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Cost Effective ApproachCost Effective Approach
for Automation
Packaging Variety is increasing!!!!
Products are short-lived
Drive Technology dominates packaging machine construction
Output cams
gearcouplerMain drive cam diskMechanical solution
Drive Technology dominates packaging machine construction
Motion ControlLogic Control
Technology
Mechatronical solutionvirtual
leading axis motion controlfunctionsMotion Control
servo drivesLogic Control Technology
50 - 70% of electrical equipment in Packaging line is drive technology
The answer: Mechatronic solutions
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From Mechanics to Mechatronics (film)
Example of a mechatronic solutionp"Line shaft" "Shaftless technology"
Mechanics Shaftless technologygy
DisadvantagesMachines are not flexible
AdvantagesHigh productivityMachines are not flexible
Lower qualityRestricted productivity
High productivityHigh flexibilityHigh product qualityMachines can be easilyMachines can be easily expanded
Mechatronics through Motion Control
Motion Control is the complete motion management
for a single or a multiple number of axes within a plant or a machine.
Motion Control System
Motion + PLC +
Motion Control System
Technology Control
&Line Module
Motor Module
Line Module
Servo control
UP
&Motor Module
Servo control
UP
DN
DN
Drive Control Motion Controller
Motion Control Functions
Positioning GearPositioning Gear
Cams Cam switches
Print-marksynchronization
Coupling-in/coupling-out
Motion Control in Packaging
Labeller Blister Pick & Place FillersLabeller
CartonerStretch Wrapper
Shrink Packing Palletizer
Basic Automation Structure for a Machine –A Motion Control System !!!!
M otion ControllerDisplay n n
Com m unicatio Isochronous Com m unication (6 m s
y
Rem oteI/O
Com m unication Bus
Isochronous Com m unication (6 m s)
Drive System �������
M otorServo
y m DP/AS-I
AS Interface
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...Servo M otor Servo M otor
SW GR
InductionM otor
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Tubular bag machine
Example of tubular bag machine
M ti C t l A i i T b lTubular bag machine Motion Control Axis in a Tubular Bagging Machine-The puller / foil feed and the sealer ( X and Y axis ) are driven by servo motors
- The seal has to take place at a specific position on the web and hence print mark correction is required.
- The cross sealer moves to synchronize with the web before it starts the sealing operation.
-While sealing it is important to coordinate with the dosing system ton ensure material falls in the pouch just after sealing starts
-In a nutshell, the sealer , the puller axis are h i d ith t i t l i i th bsynchronised with a master virtual axis i.e the bag
length
The machinery market is in transitionyNew trends are being born
Consumer behavior is becoming increasingly individualChanging forms and designsChanging forms and designsLower production costsImplementing new regulations – e.g. FDA New challenges for packaging machinery construction
Mechatronics
Individual drives
Hi h fl ibilit
Individual drives,intelligent motion
control
Higher flexibility
Short re-equipping times,
ModularizationSimulation
Shorter,online recipe change
Shorter“time-to-market”
T t ll I t t dTotally Integrated Automation
The automation environmentThe automation environmentYesterday
YesterdayYesterdayPCs
PLCs AutomationD iPCs
CentralProcessDistributed
Production
Drives
Safety TechnologySafety Technology
Approaching a solution in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interfaceC
omm
u
Data m
a
Configuring/
Controllers
unications
anagement
/programm
Distributed I/O
Drives / field devices
ing
The end of technology breaks:The end of technology breaks:Totally Integrated Automation
TODAYTODAYtotal
integrationintegration
automation environmentof the entire
of an i ti
integrationof an organization
Approaching a solution in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
Human machine interfaceC
omm
u
Controllers
unications
Distributed I/O
Drives / field devices
Profinet – The Communication Backbone
PROFINET - The Industrial Ethernet Standard for Automation
Data I/O M otion Safety Process
For all applications
For the entire work flow
For all branches
PROFINET -- The open Industrial Ethernet Standard
Open IndustrialOpen
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Approaching a solution in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
Human machine interfaceC
omm
u
Simatic
Controllers
unications
Portfolio
Distributed I/O
Drives / field devices
Vertical integrationERP, e.g. SAP
Management level (MES)
Operation level(SCADA / DCS)
PCS 7WinCC
Control level
Field level
Reduce interfaces & costs of engineeringIncrease the intelligence of the automationOptimize and speed up the production transparency
Horizontal integration
ERPe.g. SAP, Navision, etc
Management Level
Operations Level
MES
SCADAProcess control system
PCS 7
MESSIMATIC IT
Enterprise Asset ManagementPlant Maintenance ManagementPlant Information Management
Supplier
Inboundlogistics
OutboundlogisticsDiscrete
Customer
Process
Control Level
Field Level
Integrated engineering, diagnostics, communication and products
Field Level
Transparent information from the automation systemCost reduction for spare parts and resources
Approaching a solution in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interfaceC
omm
u
Simatic
Configuring/
Controllers
unications
Portfolio
/programm
Distributed I/O
Drives / field devices
ing
Customer requirements for engineering
