The Journey to More Effective Packaging Automation · The Journey to More Effective Packaging Automation ... Caser Coding filing bag ... ‒A single protocol means less worry about

The Journey to More Effective Packaging Automation

Bryan Griffen Nestlé E&A Engineering Manager

OMAC Packaging Workgroup Chair

The world’s leading nutrition, health and wellness company May 2012

Topics we will cover

• Nestlé: The world’s leading nutrition, health and

wellness company

• PackML: Our packaging automation vision

− The packaging simulation

− Designing a more effective HMI

− A specification for everyone

− Our traveling salesman…

• The value and benefits of implementing PackML

• Conclusions

2 B. Griffen May 2012

Nestlé: The world’s leading nutrition, health and wellness company

Our objective is to be recognized

as the world leader in Nutrition,

Health and Wellness, trusted by

all our stakeholders, and to be

the reference for financial

performance in our industry.


Nestlé at a glance: key figures

• CHF 109.7bn sales in 2010

• CHF 34.2bn net profit in 2010

• CHF 16.2bn Group EBIT in 2010

• 281,005 employees

• 443 factories

• Factories in 81 countries

• Products sold in more than 140 countries


1867 1866

1929

1938

1947

1960s

1970s

1980s

1990s

2000s

Henri Nestlé

1866

The Nestlé story – how it all began


http://webappps2.hq.nestle.com/appl_Bcom/Search/shFamilyPreview.asp?BRDSelect=-1&TXTCat=+All&CatId=-1&OTSelect=6&TXTKey=&TXTKey2=&TXTRef=&TXTName=&TXTDesc=&Action.x=44&Action.y=10&GotoPage=2&SO=1&FAM=1220










http://www.buitoni.com/PubAbout/International.aspx


http://www.henniez.ch/qsPortal/Home.asp?N=198&M=160

Nestlé products & brands: instantly recognizable

• 10,000 different products

• Around 1 billion products sold every day

• A product for every moment of every day, from

morning to night and from birth to old age


THE JOURNEY BEGINS… PACKAGING SIMULATION LINE


A brief history of automation and packaging at Nestlé

• Engineering in Nestlé is traditionally process-oriented – we own and

manage our process solutions – We design and automate the key process units

– Rockwell Automation is our solution provider for process automation

• We typically do not own the solutions for the packaging hall – We have a strong focus on materials, aspect and machine capabilities

– No real efforts have been placed on machine automation standards

• Packaging OEMs very often have their own automation platform

specification – Changes to their specified platform increases costs

– No guarantee on performance is given if they must use a different platform

• It is now time to set a new direction…


Goal: Purchase machines from many suppliers around globe

and integrate them to create a packing line system.

Problem:

◦ No software consistency between machines

◦ No software consistency between like machines from same OEM

◦ Horizontal and vertical Integration is difficult and time consuming

◦ Training challenges for operators and technicians.

◦ Hard to troubleshoot

Solution… Embrace & deploy industry software standards

Why doesn’t the manufacturing machine industry have software

standards like the military, IT world, financial industries, etc.?


The Wild West of software

Copyright © 2010 Procter & Gamble. All rights reserved.

Nestlé’s vision for packaging automation

• Support sustainable financial performance through reduced total cost of

ownership and increased automation

• Enhance manufacturing competitiveness by improving OEE

• Optimize the control of packaging equipment through:

‒ Implementation of international standards

‒ Realization of horizontal (line) integration

‒ Providing links to vertical MES/ERP systems

• Improve the operational safety of packaging equipment


The vehicle that will help us realize our vision… OMAC

– Organization for automation and manufacturing professionals, including end-

users, machine builders, and technology providers

– Dedicated to advancing manufacturing capabilities and efficiencies through

identifying common problems, standardization, and improvements to

processes that positively impact the way companies do business

PackML

– Industry standard programming structure that drives a common look and feel

between equipment:

– Defines operational state of a machine (State Model)

– Provides for operational modes (Auto, Manual, Jog, Clean Out, etc.)

