Standardisation for Packagingmachines

Markus Gehrke

Date 14.06.2016

Agenda

Nestlé Packaging Objectives

Nestlé – PackML

Current Condition

What is PackML

Visual Management

PackML Challenges

HMI

Nestlé Packaging Objectives

Standardization of URS for typical machine types

Standardization of URS for Line Integration by System integrators

considering horizontal and vertical communication

Standardization on equipment level

Requirements for OEE- and energy data

Standardization for OMAC PackML and HMI

3

5

Total Cost of

Ownership (TCO)

Mean Time Between

Failure (MTBF)

Mean Time to Repair

(MTTR)

Performance

Cleaning Time

Efficiency

Change Over Time

Planned

Maintenance Costs

OEE

Energy

Consumption

Waste / Material

Losses

Return on Investment

(ROI) / Payback

Typical Machine Purchase Specification

6

Current Condition

So what‘s beenthe problem Joe ?

Oh you know, the „usual“, but Monday was Good!!

I know we could solvethe problems, if weknew where to start

LINE 1

7

Line 1, is a high priority , we have to do something !?!

If only i can find out what theproblem is ..

So what is thisPACKML ?

Pre - PackML

Definition / Explanation

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OMAC:

(Organization for Machine Automation and Control)

The OMAC is a user organization the members of which comprise

End users, OEMs, System Integrators and Technology

Providers.

The majority of these members is working in the food and beverage

industries as well as the packaging sector.

The objective of this organization is to define the necessary

harmonized regulations and standard guidelines in order to reduce

the development and delivery times, use the existing resources

more efficiently and at the same time increase the profitability.

OMAC is working on different topics for

Standardization of Packaging Machinery:

Packaging Machinery

PackSoft

PackConnect

PackAdvantage

PackML

Make2Pack

OMAC brought together ..

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# End-Users, # Manufacturers, # OEMs, # System Integrators,

# Technology Providers and # Non-Profit / Government Agency organizations

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Late 1980’s

ISA began with Batch

Control Standardization

Early 2000’s

OMAC began similar journey for

Packing Machine Control

Pre 2003

PACKML v2.2 Released,

10 State Model

2003

First versions of current

template, using S88 11 state

Model

Early 2007

PACKML v3.0 Released,

17 State Model

19902000

2003

2007

2009

Current template, ISA-

TR88.00.02

2008

ISA sanctioned PACKML

ISA-TR88.00.02 Released

2008

2009

OMAC / PackML

indentified as possible

solution for Nestlé

2011

2012

2012PACKML prototype

commissioned & unveiled

at PACK-Expo

Late 2013PACKML defined in

Culinary Project

2013

2014

2015

Late 2014Complete HFFS Packing

Line integrated off site

with PACKML

ISA – International Society of Automation

OMAC – Organization for Machine Automation Control

TR – Technical Report

Where did PackML come from?

2011

PACKML line

simulation prototype

2015

Define PackML as

Automation Standard

PACKML Pack Tags

Used to provide data exchange (Interface)

and Reporting

Modes Used to Manage

access levels

Modularity Structured Programming –

Logical grouping of controls

The Four parts of PackML - v3.0 TR88.00.02-2015

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Clear definition of the current

condition of the machine.

States

PackML PackTags - Nestlé Requirement Min. 12 Tags

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PackML_Status

UnitModeCurrent DINT Number of Current Unit Mode in use

StateCurrent DINT Number of Current Model State in use

MachSpeed REAL 1/min Current Machine Speed Setpoint

CurMachSpeed REAL 1/min Current value Machine Speed

EquipmentInterlock.Blocked BOOL Machine blocked in a SUSPENDED state from Downstream event

EquipmentInterlock.Starved BOOL Machine Starved in a SUSPENDED state from an Upstream event

PackML_Admin

ProdProcessedCount[0].Count DINT pcs Total Number of Products through the Machine

ProdProcessedCount[0].AccCount DINT pcs Accumulated total Number of Products through the Machine

ProdDefectiveCount[0].Count DINT pcs Total Number of Defective Products the Machine Processed (Reject Total)

ProdDefectiveCount[0].AccCount DINT pcs Accumulated Total Number of Defective Products the Machine Processed

Alarm[0].ID DINT Unique Value assigned to each alarm, [0] for 1st fault detection,

Alarm[0].Value DINTThe alarm message number is a value that is associated to the alarm

allowing for user specific detail.

