arla foods - sesam worldsesam-world.com/_pdf/sesam-113/06-arla foods.pdf · •name: carsten...

Arla FoodsCreating the future of dairy

Standardization of automation platform incl. functionality

Carsten Nøkleby

Arne Svendsen

Claus Norup

Automation platform

Speaker

• Name: Carsten Nøkleby – Presentation made together with Arne Svendsen & Claus Norup, Arla Foods

• Education: M.Sc. & Ph.D. in building Flexible Assembly Cells

• Position: Senior Solution Architect and External consultant.

• Department: Manufacturing Execution and Automation in GBSIT – (Local Production IT).

• Arla Experience: I have been involved in Arla Foods project and standardization since 2005. 10 years as external consultant.

• Primary responsibilities: Standardization and template development in the automation and MES area

• PackML interface

• Line Controller

• Printer integration.

• Efficiency measurement,

26 May 20153

Carsten Nøkleby

26 May 20154

26 May 20155

13,500+OWNERS

FROM 7 COUNTRIES

THE 5TH LARGEST DAIRY COMPANY

MILK INTAKE12,5+ BILLION KILO

19,000+COLLEAGUES

73+ BILLION DKK

REVENUEPRODUCTS SOLD IN

100+ COUNTRIES

26 May 20156

Since the 1880’s, dairy farmers have joined together to form cooperatives

Q42009 2011 2012 2013 2014

Arla Foods Milk Partnership

7

More farmers and colleagues have joined

http://www.progratorgatetrade.com/public/billeder/Logo/tholstrup.gif

http://www.progratorgatetrade.com/public/billeder/Logo/tholstrup.gif

We will deliver our mission by following Strategy 2017

26 May 20158

Develop the core Deliver the growth Do it faster, simpler and leaner

ONE !

26 May 20159

The standardizationprocess -automation

PROCESS

The chosensolution – the automation platform -hardware and software

SOLUTION

The automation includingfunctionality

FUNCTIONALITY

The experiences that Arla has with building an automation platform

EXPERIENCE

Automation in future

FUTURE

Standardization of automation platform incl. functionalityAgenda

26 May 201510


PROCESS


SOLUTION


FUNCTIONALITY


EXPERIENCE


FUTURE


The ISSUE, we want to solve with this strategy ?What are the Supply Chain key challenges today ?

Milestone:Start Production !

E P A D I

E P A D I

!

CAPEX project challenges today: • Best Practice often not used in CAPEX projects

• Introduction of many new supplierswithout Production IT and Arla knowledge.

• Use of non standard Production IT solutions.

• Introduction of new project managers without Arla knowledge.

• Uncertainty about production IT standards

Timeline

Challenges for improvement• Inhomogenous IT-landscape on sites make it too

complex to benchmark and replicate best practices

Organisation and funding• Unclear responsibilities in Production IT context.• Unclear Funding model (SC - FI)

11

12

Production IT Strategy 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 SolutionCare

• IT-Surveys• Proactive Solution

maintenance• 24x7 Application

Support• Shared Services

2 Improvement Services

• OPEX/LEAN support• SPC/APC• LRM• Energy Management

3

ONE Delivery modelONE Production Solution

ONE Automation Solution ONE Funding Model

4

5

6

7

ProductionSolutions

AutomationSolutions

1313

Distri-bution

Forecasting, Planning & Scheduling

Supply Chain Processes:

Farmers

QualityManage-

ment

Data coll. &

Labelling

Instru-ment

ON/Atline

EnergyManage

ment

Data collection

Allsystems ..

PlantMainte-nance

Data coll. &

Labelling

Auto-mation

PerformanceManage

ment

OEE solution

Auto-mation

Ware-housing

Warehouse

Execution

Robots& AGVs.

MilkAllocation

& Collection

TACOsolution

TACO computer

ProductionManage-

ment

ProcessOrders

Automation

Scoping Production IT - Business Process perspective

InnovationManage-

ment

SPC/APC

Instru-ment

Production Data Cockpit

Utility systems (energy, air, water, cleaning)

Production IT

ONE Production IT platform- Best Practice, Replication and Standardization

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...

.. .... ...

. ... . ... ..

. .

...

.. .... ...

. ... . ... .....

.. .... ...

. ... . ... ..

