frontiers of maintenance

FRONTIERS OF MAINTENANCE

How the Industry 4.0 revolution is changing the way

Food and Beverage manufacturers maintain their assets

General

Agenda

• Tetra Pak Introduction

• Industry 4.0 in the Food & Beverage Industry

• Predictive Maintenance Journey

• Q&A

General

Our Vision and Motto

We commit to making food safe and available, everywhere

General

Tetra Pak in numbers

11,9Sales

€ billion

>5000 Manufacturing plantsServed globally

>175 Market presence

Number of countries

1952Founded

24,100 employees

187SalesBillion PackagesFirst Aseptic package

1961

physical assets

installed>100,000

General

Agenda




• Q&A

Tetra Pak May 2018

https://www.youtube.com/watch?v=ER9vFnDQcSM&feature=youtu.be

https://www.youtube.com/watch?v=ER9vFnDQcSM&feature=youtu.be

DREAM BIGSTART SMALLBUT MOST OF ALL

START

General

Industrials typically late in adopting; F&B among latest to take off

Digitalisation in different industries

Marine

Healthcare

Automotive

Finance &

Insurance

Media

ICT

Retail

Food &

beverage

Source: Lit search; Company websites; Bain analysis

Industrials Non-industrials

Bubble size indicative of industry size

Chemical

Utilities

Mining

Time

Extent of Digitalisation

Agri-

business

Oil & gas

Building

General

Pressure on Food & Beverage producers increasingDemands along the value chain

Food & Beverage producers Farming

Automotive

Process Industry

Mining

Oil & Gas

<20%

20-40%

45-60%

60-70%

70-80%

>80%

Food & Beverage

Regulators

Owners

Retailers & consumers

General

Food & Beverage producers typical need areasHow Industry 4.0 can help addressing those needs

Food Safety

& Quality

Production

Management

Production

Flexibility

through end-to-end

monitoring, intervention and

correction

allowing for products tailored to

smaller batch sizes, direct

delivery to customers

to provide advanced production

planning, scheduling and control

functionalities

Opex Optimisation

through higher automation,

reduced downtime, increased

energy efficiency etc

Traceability

in sourcing, manufacturing,

distribution and delivery to

optimize product/ material flow

across value chain

Capex Optimisation

leveraging new production

technologies to increase output

in capacity constrained

production environment

General

The journey has only started

Industry 4.0 opportunities in the Food & Beverage industry

Consumer

data integrationFlexible

production

scheduling

Cross-site benchmarking, planning optimisation and market-based capacity allocation

Processing DistributionRaw material WarehousePackaging

Automated

restocking of

raw materials

Automated

operations in

control room

Augmented

reality remote

support

Predictive

maintenance

Automated

quality control

LGVs and

robotized

palletizers

Point-of-sale

data for logistics

and inventory

General

Agenda




• Q&A

General

What if you could see the future?Imagine your plant without unexpected breakdowns

YOU WOULD NOT……lose money while standing still …dispose of valuable product…miss your delivery agreements

General

/ 17

Share of Predictive Maintenance is growing

Maintenance mix evolution

Condition Based Predetermined Corrective

Predictive

Maintenance

Tomorrow

Future

Current

Preventive

General

Service engineer

Global Quality & Performance Management Centre

Alerts and Insights based on real-time data

Predictive Maintenance – how does it work?

Food manufacturing equipment

Tetra Pak Services

GeneralTetra Pak Services

Unique insights at every step

Why Tetra Pak?

Knowledge of critical functions…

We’ve identified the most critical functions in your equipment. Sensors monitor

these functions and send real-time data to our Quality & Performance

Management Centre via secure cloud connections.

Skilled staff executing the event

…

Skilled service engineers plan and execute a preventive maintenance

event based on the insights provided by the Quality & Performance

Management Centre.

Expert analysis and alerts

Specialists at our Quality & Performance Management Centre analyse data

and provide operational insights and alerts to the local Tetra Pak staff.

GeneralTetra Pak Services

We’re uniquely equipped to benchmark

Thousands of connected linesOur insights aren’t based solely on your

equipment. We have unique benchmarking

capabilities as a result of monitoring our global

installed base.

General

Service engineer

Global Quality & Performance Management Centre

Alerts and Insights based on real-time data

Predictive Maintenance – how does it work?

Food manufacturing equipment

Tetra Pak Services

General

Functions in scope

Tetra Pak® A3 Speed

Process monitoring

Electrical power

Peroxide pump

Jaw drive system2 servo motors

Sealing

UV Lamp

Final folder – drive system1 servo motor

Jaw system

Bearings, bushings,

cams, rollers

General

Prediction pyramid

PREDICTIONPhysical or statistical model used to predict future events.

MONITORINGRaw data is de-noised, visualised, trends are detected and

anomalies are used as indicators of potential problems.

DATA COLLECTIONCollection and storage of signals from equipment targeted to

develop monitoring or predicition.

A continuous learning process

General

Prediction beyond the monitored functions

… Lubrication

failures

Other

components

damage

Mechanical

play

Monitoring servo motor allows prediction of issues in connected components

General

…but don’t just take our word for it

Dairy producer in South America

152 hDowntime avoided..

Running hours/year: 4 500 h

Customer savings

per line: €50k

Example of failure:

worn-out shaft due to

broken lubrication pipe

Dairy producer in North America

124 hDowntime avoided


Customer savings

per line: €68k

Example of failure:

worn-out belt and

bearings

Dairy producer in Southern Europe

30 hDowntime avoided..


Customer savings

per line: €25k

Example of failure:

worn bearing in peroxide

pump

General

Real-time monitoring

Sensors that monitor critical functions

and send real time data

Quality & Performance

Management Centredl

Performance specialists

utilising data analytics to interpret

patterns, develop algorithms

and predict failures.

Info from TP

Alerts & insights

Performance alerts and

insights are sent to the service

engineer on site to take actions,

e.g. schedule maintenance event.

State of the art offer enhancing Tetra Pak Plant Care solutions

Predictive Maintenance

General

Delivered through outcomes based agreements

Tetra Pak May 2018

Full production line support

JD, March 2019

General

Delivered through outcomes based agreements

Expanding to plant wide solutins

SINGLE PROCESSING AND PACKAGING LINE

JD, March 2019

General

Valuable today. An investment in tomorrow.

We will continually add

more functions to monitor,

and roll out Predictive

Maintenance for even

more machines and

ultimately your full plant.

Together, we are

defining the future

of food manufacturing.

Tetra Pak Services

General

Agenda




• Q&A

DREAM BIGSTART SMALLBUT MOST OF ALL

START

frontiers of maintenance

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