cost effective approachcost effective approach for … machine interface comm u data m a onfiguring...

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)

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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


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Human machine interfaceC

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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






omm

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Controllers

unications

Distributed I/O


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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Simatic

Controllers

unications

Portfolio

Distributed I/O


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





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Distributed I/O


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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





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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


TP177BWinCCflexible

Microbox PC420+

CPU315-2PN

CPU319-2PN

CPU319-2PN

CPU315-2PN

CPU319-2PN


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: [email protected]

cost effective approachcost effective approach for … machine interface comm u data m a onfiguring...

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