– Standard information to/from machines (PackTags)

– Modular coding for re-application libraries and diagnostics

– Foundation for horizontal & vertical machine integration


• Industry standard (ISA TR88.00.02)

• Software design methodology that leads to: ‒ Common operational look and feel between equipment

‒ Defines operational state of a machine

‒ Provides for operational modes

‒ Standard information to/from machines (PackTags)

‒ Modular coding for re-application libraries and

diagnostics

• Applicable to other types of machine systems


What is PackML (Packaging Machine Language)

Simulation line layout

Pick and place: Picks up products and

arranges them on a conveyor for the

case packer.

Case Packer: Fills cases with products

and then closes the case.

Case Maker: Erects the case, then

positions the case on a conveyor

ready to be filled.

Wrapper: Places and wraps a quantity

of cartons.

Pick and Place Case Packer

Ca

se

Ma

ke

r

Wrapper

Equipment SensorConveyor


Three-fold target of the first prototype

Validation of the Horizontal Line Integration Concept

1. Use an international standard as the solution (OMAC/PackML)

2. Make equipment coordination without a line integration PLC

3. Demonstrate that multiple automation suppliers can communicate on a single network and protocol


Packaging strategy partners


PackML state model


PackML state model implementation


Ethernet TCP/IP utilizing a Weihenstephan-based structure:

Current status: Machine-to-machine communications

18 B. Griffen

Case Packer Case Maker Wrapper Pick & Place

Ethernet TCP/IP

Status/Cmd

PackTags

Status/Cmd

PackTags

Status/Cmd

PackTags

May 2012

Successful points

Use of an international standard solution (OMAC/PackML)

Coordinated equipment without needing a line PLC

Demonstrated that Rockwell, Siemens, B&R and Schneider can communicate on the same network and protocol

Simulation line conclusion


THE CONTINUING JOURNEY: HMI, SAFETY AND MES


HMI standards are needed to improve operator efficiency Actual status of individual HMIs for one packaging line...

May 2012 21 B. Griffen

Elevator Caser

Coding filing bag Bag filler VFFS

Check-weigher

Cartoner (CAMA)

Metal detector

Bar code reader Bar code

check

X-ray detector Ink-Jet cartons

Metal detector

finish carton

Ink-Jet case

Many current machine interfaces are not user-friendly and add complexity to run machines

22

• More than 200,000 HMIs are currently

used in Nestlé Factories

• More than 70,000 people involved in

packaging operations worldwide

• All screens have a different aspect and

this creates confusion and hinders staff

flexibility

• A specific training is required for each

equipment, this costs money and takes

too much time

B. Griffen May 2012

A standard HMI solution has been developed Packaging and Automation have worked together to define a standard

look-and-feel for operator interfaces


Advantages of using an HMI template: 1. The users interface will be more friendly

2. The operators will be more mobile

3. Gives more diagnostics on equipment

Current status: • Initial HMI specifications is completed

• Currently under internal validation

• Pilot applications are being executed

HMI harmonization will simplify machine operations


Next Steps: • Integration with PackSpec initiatives from OMAC

• Inclusion in the general URS for packaging

equipment sold to Nestlé

Next steps: On screen diagnostics will reduce downtime and improve efficiency


Next steps: One safety standard for the entire production plant

Creating an open safety protocol (similar to the PackML concept) enables

increased productivity for the plant

• Cost reduction

• Less down-time

• Higher productivity

• Easy maintenance

Concept under review


Provide real-time data for:

• Machine/line configuration parameters

• First-fault determination

• OEE calculations

Next steps: Vertical integration into the MES layer


THE PACKAGING USER REQUIREMENTS SPECIFICATION


A general URS with eight modules covers Nestlé’s packaging requirements

1. Procurement module

2. Line integration module

3. Equipment module

4. Safety, health and

environment module

5. Hygienic module

6. General design module

7. Quality module

8. E&A module

- Checklists


A packaging Equipment is composed of 6 important modules

Fully Integrated Packaging

Electrical

Line Integration

MES

PLC

HMI

Safety

Software

& Hardware


Electrical specifications were the basis to start the standardization

Content

• Labeling

• Grounding and shielding

• Wiring

• Buttons and alarms management

• Documentation

Status

• Delivered in September 2011, currently in use for all new machine

specifications

• Used as a check-list during the FAT


Working group :

• Safety, Health and Environment

• Manufacturing Operations

• Packaging

• Engineering

Two tools have been developed :

