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DAu konference - september 2013
Sådan sikres ensartet kvalitet i MES applikationer implementeret på 70 Arla mejerier Allan Møller Schmidt, Solution Consultant Arla Foods GBS-IT, MSA
23-09-2013
Tema - Rejse
2 23-09-2013
Agenda
• Introduktion
• Rejsen mod ensartet Arla standard MES løsning
• Hertil
• Fremad
• Arla produktions IT strategi 2017
• Erfaringer / konklussion
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KORT OM ARLA
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Arla i korte træk
5
Medarbejdere: 18.112
Ejere: 12.256
Omsætning: 63 mia. DKK
Produktion i 12 lande
Produkter sælges i mere end 100 lande
Mælkeindvejning: 10.410 mio. kg.*
*Heraf 2.881 mio. kg. der ikke er ejermælk
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Arlas udvikling siden 1970
6
Kilde: Arla Foods, februar 2013
1970 2000 2011 2012
Arlas tre globale brands:
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De tre fokusområder i Strategi 2017
7
Vækst på markeder uden for EU
Udvikle kerneforretningen og de tre globale varemærker
Mere effektiv i hele værdikæden
Kilde: Arla Foods 2013
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REJSEN – TIL NU
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► Proprietary Solutions
PI-PCS … …
SAP Business Connector / XML
MES
System X
Plant A,B,C ..
MES
System Y
Plant M,N,..
MES
System ..
Plant ..
PLC PCS
► Open Standards
SAP R/3
MM – PP-PI – QM
PLC PLC PLC
SAP R/3
MM – PP-PI – QM
MES/PCS
Plant X
MES/PCS
Plant Y
MES/PCS
Plant ..
PI-PCS …
MES/
PCS
…
ISA-95/WBF standard
(B2MML XML)
MOTIVATIONEN for at standardisere
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Energy &
Environ.
Maint. measure
SAP OEE Downtime
Siemens Process
control
IGSS Operator
SW/HMI
Manu-
facturing
Applications
(The MES
area)
Siemens
FIX
SattCon
SattGraph
Siemens
WW IGSS
P-net/Siem.
P-net / ?
Foxb/Siem
Foxboro
Siemens
Foxboro
System landskab i Arla
SattCon
Process optimisation applications
ArchestrA ArchestrA ArchestrA ArchestrA ArchestrA ArchestrA ”Other..”
SITE1 SITE 2 .. SITE ”99”
ISA S95
Weighing systems, Cleaning optimise, Permance & down-time software ETC ..
Online near-infrared instruments & applications
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Arla Produktions Server
Arla Foods’ term for
software og hardware komponenter nødvendige for at kunne levere
MES og SCADA
funktionalitet på en ensartet måde til enhvert mejeri.
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MII
Arla developed component Standard component
MES Web
service
SAP LMS
(MII Client)
Job Queue MES DB
MES 4.0
IAS_Queue
(Object - per entity)
PLC_Queue_Sequencer
(Object)
IAS
IAS_Queue_Sequencer
(Object)
PLC PLC_Queue PEM_Queue
Dispatcher
(Object)
PEM
(Object)
Prod DB
MII Web
service
EMO
(Object)
EMS
(MII Client)
Efficiency DB
IAS/PLC control
modules
Site
DB
RMS
(MII Client)
Recipe
DB
OCO
(Object)
Reporting
System/Program
SCADA objects
Historian
DB
(runtime)
Sporbarhed
OEE
Job afvikling
Recept
His
tori
an
SCADA
Brugerflade (ordrehåndtering, rapportering)
ERP Integration
(B2MML)
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Integration (PackML)
Prod DB MES DB Efficiency
DB Site
DB
Recipe
DB
Historian
DB
(runtime) …
Production Data Warehouse
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Production Data Warehouse
Analysis
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Arla Production Server
Standard information
model KPI
definition Aggregering
Ad hoc
Reporting
KPI
benchmarking Data mining
1 portal til rapporter & analyser
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REJSEN - HERFRA
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Timing
• 2004-2011 Production-IT, meget teknologi orienteret
• Nov. 2011 – Supply Chain Board kræver ny klar strategi
• Det er tid til standardisering på på tværs af Arla Foods
• Strategi proces Jan. 2012 –> Okt 2012: Version 1 godkendes
• ONE Production Solution
• Automation afsnit tilføjes Jun. 2013: Version 2 godkendes
• ONE Automation Solution
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Production
Solutions
Automation
Solutions
Distri-
bution
Forecasting, Planning & Scheduling
Supply Chain Processes:
Farmers
Quality
Manage-
ment
Data coll. &
Labelling
Instru-ment
ON/Atline
Energy
Manage
ment
Data collection
All systems ..