Market situations and customer requirements go hand in hand
Tasks are growing increasingly complex
The only way to meet these market demands and customer requirements is to integrate and achieve consistent approachesrequirements is to integrate and achieve consistent approaches throughout all automation applications
The response – Totally Integrated Automation Portal
One framework – The total integration of necessary tools and g ytechnologies, such as PLC, HMI and drive technology programming into one single platform
TIA Portal – an engineering framework that will make a differenceg g
The 3 main objectives for TIA Portal were: Intuitive, efficient, proven
Benefits of Totally Integrated Automation Portal
all integrated software products share uniform services provided by the engineering framework
Data consistency through out all editors significantly reduces errors and saves time
a single and consistent look and feel of all software products makes them easier to learn and more intuitively to use
Approaching a solution in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interfaceC
omm
u
Simatic
Configuring/
Controllers
unications
Portfolio
/programm
Distributed I/O
Drives / field devices
ing
I t bilitImprove traceability
Using reliable identification techniquesUsing reliable identification techniques
Challenges and requirements in the market
Comply with legal and consumer protection requirements (e.g. EC 178/2002)
Recall of specific and differentiated range of products
Ensure not to have „wrong deliveries“
Increase protection of public health and safetyIncrease protection of public health and safety
Identify the origin of an individual product/ingredient and to whom a product has been supplied (one up/one down traceability)
Enable unique identification and seamless monitoring of intermediate q gand end products
Brand protection - especially for valuable products in order to avoid counterfeits
Optimization of the production and logistics process
Comply with customs and tax regulations
Ensure trouble-free and traceable cooperation and collaboration between all parties involved, both in-house and with external partners
Pressure of retailers (like Walmart and Metro)
Tracking & Tracing of products along the supply chain – from
Tracking & Tracing (T&T) is the action taken to track and trace products:
g & g p g pp yproduction to the consumer
internally - within the production site and/or externally - along the complete supply chain
FinishedFilli /Raw
ConsumerRetailDistribu-tion
FinishedProduct
Warehouse
Filling/ Packa-
ging
Produc-tion
Raw MaterialIntake/
warehouse
Supplier
ExternalInternalExternalT&TT&TT&T
Forward/Downstream T&T (from raw material to product)
Backward/Upstream T&T (from product to raw material)
T&T is based on traceability-data that is generated during the production process. This data provides information about the genealogy of the product.
Various AutoID technologies are used for the tracking & tracing solution – such as RFID, Data Matrix Code and Bar Code.
The internal T&T starts with the material intake and continues in the &production process
= Affected shipment, raw material, palletInternal T&T -
Raw Mat. Intake/Production
Identification of bad quality in a
Identify all affected shipment units
Starting Point Identification Track forward Block shipment
Identify all affected batches via
Block shipment units still inquality in a
delivered raw material or inter-
mediate product
shipment units (e.g. via pallet
identification)
batches via genealogy (e.g. intermediate products, blending, packaging)
units still in warehouse.
Recall affected deliveries
Affected shipments/raw materials are identified within the production process at the starting-/delivery-point.These raw materials are tracked though the primary and secondary production (e.g. mixing, blending)blending).At the end of the process affected finished products can be blocked in order to avoid their delivery or tracked & traced through the external supply chain.
The product hierarchy is provided through p y p gthe entire internal T&T
* RFID or other AutoID technologies (such as bar code, data matrix code etc.) Internal T&T -Filling/Packaging
(inside)1 AutoID Tag*
package
Packaging machine 4
Read pallet at thegoods issue
AutoID Tagon the package
Shipping gate
g g g
goods issue and create ASN
g
Combine packagesto a case with an AutoID Tag on
2
with an AutoID Tag
Combine cases to a pallet
3
the secondary package with an AutoID Tagon the pallet
The T&T solution does consider all product hierarchies from the single item to the pallet.pallet.The product-hierarchy functionality is not limited to the filling/packaging process but applicable within the entire T&T.
External T&T provides the traceability of products
External T&TSupply Chain
& p y pwithin the supply chain
pp y
ExternalT&T
InternalT&T
ExternalT&T
Identification of bad quality in a delivered raw material or inter-
mediate product
Identify all affected
shipment units
(e.g. via pallet identification)
Starting Point Identification Track forward Bloc shipment
Identify all affected filling batches via genealogy (
Block shipment units still in warehouse.
Recall affected deliveri
Suppliers RetailWholesaler
es
ID Points
AutoID Identification points (e.g. at supplier, wholesaler, retail) provide data for the T&T along the supply chain.The data captured at the ID points can be provided to the manufacturers ERP system of the manufacturer in order to have a complete internal and external T&Tmanufacturer in order to have a complete internal and external T&T.