(Minumum PackTags v1.0)

EXECUTE

HELD

SUSPENDED

HOLDING

COMPLETING

SUSPENDING

COMPLETE

UN-

HOLDING

STARTING

RESETTING

IDLE

UN-

SUSPENDING

CLEARINGSTOPPINGSTOPPED ABORTED ABORTING

PACKML v3.0

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PackML Model States – Nestlé Requirement 17 States

PRODUCTION

MAINTENANCE

MANUAL (Factory)

MODES are defined to handle the interlocks or accessibility to specific states.

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PackML Modes – Nestlé Requirement 1-10

UnitModeCurrent: DINT

Value Mode

1 PRODUCTION

2 MAINTENANCE

3 MANUAL (Factory)

4 CHANGE OVER

5 CLEAN

6 SET UP

7 EMPTY OUT

8 reserve

9 reserve

10 MANUAL (OEM)

OMAC def.Nestle def.

Level Factory

Level Packing Hall

Level Packing Line

Level Machine

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PackML Modularity – Nestlé Requirement

Film

Forming

Pouch

Forming

Pouch

FillingPouch

Sealing

HFFS

CM_1 CM_2 CM_1 CM_2 CM_1 CM_2 CM_1 CM_2 CM_1 CM_2 CM_1 CM_2

EM_Doser

1

EM_Doser

2

EM_Film

FormingEM_Pouch

Forming

EM_Pouch

Filling

EM_Pouch

Sealing

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Unit / Machine level

Equipment level

Equipment modules

PackML Modularity – Nestlé Requirement

Visual Management – Light treeThe light tree shall be four Lamps and a buzzer

as shown, with the following links applied to

the PACKML Machine states.

14/06/201624 (Light tree V0.54)

Basic physical Operating elements

Light tree:

4 lights + buzzer

3 Buttons:

Start – Stop – Reset

Key – Switch: (Password level)

Access level management

Alternative: RFID

Emergency button:

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Data capture in a transparent way

27

Data capture in a traceability way

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Post – PackML

29

LINE 1

Total Cost of

Ownership (TCO)

Performance

Mean Time Between

Failure (MTBF)

Mean Time to Repair

(MTTR)

Change Over Time

Cleaning Time

Planned Maintenance

CostsEfficiency

OEE

Energy Consumption

Waste / Material

Losses

Return on Investment

(ROI) / Payback

Validated with Real

Data

Consistent Look and Feel

Real / actual data directly from machine

Defines standard information in / out of a machine

Common behavior for “Plug & Play” line integration

Modularity for quicker future development

Decreases debug time

Share data with OEM for feedback to Design

Decrease MTTR

Focused improvement opportunities

Provides the machines with

a Voice to communicate ..

„I was cleaned at 13:45 ! No majorstoppages in production!

Question..

31

So, why not implementPACKML ?

PackML provides a standardized way of operation and

collects uniform data from machines, which will give us real

data of machine stoppages with the actual error or reason

code of every stoppage, helping us to improve machine

analysis, problem solving and ultimately improve Efficiency.

Which is my best Integration Level?

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Challenges of PackML

Agenda

Nestlé Packaging Objectives

Nestlé – PackML

Current Condition

What is PackML

Visual Management

PackML Challenges

HMI

Actual status of individual HMIs for one packaging line...

Elevato

r

Case

r

Coding filing

bagBag filler

VFFSCheck-weigher

Cartoner (CAMA)

Metal detector

Bar code reader Bar code

check

X-ray

detectorInk-Jet

cartons

Metal detector

finish carton

Ink-Jet

case

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HMIs today

Nestlé has around 450 factories in more than 85

countries.

More than 200,000 HMIs are currently used in Nestlé

factories.

More than 70,000 people involved in packaging

operations worldwide.

Each screen has different aspects, and this creates

confusion.

A specific training is required for each equipment,

this costs money and takes too much time.

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HMIs today, background, challenges

Nestlé-HMI-Application Example

47

HMI Implementation based on Nestle-Template

creates a common Look & Feel.

Benefits out of HMI standardisation

HMI harmonization will simplify machine operations.

Screen diagnostics will reduce downtime and improve efficiency.

Reduction of training for Operators, Supervisor and Maintenance.

Easier to operate and more clarity due to harmonized:

style, wording, navigation, alarm handling, ...

Benefits of HMI template:

Will help to understand HMI specification.

Will gide the programmer to use the prepared structure.

Will reduce implementation time.

Easier to maintain the software by using common structure.

Will lead to a common Look & Feel.

48

THANK YOU