industry 4.0 reality check weighing works for quality control

16News

OEM & System Integration

Weighing Components

mation for manufacturing, such as parts list, production status, the name to be en-graved and quality parameters. The data stored on the RFID tag allows the cases to actively manage their own produc-tion. That allows the individual case to be made without the need for extra produc-tion control, which is the prerequisite for flexible and individualized mass produc-tion with lot size 1.

Flexible manufacturing facilitates fast changeoverFuture manufacturing concepts have to be flexible to efficiently adapt to new products and to be moved to new loca-tions. To do that, SmartFactoryKL® com-prises nine mobile modules. The modules are supplied with electricity and com-

The SmartFactoryKL®, which is founded by the German Research Center for Artifi-cial Intelligence (DFKI), developed a fully functional demonstration machine for discrete manufacturing as a showcase for Industry 4.0 (or The Internet of Things). The SmartFactoryKL® and the institute were supported by 50 leading automation and software companies.

Individualized mass production is possibleTo demonstrate individualized produc-tion with lot size 1, SmartFactoryKL® pro-duces personalized business-card cases in various colors. The case has “prod-uct memory” in the form of a radio fre-quency identification (RFID) tag. This RFID tag stores all the necessary infor-

Industry 4.0 Reality CheckWeighing Works for Quality Control

A new Industry 4.0 demonstration machine shows individualized production with lot size 1,

flexible manufacturing and future concepts for IT integration. High-resolution weigh mod-

ules proved to be the ideal solution for reliable, flexible and simple quality control of indi-

vidualized products.

METTLER TOLEDO OEM & System Integration News 162

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execution systemsSmartFactoryKL® doesn’t require a man-ufacturing execution system to steer the product through the production process. Data exchange via OPC UA between mod-ules is limited to the mutual recognition for clarification as to whether the adja-cent module fits with the next manufac-turing step.

pressed air and connection for data ex-change via one loose cable. That allows the modules to be completely independent from one other and allows the production team to shift the modules in different or-ders as needed or to even take out mod-ules if they are not needed. Their inde-pendence allows efficient commissioning

and format changes for different products. The individual modules correspond to the Reference Architecture Model (RAMI 4.0), which describes Industry 4.0-compliant production equipment. They represent the element “Station” which include “Control Devices” and “Field Devices”.

Publisher / ProductionMettler-Toledo GmbHIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 02/2017 Mettler-Toledo GmbH

1 Layers

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Life Cycle & Value StreamHierarchy Levels

IEC 62264 // IEC 61512

IEC62890

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Reference Architecture Model RAMI 4.0The overview below shows SmartFactoryKL® application dis-played using the RAMI 4.0 model of Industry 4.0 or Internet of Things.

1 Layers1.1 Business: Giveaway for visitors at the trade show1.2 Functional: Holding Business cards with name of owner1.3 Information: All product data. Ensuring data integrity

1.4 Communication: Data format1.5 Integration: RFID tag1.6 Asset: Physical component. Business card case

2 Life Cycle & Value Stream2.1 Type: Development and Maintenance of Product2.2 Instance: Individualization with color and name of holder

3 Hierarchy Levels3.1 Product: Business Card Holders3.2 Field Device: Motors and conveyors3.3 Control Device: Scale for quality control3.4 Station: Module with PLC, motors, conveyors, scale and other sensors3.5 Work Center: Production Line3.6 Enterprise3.7 Connected World

METTLER TOLEDO OEM & System Integration News 16 3

Weighing is the right choice A manufacturing process consisting of automatic and manual modules does not automatically guarantee perfect quality. Therefore, the cases are weighed for qual-ity control with a high-precision WMS weigh module. Their weight value is com-

Business Card HoldersIndividualized business card holders in different colors and with holder’s name engraved. Each card holder has an inte-grated RFID tag to memorize all prod-uct data.

pared with the specific target weight that is stored in the RFID tag. Weight detec-tion with a high-precision weigh module makes it possible to detect faulty, miss-ing or excess components with great cer-tainty, even if a part is not visible from the outside of the product.

www.mt.com/IND-4-0-oe

WMS Weigh ModuleHigh-precision weigh module for qual-ity control detects deviations of one point in four millions with a capacity of 400 grams and repeatable readability of 0.1 milligram.

www.mt.com/WMS-oe

Weight-Based Quality Control

This white paper explains advantag-es and provides application hints for weight based quality control in auto-mation.

www.mt.com/ind-wp-wbqc-oe

by courtesy of SmartFactoryKL®


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Fully engineered Device Description files for Siemens and Allan-Bradley PLC Systems allow

you to simply integrate weighing devices via drag and drop in their well-known program-

ming tools. After wiring is completed and all devices run, typically it takes less than five

minutes to transfer weight values into the PLC input register.