Wirering Fieldbus / sensor bus Remote I/O

PLC PLC

Processnetwork

Factorynetwork

network

Fieldnetwork

SCADA

MES

ERPCentralized ITSystem - SAP

Site specific IT systemsE.g. MES, HMI , PLC and Device Integration

Best Practice, Replication and Standardization

HMI

SAP ApplicationCompany

ONE Production

Solution

ONE Production

Solution

ONE Production

Solution

ONE Production

Solution

ONE Production

Solution

ONE Production

Solution

ONE Production

Solution

ONE Automation

Solution

Manufacturing Execution and Automation

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PROCESS


SOLUTION


FUNCTIONALITY


EXPERIENCE


FUTURE


Standard MES Platforms

Application Server

Global network

Local production network

Application Server

Wonderware System Platform Production server Historian InTouch

Workflow

SAP MII

Database Layer

SAP MII

DWM

Line Controller – Siemens PLC

Siemens PLC Rockwell PLCPackaging Unit Filling Unit

Standard MES Software Packages

26 May 201517

Manufacturing Integration and

Intelligence (SAP MII)

Line Management System

Production Reporting & DWH Warehouse Control System

Automatic Guided Vehicles

Control System

Statistical Process Control / Advanced

Process Control

Energy DataCollection

Schneider Electric WonderwareArchestra platform

Human Machine Interface System

Manufacturing Execution System

Database

PrinterInterface

ScannerInterface

WeightInterface

MachineInterface(PackML)

InstrumentInterface

Recipe Management System

Efficiency Management System

Sit

e A

Sit

e B

Be

st P

ract

ice

Re

pli

cati

on

PLC ProcessInterface

x xArla standard software application. Application owner and responsible for consulting and implementation.

Non standards. Only Product Owner – In future development according to a product roadmap..

xStandard software platform. Product owner and responsible for consulting and implementation. x Arla standardization in progress. Only Product Owner – In future

development according to a product roadmap..

Sit

e N

Be

st P

ract

ice

Re

pli

cati

on

Best Practice Replication- ONE Automation Solution

Sit

e A

Sit

e B

Sit

e N

Be

st P

ract

ice

Re

pli

cati

on

Be

st P

ract

ice

Re

pli

cati

on

Scannerinterface

Weightinterface

Instrumentinterface

Packaging, Filling & Warehouse Area

PLC/HMIStandardMachine



Machineinterface(PackML)

Process Area

HMISCADA

PLC

I/O

PLC

I/OI/O

PLC

PLC Processinterface

HMISCADA

Printerinterface

MachineInterface(PackML)

PLC Procesinterface

18

x xArla standard software application. Application owner and responsible for consulting and implemention.

Non standards. Only Product Owner – In future development according to a product roadmap..

x Standard software platform. Product owner and responsiblefor consulting and implemention.

LineMaster

PLC

WW IntouchSiemens,Rockwell

WW IntouchSiemens,Rockwell

26 May 201519


PROCESS


SOLUTION


FUNCTIONALITY


EXPERIENCE


FUTURE


26 May 201520

UNIT standardization

Inteface requirements and specifications for units, PackML for unit supplyer

22

How is the solution? - Technical: The Interface State Model

Why standardize interface to units?

Overall Interface demands

Interface details defined

Time

No

w a

nd

in f

utu

re

Appendix 10: PackML

Appendix 10: SDS

1 meter PackML test

suitcase

24

Demands to unit supplier- Specifications & test: Test suitcase for Factory Acceptance Test

Test Suitcase for Factory Acceptance TestAt the Factory Acceptance Test Arla Foods provides a test suitcase. The test suitcase act like a Line Controller. All communication data from the packML interface can be simulated from the test suitcase.

PackML test- Test suitcase

SETUP

UNIT

TEST SUITCASE

TEST SUITCASE UNIT

25

26

Demands to unit supplier- Specifications & test: Test suitcase for Factory Acceptance Test

Test step, from Test suitcase :1. Start Unit from LC (Test State & Event ID)2. Suspend Unit Starvation (local Suspend test State & Event ID)3. Unsuspend Unit Starvation (local Suspend test State & Event ID)4. Suspend Unit Saturation (local Saturation test State & Event ID)5. Unsuspend Unit Saturation (local Saturation test State & Event ID)6. Suspend Unit from LC (LC Suspend test State & Event ID)7. Unuspend Unit from LC (LC Suspend test State & Event ID)8. Hold Unit (local Hold test State, Event ID & Detailed error info)9. UnHold Unit (local Hold test State, Event ID & Detailed error info)10. Complete Unit (Unit Complete test State & Event ID)11. Job data upload (test upload Job data according to spec.)12. Job data download (test download af job data)13. Reset Unit on unit itself (Test State & Event ID)14. Stop Unit from LC (Test State & Event ID). Check from different states

1. EXECUTE, HELD, SUSPENDED, IDLE and COMPLETE.15. Start Unit from LC (Invalid Job data test State, Event ID & Detailed error info)16. Abort Unit (Test State & Event ID)

Line Controller functionality

26 May 201527

LINE CONTROL standardization

26 May 2015 28

Easy connection of units and Line Controller

26 May 2015 29

Line Controller setup - Structure

26 May 2015 30

Line Controller setup - HMI

26 May 2015 31

Line Controller setup - HMI

Control functionality (Use case)

• Review of the 3 groups of functions within a Line Controller

• Line Controller Functionality

• The functionality that can be issued by an operator via the Line Controller (start, stop, suspend line, etc.)