Track and Trace Packing Line – OPL Architecture
Plant Line – Server Li HMI
OptionalExternal Line Overview INTERNET
Line HMI Access
EngineeringStation
Diagnosis-Maintenance Station
Overview Station
Mobile Overview Station
Panel PC6x7B Touch, 15" WinCC SingleStation
WinCC/ Web NavigatorBackup&Recovery ADDM
SIMATIC PGEngineering Software
High Performance Wireless PCWinCC Web Client SCALANCE
SecuritySwitch
SCALANCE S
CC S g eS a o Engineering Software
SCALANCE X414-3
Line SwitchWinCC Web Client SCALANCE
W788
Labeler Palletizer WrapperFiller TopConveyorBeverage Proc
Local HMI Panel
Machine PLC
Panel PC6x7BWinCCflexible
Panel PC6x7BWinCCflexible
TP177BWinCCflexible
Microbox PC420+
CPU315-2PN
CPU319-2PN
CPU319-2PN
CPU315-2PN
CPU319-2PN
Panel PC6x7BWinCCflexible
SCA-LANCE X204-2
Machine Switch
Sub Machine Motion Control
Microbox PC420+FlatPanel,WinCCflexibleSIMOTION D445
ET200S CPU
RF180CPROFINET
Connection block
MV4401D/2D-reader,IP65
e.g. RF620RRFID readerRead/write distance 2 m
Track & Trace solutionTrack & Trace solutionLine controller package – already available
Track & Trace controller box10,4 or 15” Touch Panel Ethernet NetworkTrack & Trace controller box
Power
I/OController
10,4 or 15 Touch Panel
Power Supplyfor Controllerand Devices
Ethernet NetworkSite Level
..... . ..
Supply
e.g. PROFIBUSOptionally:Additionally signals
Packer I/O
LabelApplicator
Output LabelApplicatorRFID or
C
DMC reader or Barcode
Connected viaBluetooth / USB
to CMC Controller
Packer I/O
e.g.PROFINET
These devices can also be
t d t
F h l l b dl t f th T&T li t l b d!
Handheld Reader(optionally)
Applicatorand Printer
Input LabelPrinter / Applicator
Applicatorand Printer
Output Label Printer / Applicator
DMC reader
Input Reader
or Barcode Scanner
Output Reader
connected to an existing PLC!
For each level, e.g. bundle to case, one of these T&T line controler can be used!It is also possible to connect all reader of a complete line to one controller with one HMI
Use Cases and TasksUse Cases and Tasks
Read DMCon item level (single DMC)on bundle/case level (single or bulk DMC)on palette level (single DMC)
Reading a DMC is done on each level. Highest speed the packaging machines have on item level with a maximum speed of 400 items / min. OEMs have machines, that are much faster, but this high speed is not used by the pharma end customers
Trace production
The difference of reading and verifying is
on palette level (single DMC)not used by the pharma end customers.
Verify DMCon item level (single DMC)
The difference of reading and verifying is, that the quality of the DMC is controlled. Several parameters of the code are checked, described later in this document.
Control DMC marking quality
Read DMC and/or human readable text
i l l
Reading human readable text, is only needed on item level. VS72x can be used for that and in the future MV440-OCR.Trace plain text
E PedigreeSiemenssolution forpharama industry
on item levelPreferably OCR-B text shall be used.
The AutoID/RFID T&T solution provides interfaces to MES and to
SAP OERFunctionalities & Benefits of the solution
Internal T&TExternal T&T
/ & p SERP (i.e. SAP, etc.)
• Integration to SAP ERP dependent on business workflows:
• if external T&T may interface directly SAP AII
• if internal T&T, contextualization to MES data is made SAP ERP other ERP
SAP OERSAP AII / XI
by SIMATIC IT
• Possible cross entity integration via SAP OER.
• Scalable, modular and flexible solution based on a
SAP AII / XI
on standard platform
• Identification of objects basing on the EPCglobal standards (EPC, EPCIS, UID, etc.)
• Device- and data-management for SIMATIC IT and AII
AutoID/RFID Core SolutionsI t f t 3 d t tD
T&
T So
lutio SIMATIC IT
and AII
• Interfaces with SIMATIC IT for Manufacturing operations
Interface to 3rd party systems
Device Management (Siemens & Non-Siemens)
Data management / Business logic
Aut
oID
/RFI
• AutoID devices are managed by the AutoID/RFID Core Solutions.AutoID Devices:
RFID Tags/Readers, Data Matrix Code, Bar Code
Benefits
Higher product safety to improve the protection of your brandHigher product safety to improve the protection of your brand,
your customers and the consumer of your products
Faster recall capability
Reduction of administrative cost
Flexible response to rising market requirements
Increase efficiency of tracking and tracing operationsy g g
Better governance of quality operation
R d ti f d kReduction of scrap and rework
Benefits – unique selling proposition
Siemens offers the only all-in-one Tracking & Tracing solution available across the world
Siemens is one of the world largest Tracking & Tracing d t f tproduct manufacturer
Many years of experience in the realization and use of Tracking & Tracing solutionsTracking & Tracing solutions
Complete solution from hardware through MES System, systems integration and operation to process consulting
Ready to use solutions for all steps the product life cycle
Fast roll-out and high quality g q y
Th kThank you
N Vi k RName: Vivek Roy
Department: I IA SC IC
Phone: +91 22 27645765
Mail: prasad.raverkar@siemens.com
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