The present and future of production network technologies are based on the Industrial Ethernet standard. The most common solutions using that technol-ogy are PROFINET IO RT and EtherNet/IP. Sensors and actuators that comply with those standards can be easily inte-grated into PLC systems if vendors pro-vide the right tools and design installa-tion-friendly products.

State-of-the-art connectivity METTLER TOLEDO offers a comprehen-sive range of transmitters, weigh modules, scales and weighing platforms, which are made for easy integration into machines and instruments. The product range cov-ers capacities from 100 grams up to hun-dreds of tons with the smallest readability of 0.1 milligram. All models can be con-nected to PROFINET IO RT and EtherNet/IP directly or via an optional easy-to-in-stall gateway.

Integrate Weighing into a PLCIn Less Than 5 Minutes

The fully prepared device description file can be imported into the PLC programing tool with drag and drop. All data for the PLC’s input/output-image are pre-configured. The program-mer doesn’t have to give symbolic names for convenient programing, because it is done already.

The PLC integration can easily be done with the well-known Siemens TIA portal or Allan Bradley‘s Studio 5000 programing tool.

Direct Connectivity for Siemens S7 via PROFINET IO RT

Direct Connectivity for Allan Bradley via EtherNet/IP

Two typical network-Topologies for PROFINET IO RT or EtherNet/IP including a Siemens or Allan Bradley PLC plus Computer for programing, switch, power-supply and a weighing device.


Standardized PLC-I/O image offers flexibilityAll METTLER TOLEDO weighing devices with incorporated connectivity to PRO-FINET IO RT and EtherNet/IP have the same data at their input/output image inside the PLC. This simplifies weighing equipment standardization for the ma-

chine manufacturer because different weighing devices may be exchanged with-out changing the PLC programming. That provides unlimited freedom for the ma-chine manufacturers to always select the right weighing devices.

www.mt.com/ind-connect-PLC-oe

Engineering Note: Connectivity to PLC

This engineering note explains and shows how easy it is to connect a comprehensive range of METTLER TOLEDO weighing devices to the most common PLC Systems.

www.mt.com/ind-connect-PLC-oe

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4 METTLER TOLEDOWhite Paper Engineering to PLC

© 05/2016 Mettler-Toledo GmbH

1.1. Check configuration of weighing device via the webserver

The configuration of the weigh module can be checked from the webserver. Connect the weigh module to a computer via a Power-over-Ethernet Switch using an RJ45/M12 patch cable. Enter the weigh module’s IP address (default: 192.168.0.55) into the computer’s browser.

Note: An IEEE 802.3af Power-over-Ethernet Switch is nec-essary to provide electric power to the weigh module.

The webserver identifies the individual weigh module configuration including type, software version, IP-Ad-dress but also specifications and weighing parame-ters. It is also possible to show the weight value.

Network for connecting to a Siemens PLC over TIA Portal or Simatic Step 7 Manager via PROFINET IO requires an IEEE 802.3af Power-over-Ethernet switch to provide power to the weigh module.

2. Connecting Siemens S7 PLC via PROFINET IO

The configuration is illustrated with TIA Totally Integrat-ed Automation. The configuration with Simatic Step 7 Manager is similar to TIA portal.

PowerSuppliy

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5 METTLER TOLEDOWhite Paper Engineering to PLC

© 05/2016 Mettler-Toledo GmbH

After installation of the GSDML file, the WMF weigh module is available in the hardware catalog. It can be added to the project by dragging and dropping the file.

The Device Description File of the weighing device in-cludes all the needed information. There is no addi-tional configuration needed.

The configuration parameters for the WMF weigh mod-ule are available, as well as the Module Parameters, such as filter settings, stability criteria and adjustment configuration.