Plant
Mainte-
nance
Data coll. &
Labelling
Auto- mation
Performance
Manage
ment
OEE solution
Auto- mation
Ware-
housing
Ware house
Execution
Robots & AGVs.
Milk
Allocation
& Collection
Production
Manage-
ment
Process Orders
Auto mation
Innovation
Manage-
ment
SPC/ APC
Instru-ment
Production Data Cockpit
Utility systems (energy, air, water, cleaning)
Production IT
Scope for Produktions-IT i Arla Foods:
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Manufacturing Integration and
Intelligence (SAP MII)
Best Practice replikering - ONE Production Solution
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Line Management System
Production Reporting & DWH Warehouse Control System
Automatic Guided Vehicles Control System
Statistical Process Control / Advanced
Proces Control
Energy Data Collection
Invensys Wonderware Archestra platform Human Machine Interface System
Manufacturing Execution System
Database
Printer Interface
Scanner Interface
Weight Interface
Machine Interface (PackML)
Instrument Interface
Recept Management System
Efficiency Management System
Sit
e A
Sit
e B
Sit
e N
Best
Pra
cti
ce R
ep
licati
on
PLC Proces Interface
Best
Pra
cti
ce R
ep
licati
on
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Best Practice Replikering - ONE Automation Solution
Sit
e A
Sit
e B
Sit
e N
Best
Pra
cti
ce R
ep
licati
on
Best
Pra
cti
ce R
ep
licati
on
Scanner interface
Weight interface
Instrument interface
Packaging, Filling & Warehouse Area
PLC Standard Machine
PLC Standard Machine
PLC Standard Machine
Machine interface (PackML)
Process Area
HMI SCADA
PLC
I/O
PLC
I/O I/O
PLC
PLC Process interface
HMI SCADA
Printer interface
Machine Interface (PackML)
PLC Proces interface
Line Master
PLC
WW Intouch
Siemens,
Rockwell
WW Intouch
Siemens,
Rockwell
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Produktions IT Strategi 2017
Our Character (LEAD, SENSE, CREATE)
Strategic ambition
Ensure optimal utilisation of Production IT in Supply Chain
CAPEX project Services
• Master Plans
• CAPEX project
support
• Production IT project
managers pool
1 24x7 Solution Care
• IT-Surveys
• Proactive Solution
maintenance
• 24x7 Application
Support
• Shared Services
2 Improvement Services
• OPEX/LEAN support
• SPC/APC
• LRM
• Energy Management
3
ONE Delivery model ONE Production Solution
ONE Automation Solution ONE Funding Model
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5
6
7
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SolutionQA - Mål
• Kvalitetssikring
• Sikre best practices
• Ensartede standard løsninger
• Minimere risiko
• Let at supportere
• Feedback
• Til ”One Production solution” (Arkitekter)
• Til Supplier Relations
• Up-to-date standard
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SolutionQA – Hvornår?
Design review
• FDS review
• Komplekse/strategiske projekter:
Arkitekt på hele vejen
• Tager eksisterende app med i
vurderingen
HOTO review
• Ensartet HOTO proces for
projektoverdragelse til drift/support
• Sikre at den modtagende
organisation er klar til at overtage
projektet
• Site og support
Udfordringen: Kommunikation!
• Internt
• 7 Business Groups på BG-ledelses, mejeri-ledelses og teknisk niveau ( Ca. 70 x 10 personer)
• Arla-IT kolleger( 250 personer)
• Andre centrale funktioner: OPEX, Indkøb, HR, QEHS,..
• Leverandører ( ca. 200 ”relationer”)
• 4 Platform leverandører( SAP, Wonderware, Siemens, Rockwell)
• 8 foretrukne MES/PLC Integratorer
• 10? Turn-key leverandører(Tetra Pak, GEA, SPX, Krones, ..)
• 150+ Udstyrs leverandører/Maskinbyggere (PackML)
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ERFARINGER - KONKLUSION
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Erfaringer
• Multi leverandør setup kræver opmærksomhed
• Det kræver standard løsning for at kunne optimere implementering, drift og support
• ”Kvalitet” dækker både organisation, implementering (projekt) og løsning (funktion)
• Kommunikation tager tid
• Forandring er svært
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