PBWW342 Successful MES Rollout Strategy

1. PBWW342 Successful MES Rollout Strategy Integrated Process Automation & Control Technologies

2. Agenda IPACT has implemented a Wonderware MES 4.0 solution that lowers risk, effort, cost and shortens the time to value for clients: Here is how! • Introduction • Client Overview • Project Overview • Rollout Overview • Conclusions

3. Introduction

4. Background and Overview • A fresh approach to process and project design • Incorporated in 1986 • Located about 40 miles southeast of Chicago in Valparaiso, Indiana • A core group of engineers with an average of 15 years of process experience in a variety of industries • Engineered and installed systems world wide www.ipact.com

5. Background and Overview • IPACT is proficient in process-related disciplines, ranging from mathematical process modeling and control system design to statistical quality control. • IPACT delivers Manufacturing Execution Systems (MES), Product Tracking, ERP integration, Factory Quality Control Systems, Supervisory Control Systems and Process Setup Models. • IPACT executes Manufacturing Assessments, Functional Analysis and Specifications, System Design, Development and Implementation • IPACT can provide staff support for control applications. Business Systems, Finance Systems • Plant floor control through integration to ERP systems Supervisory Control and Manufacturing Information Plant Automation Process Control

6. Background and Overview Certifications and Experience Industries Disciplines Project Engineering Level 1 Automation Level 2 Automation Mill Modeling Statistical Process Control Production Simulation and Modeling Enterprise-wide Integration Motion Control Device Drivers Drives Packaging Material Handling Laboratory Information Systems Manufacturing Execution and Operation Systems Manufacturing Assessment and Consulting Instruction and Training Productivity, Efficiency, Overall Equipment Effectiveness Automotive Food Metals Pharmaceuticals Aerospace Paper

7. Background and Overview Wonderware’s First North AmericaEndorsed System Integrator To achieve MES 4.0 Certification!

8. Client Overview

9. Client Overview • Plants • Make (3) • Package (5) • Initial Plant Lines • Slice (7) • Bar (5) • Shred (8) • Misc (2) • Privately Held Company • Produce Several Premium Brands • Award-winning cheeses • Contract Packager for many channels • Over 60% of all packaged sliced cheese in North America goes through their facilities

10. Client Overview • Client wanted more involvement than typical IPACT customer • Wanted to be involved in the development process • Interest in RAD • Plan to take on system support in-house • What they are: • Experienced, committed engineering and I.T. professionals • Closely linked with operations • Supported at highest levels of management • What they do nothave: • Deep pool of resources • Heavy ArchestrA development experience

11. Goals • Improve yield • Provide visibility of operations and performance • More accurate and detailed tracking (by order) of: • Overall line and equipment efficiency • Product traceability • Product quality and reduce variability • Labor • Trim • Giveaway and Vendor loss • Shrink (scrap) • Packaging Materials Tracking (deferred to a later phase) • Integrate the new MES to the existing SAP • Simplify production reporting • Track and Trace • Performance Measurement – Yield and OEE • SAP updates • Specifically------->

12. Project Overview

13. Scope • Project Scope • Initial effort focused on a Packaging Plant • Included all line types • Slice, Bar, Shred • ReBox, ReWork • Wonderware MES 4.0/Operations and Performance • SAP integration • Control Systems integration • Case and Pallet labeling • Coexistence with legacy SPC system

14. Process • Initial design and development • Generic design that would accommodate future line types • Mock-ups, Weekly Calls, On-site visits • FAT, SAT, Pilots, Commissioning • Remote support • Full simulation environments at customer and IPACT sites • Pilot first line • Refine design based on experience • Rollout additional lines of same type • Simultaneously address refinement of next line type • Repeat!

15. Resources • Project Resourcing • Customer • Project Manager • Systems Engineers (3) • Operations • Supervisors (3) • Line (4 – 5 each) • IPACT • Project Manager • Technical Lead • Engineers • (2) Full-time • (6) Rotating

16. Functional Diagram

17. Architecture

18. Converting Process 600# Cheese Loaves Slices Packages Cases Rework Pallet T T T Cheese is pushed through Harp to make loaves

19. Rollout Overview

20. Rollout Strategy Shred Line 4 Shred Line 5 Shred Line 6 Shred Line 7 Shred Line 8 Shred Line 2 Shred Line 3 Shred Line Pilot Bar Line 4 Bar Line 2 Bar Line 3 Bar Line 5 Re-Box Line Re-Work Line Slice Line 6 Slice Line 4 Slice Line 7 Slice Line 3 Slice Line 2 Pilot Bar Line Pilot Slice Line Slice Line 5 Pilot Slice Line

21. Rollout Strategy 22 Lines 15 Lines 17 Lines 10 Lines 18 Lines Plant 1 Plant 2 Plant 3 Plant 4 Plant 5 12 months 9 months 9 months Constraints: Client Resources, Hardware Modification / Installation, Training