The WMF Weigh module’s IP address and device name must be configured in the project and in the HW configuration tool. Default values are “WMF” and “192.168.0.55.”

If more than one weigh module is connected, the ad-dresses of the additional modules have to be changed. For example: 192.168.0.51, 192.168.0.52, etc.

The status LED on the weigh module shows instal-lation and communication is working.

The second LED blinks in red if the module is not connected to a PROFINET network.

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e Efficient Integration Weighing for Common PLC Systems

The present and future of network technologies in production are based on the Industrial Ethernet standard. Common solutions using this technology are PROFINET IO RT and EtherNet/IP. Sensors and actuators that comply with those standards can be easily inte-grated into PLC systems if vendors provide the right tools and designed installation-friendly products.

Content1. Configuring weighing device via the web

2. Connecting Siemens S7 PLC via PROFINET IO

3. Connecting Allen-Bradley PLC via EtherNet/IP

4. Programming the PLC with weighing data

5. Conclusion

OverviewThis document explains the key points for integrating a WMF high-precision weigh module into Allen-Bradly and Siemens PLC Systems. It addresses project managers, network designers and software engineers by providing a brief guideline for establishing basic connectivity to test the functionally of hardware and software.

ApplicationThe examples in this document use the WMF high-pre-cision weigh module. However, the content is not limit-ed to that particular weighing device. It can be applied to many other METTLER TOLEDO products that provide PROFINET IO and EtherNet/IP connectivity.


ISO 9001 Regulation Revision due 2018New Business Opportunity for Machine Builders

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Compliance with the ISO 9001:2015 revision requires a risk-based approach. To comply with the

revised standard, your customers must evaluate weighing equipment installed in machines that

you have supplied. We support machine manufacturers in consulting their customers and we also

perform the necessary on-site calibrations.

Experts to Consult Machine Manufacturers and CustomersExperts from METTLER TOLEDO can consult machine manufac-turer and customer in performing a risk analysis, determining the right test weights and calibration intervals including documentation.

Availability of Certified Test Weights in the Right ClassAll METTLER TOLEDO Service Organizations are in possession of certified test weights in the accuracy class that suits to the process tolerances of your customer’s application.

Good Weighing PracticeTM Includes Risk AnalysisGood Weighing PracticeTM is applicable to new and existing equipment from any manufacturer for selection, calibration and operation of weighing equipment including risk based thinking.

Partnering to create a win-win situationOur experts use Good Weighing Prac-tice™ (GWP®) methodology to evalu-ate and recommend calibration processes based on a risk-based thinking approach. With GWP®, you receive a document with all the necessary information, including results of our risk assessment and the rec-

Many of your customers are likely ISO 9001 certified. Due to the recent revision of the standard, they will have to evaluate their performance verification processes for their measuring equipment by 2018.That evaluation is required for weighing equipment incorporated into machines and instruments.

Turn new requirements into businessAs a result, customers might contact you to evaluate the calibration of the weigh-ing equipment you installed a while ago. Such consulting can trigger new service business for you, as recalibration services are an enhancement to your existing pre-ventative maintenance services.


ommended intervals for recalibration for compliance with the new requirements.

We can provide weighing-equipment ver-ification with a GWP Verification at your customers’ sites. In addition, we are able to perform the calibration on your behalf.

This partnership offers you incremental business when your own service techni-cians and the necessary test weights are not available.

www.mt.com/OEM-Service-oe

METTLER TOLEDO serves global customers with one of the largest sales and service networks in our industry – over 5,000 sales and service specialists strong. Machine ma-nufacturers can benefit from this organization by cooperating with our experts and service technicians for better serving their own customers.

New ISO 9001 Requirements are due 2018

The 2015 revision of ISO9001 has brought some major changes. The combination of the process ap-proach with risk-based thinking, and employing the “Plan-Do-Check-Act Cycle” at all levels in the orga-nization is relevant for weighing ap-plications with relevance for product quality. Companies have to up-date their processes until Septem-ber 2018.

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How does a tablet manufacturer benefit from a continuous approach?A tablet press can be considered a contin-uous system already. However, the tablet mixture has historically been prepared in a batch mode. Making the entire pro-

cess continuous provides significant ef-ficiency gains and contributes to better product quality.