• Back ground functionality

• The functionality that is handling the background tasks as OEE, Status, etc.

• PEM functionality

• The functionality to handle tracebility and material handling

• Illustration of use cases.

32

26 May 2015 33

Line Controller setup - Functionality

Start production

LMS RMS EMS APSInTouch

HMILine

ControllerUnitSAP

Unit 1

Unit 2..N

Operator releases

orders

Production

Planning

releases

process orders.

Release Processs ordersA list of process orders are released

Prepare process orders with parameters and job data for each unit

Prepare process orders

Order ready for production

Line Controller order list

Operator start

order

Start order

Job data - Unit 1

Job data - Unit 2..N

Unit 1State = EXECUTE

Unit 1Unit 1

Command = Start

Unit 2..NState = EXECUTE

Start Unit 2..NCommand = Start Unit 2..N

Unit 1State = Starting

Unit 2..NState = Starting

Storage of data

A

B

C

26 May 2015 34

Line Controller setup - Functionality

Order completion – Stop production

LMS RMS EMS APSInTouch

HMILine

ControllerUnitSAP

Unit 1

Unit 2..N

If ‘Auto complete’ is DisabledOperator Stop order

Stop Unit 1Command = Stop

Unit 1Job data

Forbrugsregistrering for Unit 1 via PEM

Unit 1State = STOPPED

Stop Unit 2..NCommand = Stop

Unit 2..NJob data

Unit 2..NState = STOPPED

Forbrugsregistrering for Unit 2..N via PEM

Upload Job data for Unit 1

Upload Job data for Unit 2..N

Process order completedForbrugsregistrering for Unit 1..N via PROD DB

Stop order

Storage of data

Storage of data

D

Message x% beforework order completed

If ‘Auto complete’ is enabled Stop order

Product

counter

reached Message work order completed

35

System integrator requirements

• SDS per unit • Line Controller configuration specification

Basis for the offer

System integrator requirements

SDS-dok/Arla Foods Group Appendix 10 Automation Standard - SDS template - V01.docx








SDS-dok/Arla Foods Group Appendix 11, Project konfiguration V01C.docx

SDS-dok/Arla Foods Group Appendix 11, Project konfiguration V01C.docx

36

Appendix 11:Line Controller

Appendix 11 + N x Appendix 10

Configuration

1 kmPackML Line

Controller FAT

Line Integration specification

Unit and device definition

• Definition of unit (PackML definition)

• Illustration from packaging line with units (Seen from an interfaces perspective)

• Illustration of X-Ray and the extra conveyer belt

• Illustration of scale (check weight)

• Devices part of a unit.

37

26 May 201538


PROCESS


SOLUTION


FUNCTIONALITY


EXPERIENCE


FUTURE


Specification (ECO)

• Reuse of specification for packaging lines.

• Cost example

0

10000

20000

30000

40000

50000

60000

70000

1 2 3 4 5 6

Site 1

Site 2

Number of projects on site

Co

stp

er

spe

cifi

cati

on

(Eu

ro)

11-05-201539

Start cost at site 3..N

Implementation (ECO)

• Implementation cost

• Line controller.

• Target cost for preconfigured Line Controller: 100.000 DKK.

• Target cost for configuration: 100.000 DKK

• Target for full line integration from SAP < 1.0 mill DKK

11-05-201540

•Hardware cost•Software cost•Engineering cost•Service cost•Education cost

Organizational

• Line controller supplier becomes organizational hub

• All units have only one interface to the LC

• Reduction of interfaces A-LC, B-LC, ..

11-05-201541

Unit A

Unit B

Unit C

Unit N…

Unit A

Unit B

Unit C

Unit N…

Line Controller (S)

A BA CA QB QB CC Q

It system (Q)

A SB SC S

•Reduce organizational complexity•Responsibility defined•Clear interfaces that can be tested befor delivery.

Project monitoring

• Select a number of project

• Monitor and measure time spend on specification, implementation, test and commissioning

• Monitor and measure the costs for hardware, software and engineering time during implementation.

• Monitor and measure the quality of the system – number of incidents after startup

11-05-201542

Tim

e

Projects

Co

st

Projects

Inci

de

nts

Projects

26 May 201543


PROCESS


SOLUTION


FUNCTIONALITY


EXPERIENCE


FUTURE


Implementation plan

• Define Line Controller standard

• Documentation

• Software

• Hardware

• Interfaces

• Select system platform

• Develop software application – preconfigurable Line Controller

• Pilot project

• Configuration of Line C ontroller to specific project

11-05-201544

Specification of generic Line Controller

• Based on

• The PackML interface

• The MES interface

• The Line Controller Functionality

• Purpose:

• Be able to configure a Line Controller for a specific line with very fewressources and costs.

11-05-201545

Carsten NøklebyArne SvendsenClaus Norup

Arla Foods

26 May 201546

Thank You - Questions

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