• Safety specifications

• Safety check-list

Status:

• Safety specifications delivered in November 2011

• Training material currently under development

Safety is a key module for us


Copy of MSC-v01.1 - Machinery Safety Checklist.xlsx

OUR TRAVELING SALESMAN… PROOF POSITIVE FOR PACKML


A physical prototype will help us to validate the line integration model

This platform will be composed of : - Festo modules

- Staubli robot

- 4 vendors PLCs and HMIs (Siemens, Rockwell,

Schneider and B&R)

- 1 SCADA (Wonderware)

Goal of the prototype : - Communicate M2M

- Implement line supervision

- Fully implement OMAC state model

- Evaluate the HMI template

- Implement stoppage reason codes for MES

Timing : - Commissioning in week 21 (this week)

- OMAC line integration implementation guide

(addition to P&G guideline) planned for September


Screen examples of the line SCADA:


VALUE & BENEFITS OF PACKML


OPW directly addresses business drivers


Benefits of PackML for end users

• Benefits of implementing a standard ‒ PackML & PackTags are part of an international standard

‒ Consistent data and control structure to share information both horizontally

(machine to machine) or vertically (machine to SCADA/MES)

‒ Easier line integration and startup

• Enhanced operations ‒ A consistent state model enables common engineering platform for all

machines within a packaging line

‒ Common look and feel for HMI requires less training

‒ Standardized interface and predefined PackTags enables easy integration

with factory standard HMI/MES

• Business benefits ‒ Promotes best-in-class solutions focused on innovation

‒ Reduced total cost of ownership (TCO)


Benefits of PackML for OEMs

• Improved development cycle ‒ Control platform independent, allowing the OEM to select the technology

platform that will best suit their needs

‒ Greater reapplication of reusable, modular programming modules that work

for a variety of End User

‒ Less customized code to test

• Improved customer delivery ‒ Reusability of proven software reduces time to market

‒ Easy integration and startup at customer site, especially when working with

other OEMs and Systems Integrators

‒ Simplified post-sale support due to consistency from End User to End User

• Business implications ‒ Allows for greater focus on innovation & machine capability

‒ Intellectual Property still maintained


Benefits for Systems Integrators

• Reduced engineering effort ‒ Consistent data and control structure for bringing in information from multiple

OEMs and serving it up to End User SCADA/MES systems

‒ Consistency when working with multiple automation platforms and OEMs

‒ Consistent structure enables concurrent engineering

‒ Reusable, modular programming modules applied for a variety of End Users

• Enhanced offerings ‒ Focus on value-added activities such as MES, maintenance tools, etc. instead

of integration concerns

‒ Ability to develop “standardized” integration packages that result in

reapplication of code and bigger margins

• Improved delivery ‒ A single protocol means less worry about start-ups, faster commissioning, etc.

‒ Less service calls for integration concerns that may not have been discovered

during start-up


Benefits for Technology Providers

• Development strategies ‒ Wider range of discrete machine applications by using an industry standard

(ISA TR88.00.02 plus S88 Part 5) instead of a propriety solution

‒ Easy integration of control systems into an existing environment

‒ Reduce the efforts in developing multiple networks and protocols

‒ Concentrate on innovative technologies

• Business implications ‒ PackML standards are becoming widely accepted by End Users, Technology

Providers and OEMs

‒ Show competitive advantages instead of discussing integration issues over

and over again

‒ Open the global market of packaging machines to all Technology Providers

(get rid of the hard specification of one single supplier)

‒ Internal efficiency and consistency when training engineering and customer

support teams, as well as for on boarding of new engineers


What we have learned in our journey

• We believe that we have found a solution to improving the

overall effectiveness of our packaging lines – PackML

• We have shown that horizontal communications can be achieved

with disparate control platforms using PackML standards

• We are building a platform for testing the vertical integration to

the MES systems using PackML standards

• We are fully committed to the PackML strategy, and we are

moving towards specifying this as a required standard from our

packaging vendors

“It’s good to use a common language. Now we can all understand each other.”

– Christian Chatel, Schneider Electric


Thank you for your attention

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The Journey to More Effective Packaging Automation · The Journey to More Effective Packaging Automation ... Caser Coding filing bag ... ‒A single protocol means less worry about