What is the role of dosing and mixing in this process?The continuous dosing-mixing module is an essential element of continuous OSD production. It typically consists of grav-imetric feeders for APIs and excipients, as well as a mixing module that feeds di-rectly into the tablet press, granulator or extruder. Such a system requires much less floor space and substantially reduces development and validation time because scale-up is no longer needed. Current sys-tems can process between 50 grams and 250 kilograms per hour.

What needs to be considered when switching to a continuous process?Product quality is substantially deter-mined by the accuracy and consistency of upstream gravimetric dosing processes. Any error will result in a deviation from target quality. Additionally, mix homoge-neity is influenced by mixing chamber and paddle design, rotational frequency

A Leap in Process EfficiencyExpert Advice: Continuous Solids Dosing

Continuous manufacturing of oral solid dosage (OSD) forms provides significant efficiency

and quality benefits – but it can also pose substantial process-development challenges.

Dr. Ralf Weinekötter, an expert on continuous dosing and mixing, provides insights on the

capabilities and limitations of such systems.

Dr. Ralf WeinekötterGeneral Manager, Gericke AG, Switzerland

Dr. Weinekötter studied Chemical Engineering at University Karlsruhe, Ger-many and ENSIC Nancy, France. He was awarded his Ph.D. at the ETH-Zürich, Switzerland on the topic of “Continuous mixing of fine solids.” Weinekötter is a re-spected author of articles, papers and books, includ-ing Mixing of Solids, pub-lished by Springer Verlag, Germany.


Key Benefits: Continuous Solids Processing

• Better quality: Easy integration with downstream processes, such as tablet compression, reduces segregation risk.

• Improved efficiency: Continuous manufacturing is an automated process with integrated sophisti-cated online measuring devices and control tech-nologies to ensure accurate formulations.

• Faster time to market: Scale-up from lab to pilot to production is no longer necessary. Extend-ing the operating time of the pilot module to reach normal production output is sufficient.

• Less space: A continuous dosing-mixing-mod-ule’s footprint is just 2 x 2 x 2 meters.

www.mt.com/ind-continuous-dosing-oe

(shear rate) and residence time distribu-tion. Continuous processes have a reduced segregation risk compared to batch mix-ers because the product is directly fed into the next process without the use of inter-mediate bins with a high segregation risk.

Material properties can also pose chal-lenges. Cohesive materials, for example, require extensive engineering to ensure accurate dosing and mixing.

Why is weighing technology a critical part of continuous dosing systems?Dosing of micro-components, such as APIs, requires a level of accuracy that only can be achieved with gravimetric dosing feeders. Other technologies for powder dosing, such as flow meters, are significantly less accurate.

What are important specifications for weighing sensors in these systems?Precise feeding requires advanced weigh-ing, optimal design of the screw feeder and a sophisticated controller that an-alyzes weighing-sensor data and selects the optimal settings to ensure a constant feed rate.

The weighing sensor must combine high accuracy with a large capacity. The ca-pacity is essential because the sensor has to carry the screw feeder with the feed hopper, which contains the dosing mate-rial. Not many weighing technology com-panies, apart from METTLER TOLEDO, can provide sensors that master this chal-lenge of high capacity with pristine ac-curacy. In addition, the weighing sensor must provide a high measurement up-date rate and fast transmission of weigh-ing data to the controller. This is neces-sary to accurately control the screw feeder and ensure constant material throughput. Are continuous processes the future of pharma preparation?Continuous processes provide significant benefits in terms of efficiency, quality and process safety. We have reached a point where suitable systems are available to help companies transition to the contin-uous method, and we believe the coming years will generate many more exciting developments.

www.gericke.net


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e Trust Your Old Weighing Equipment?You Could Have False Sense of Security

Process tolerances in your manufacturing process could have changed a while ago. Old

measuring equipment which, despite frequent recalibration, might not comply with today’s

accuracy requirements. We can get you compliant with a professional verification.

Efficient Weighing and Piece CountingCompact bench scales for simple weighing or piece counting with printer and scanner provide fea-tures for efficient printing of cus-tomized labels. Connectivity to ERP System support state of the art data management.

Floor Scales for Simple Weigh-ing in Production and LogisticsDifferent platforms sizes includ-ing ramps and pit frames made of painted carbon steel up to 316 stainless steel with IP69k protec-tion offer the right solution for any environment and application.

