operators, Supervisors & ‘Reporters’

  3. Wonderware Industry Application for Packaging 1.0

  4. Wonderware ‘Industry Application’? • Industry domain Solutions that accelerate success and reduce risk • Industry Application (in yellow) is a “Product”; • Industry Targeted • Has a life cycle/future versions • Has revenue streams • Is supported Collaboration Framework Information Integration Operations Framework ( e.g. MES/ Quality) Real-time Visibility Intelligence Supervisory Platform

  5. Scope • Targets Packaging Area • OMAC/PackML ready

  6. Current Situation cont. Line 1 OEM 1 OEM 2 OEM 3 OEM 4 SCADA/HMI Control A Control B

  7. Industry Application for Packaging - Built To Succeed • ‘Industry Application for Packaging 1.0 – Standard Edition’ is built on: • System Platform 3.0 (ArchestrA technology) • Wonderware Performance 3.5 • InTouch 10.0 applications • Wonderware Information Server 3.0 • ‘Premium Edition’ release in 2010 • Augments “Standard Edition” functionality with: • Wonderware Operations Software 4.0 • QI Analyst 8.0

  8. Wonderware MES Software Solution Offerings ERP (SAP, Oracle, Microsoft..) Database Applications System Platform LIM Systems Empowering All Roles in the Plant Devices, Applications, Enterprise Integration Asset Management Devices System Interoperability Information / Visibility Real-Time Manufacturing Operations Management Wonderware MES & EMI Software Solutions Packaging Asset Monitoring Enterprise Integration Performance Quality Batch Operations Industry Applications & Industry Packs Clients Microsoft Technology & Industry Standards

  9. 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.,2010’) to Control Systems • On-Line Quality (‘Premium Ed.’,2010) Visualization and Reporting • Connects to Line and Equipment PLC-level information through PackML standard tags

  10. WW 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 • Object Setup Utility • Demo (on VMWare) • Packaged Services (required) • Delivered by Endorsed SI • Finite scope

  11. Industry Application for Packaging - Planner Screen

  12. Packaging Area overview Line 1 Line 2 Line 3 Workorder : WO 001 Workorder : WO 002 Workorder : WO 003 Order Qty : 100 Cases Order Qty : 100 Cases Order Qty : 100 Cases Product : Prod1 Product : Prod1 Product : Prod1 Workorder Status : Started Workorder Status : Allocated Workorder Status : Started Line State : WO Producing Line State : Allocated Line State : WO Producing

  13. Close-up of Line Summary Line 1 Production Alarm Workorder : WO 001 Order Qty : 100 Cases Quality Alarm Good Count : 20 Cases Performance Alarm Product : Prod1 Process Alarm Workorder Status : Started Line State : WO Producing System Alarm

  14. Line Detail

  15. Equipment Summary Filler_001 100 Production Alarm Mode : Automatic 70 Status : Execute Quality Alarm Target Rate : 100 Performance Alarm Actual Cuml Rate : 70 Process Alarm Good Counts : 20 System Alarm

  16. Equipment / Line Faceplate

  17. “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 • Works with Equipment Operations/PEM

  18. 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

  19. Entry-level Features cont. • Support Line Configuration • With Parallel processing (like Labelers) • Line Shared Equipment (like Palletizers) • Pre-configured for three (3) roles • Line Operator • Line Supervisor • Production Planner • Exception management workflows • Email planner if WO done out of sequence • Leading Indicator • Signaling if packaging is falling behind plan

  20. Implementation Services – FIXED Scope Includes… • No PLC configuration • Production counters • Reason codes • By Default • English language • PackML reason codes • PackML tags • Three user types • Daily schedule (CSV/XML format)

  21. What if the customer… ? • Has PLCs that are not OMAC-ready • That’s OK. Incrementally move from manual to automatic data collection • The system supports both scenarios • Needs ERP integration for planned orders • Create orders manually or import from csv or xml • Needs a localized system? • Supported • Needs to extend the system with standards • System Platform allows you to scale users and scope independently

  22. What if the customer…? (cont.) • Has his own OEE calculations… • ‘Industry Application for Packaging 1.0’ does not support custom OEE metrics • Needs to change standard eqpmt graphics? • Only if you follow best practices when upgrading to new versions ($mprocessunit derivation) • Wants to extend the Industry Application? • Supported – both customer and endorsed SI -- by following derivations guidelines and object templates.

  23. Industry Application for Packaging – Top 3 Values • Top 3 Values: • Increase Line Efficiencies (“make do”) • 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 (1 week) • Quick deployment • Meets needs of Planners, Operators, Supervisors & ‘Reporters’

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