22. Pilot Strategy • Full on-site IPACT support • 5 people for first, 2 for second / 5 people from client organization • Shred lines are significantly different and will require 2 – 3 Resources similarly approximately 3 people from client organization • Appling learning from implementation to implementation • IPACT controlled lines for initial starts • Monitor transactions, signals, operator actions, etc • Minor impact on production schedules • GLC coordination critical • Operational understanding and direction • Operator education and adoption • Site Prep, Logistics, Cut to Production

23. Jan Feb March April May June July Aug Sept Oct Nov Dec 2011 • Site 1 Schedule • Site 1 Schedule • Initial Pilot completed December 2010 • Currently 15 lines operational, 5 different line types • Executing multiple lines per month • Several line start-ups have been executed remotely • Entire plant – 18 lines, 3 types from inception to completion in 18 months • Initial pilot to final rollout - < 12 months Pilot Soak Period Rollout Phase Start Slice Rollout Bar Rollout Shreds Pilot Shreds Rollout Target

24. Keys to Success • Having the right tools / technology • ArchestrA • Galaxy Object Manager • Transaction Simulator • Methodology • Standardization / Abstraction / Documentation • Consistent, Repeatable Process • Change management • People • Customer team engaged • Design, Development, Testing, Implementation, Support

25. The Right Tools • ArchestrA - • Object based, Open Architecture • Galaxy Object Manager – GOM • System Platform and MES 4.0 • Replication • Design Changes What else is there to say?

26. Galaxy Object Manager • Lowers Cost of Implementation Services • How Dramatic? • “Normal IDE” benefit is 25% on lines / plants – 3,4…. • IPACT Model can be as high as 80% • Lowers Risk • Fewer data entry errors • Ability to better handle last minute changes • Lower commissioning effort

27. Galaxy Object Manager • Functionality • Import / Export of entire Galaxy Object Model including: • User defined and third party object • All Templates and Instances • All User Defined Attributes • All I/O Listing • All Scripts • Scripts can be edited and maintained externally with full search and replace

28. The Right Tools • Simulation and ‘Virtual Production’ • Transactional • Test end-to-end, including ancillary systems • Confirms understanding of production environment • Testing and Training • Internal • Given to Customer

29. Methodology • Standardization • Control Level • System Platform Model • MES 4.0 configuration (UCO, OCO) • Abstraction from Equipment • MES PLC • System Platform Modeling for Re-use • Use of templates, inheritance • Up-front design time • Build for extension • Documentation • Configuration Guide

30. Jan Feb March April May June July Aug Sept Oct Nov Dec 2011 Methodology • Consistent Repeatable / Process • Initial design and development • Generic design that would accommodate future line types • Mock-ups, Weekly Calls, On-site visits • FAT, SAT, Pilots, Commissioning • Remote support • Full simulation and test environments both Great Lakes Cheese and IPACT • Pilot first line • Refine design based on experience • Rollout additional lines of same type • Simultaneously address next line type • Repeat! • Each iteration, client took on more responsibility Start Actual Target Bar Rollout Shreds Pilot Shreds Rollout Updated 08/16/2011

31. Methodology Change Management • Management & classification of bugs & enhancement requests • Management and testing of enhancements • Coordination of development system, sandbox system and live system • Implemented in VMware with nearly a dozen different images

32. People • Very strong, well organized client team • Although not very big, deep – very deep in process knowledge • Representing all aspects of organization • Executive Sponsor – support, but removes road blocks to success • Amazing Project Manager – single point of contact • IPACT Team • Great Technical Skills • Good Support from Wonderware • Strong Executive Support • Excellent Project Management

33. Struggles / Challenges • BarcodingSolution needed some configuration memory tweaks • Lack of access to SPC application for original pilot • Equipment Availability for installation and testing • Client’s loss of MES Expert • Client’s expectations (ERP “like”) of implementation • Co-development • On-site development • Rollout • Changing scope • New Line types • Modification of infeed • Equipment OEE versus Line OEE • Simplification of HMIs

34. Conclusions

35. Conclusions • New Paradigm for MES • With the right set of tools, methodology and people, MES implementation can be lower risk, lower cost – shorter time to receive value from the application resulting in higher Net Present Value • MES implementation costs don’t need to be a multiple of software licensing but now can be a fraction of software licensing • Select a Wonderware Endorsed System Integrator with a track record, tools, process and team that help you achieve success

36. Continuing Success • The Best measure of customer satisfaction is interest in working with you on future projects: • Development of an Office of Excellence to provide support and change management • Conveyor Controls Interface • PLC support and Development • New Printer Interfaces • Planning Stages for Subsequent Plants • Beginning engagements in “make” plants