Portable Scales Provide FlexibilityFactory layouts change often to make manufacturing processes more efficient or adapt quickly to new products. Portable scales or mobile pallet truck scales provide flexibility to adapt fast and easy to new situations in the future.

Auditing an installed baseOur service technicians can help you comply with the ISO revision using our Good Weighing Practice™ (GWP®) method. It includes risk evaluation and provides a statement regarding whether the scale is suitable for the particular ap-plication for which it is used.

Most machine manufacturers use weigh-ing in their own production for logis-tics, formulation or quality control. Their scales were often procured long ago and they are no longer accurate enough be-cause process tolerances have changed. That can happen even when scales are regularly verified with test weights

as part of the quality-control process.

New regulations might require actionThe new ISO9001:2015 revision requires a risk-based evaluation of measuring equipment. It could also require a reeval-uation of existing equipment.


Weighing Terminals for a Multitude of Applications Windows-based weighing termi-nals combine PC based standard applications or customer-spe-cific software with weighing. Their IP69k protection, including rug-ged cable connectors allow use in harsh environment.

Additionally, the user receives a recom-mendation for calibration intervals and suitable test weights for calibration.

Scientific selection methodGWP is applicable to new and existing equipment from any manufacturer. It supports you with a standardized scien-

tific methodology for secure selection, calibration and operation of weighing equipment. It also provides documented evidence for reproducible weighing results in harmony with all current quality stan-dards in laboratory and manufacturing, including a risk evaluation.

www.mt.com/GWP-oe

Good Weighing PracticeTM Certificate

Documenting proper evaluation of

existing and new equipment. A cer-tificate documents the performance of each balance versus process re-quirements based on a calibration. The safe weighing range displayed in the certificate visualizes the spe-cific weighing security and risk of each scale.

www.mt.com/gwp-oe

MTSI-103-20160815-18-1 1 / 2

GWP® RecommendationCompany ABC Machine ManufacturerContact john SamplemanDepartment / Position Production ManagerBuilding Machine AssemblyStreet Road to SuccessZip code / City 1234 Moderntown

Date Monday, 15. August 2016

Specified Scale

Scale PBK989-AB30(300'000d)

Maximum capacity 30 kgReadability (d) 0.1 gHazardous approval noWet application (≥ IP 65) yes

Terminal type name ICS429

User Requirements Value UnitMaximum weight 30 kgSmallest net weight 50 gWeighing accuracy 1 %Safety factor required 2Standards and RegulationsExpansion Factor k 2

AchievementsMinimum weight typical 101) gWeighing accuracy 1 %Safety factor* 5

* Based on typical minimum weight The specified device meets the user requirements for accuracy

In addition to a GWP® Recommendation, METTLER TOLEDO recommends GWP® Verification to determine the actual minimumweight and safety factor of this device on site. Furthermore, GWP Verification provides all necessary information on testprocedures, test frequencies and weights to maintain reliable weighing accuracy of the device over time.

GWP Verification can be issued for all weighing equipment of any manufacturer.

Ask for a GWP Verification of your installed base to reduce costs and risks. Plus, receive complete audit-proof documentation atone glance.

www.mt.com/ind-oe

Pharma Workflow

For more information

Predictive MaintenanceRemote Performance Monitoring

InTouchSM Remote Services is a cloud-based, off-the-shelf solution that is making main-tenance easy and downtime a thing of the past for businesses large and small. Machine manufacturers can pass on the benefits of InTouch predictive maintenance and monitoring to their customers.

Besides gaining a competitive advantage with InTouch, you can receive valuable information about the performance of your equipment during warranty and later as paid service.

For more information about Remote Performance Monitoring visit:

www.mt.com/ind-intouch-remote-oe

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Local contact: www.mt.com/contacts

Mettler-Toledo, LLC1900 Polaris ParkwayColumbus, OH 43240

Mettler-Toledo Hi-Speed5 Barr RoadIthaca, NY 14850

Mettler-Toledo Safeline6005 Benjamin RoadTampa, FL 33634

Mettler-Toledo CI-Vision2640 White Oak Circle, Unit AAurora, IL 60502

Mettler-Toledo, Inc.2915 Argentia Road, Unit 6Mississauga, Ontario L5N 8G6

industry 4.0 reality check weighing works for quality control

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