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PROPERTY OF PIOVAN - DATA CLASSIFICATION: CONFERENCE PROCEEDINGS

www.piovan.com


Industry 4.0

GIORGIO SANTELLA – PIOVAN GROUP


Piovan is the world leader in supplying ancillary equipment andservices for the plastics industry

Understanding our customers’ needs


940 employees

7 production sites

24 subsidiaries

50 countries with direct presence

70 countries followed by distributors

Understanding our customers’ needs


Industry 4.0: Process control & production output optimization


• «Industrie 4.0» was devised in Germany

• It is a strategic initiative of the German government, that wasadopted as part of the High – Tech Strategy 2020 Action Plan.

• It was launched in January 2011 by the CommunicationPromoters Group of the Industry- Science Research Alliance.

• Its initial implementation recommendations were formulated by the Industrie 4.0 Working Group in October 2012.

INTRODUCTION


THE 4° INDUSTRIAL REVOLUTION


• Cyber Phisical Systems (CPS): businesses will establishglobal networks to incorporate machinery, warehousingsystems and production facilities (Smart Factories)

• Horizontal Integration through value networks

• End to end digital integration of engineering across the entire value chain

• Vertical Integration and networked manufacturing systems

THE 4 PILLARS OF INDUSTRY 4.0


Cyber Physical Systems

CPS – INDUSTRY 4.0 AS PART OF A SMART, NETWORKED WORLD


CPS – INDUSTRY 4.0 AS PART OF A SMART, NETWORKED WORLD


Industry 4.0 will lead the

development of new business

and partnership models that are

more geared towards meeting

individual/last minute customer

requirments

HORIZONTAL INTEGRATION THROUGHVALUE NETWORKS


NIKEiD is a service provided by Nike allowing customers to personalize and design their own Nike merchandise.

USA, United Kingdom, Italy, France, Spain, Germany, China and Australia.

END TO END DIGITAL INTEGRATION

https://en.wikipedia.org/wiki/Nike,_Inc.


END TO END DIGITAL INTEGRATION


- Additive Manufacturing

- HMI – augmented reality

- Sensors for IoT

- Connectivity

- Big Data

- Advanced analitycs

- Cloud

IMPORTANT TECHNOLOGIES AND TRENDS


- cooperating with machinery suppliers to utilize the new protocol

OPC – UA (Open Platform Communications – Unified

Architecture)

- introducing Winfactory 4.0

- launching the evolution program of Winfactory 4.0

to have mobile access through Smart Devices

- developing a complete system for Energy metering and energy

efficiency (generation of Key Performance Indicators)

TODAY’S ACTIVITIES AT PIOVAN


Winfactory 4.0


0

20

40

60

80

100

120

2008 2009 2010 2011 2012 2013 2014 2015

LIC

ENC

E

YEAR

Winfactory License by year and type

5E 10E 20E 35E 50E 65E 80E

WINFACTORY – 8 YEARS IN NUMBERS


Chiller2%

drying30%

energy1%

feeding46%

dosing13%

others8%

Winfactory family share

WINFACTORY – 8 YEARS IN NUMBERS


LICENSE TABLE

BASE

+

configuration

+

TAGS

+

On-demandfunctions

+

On-demandservices

WF4.0 StandardPET – pref & bottMED – medicalFILM – extrusionSVS – customENERGY….

152550100200400800

MTSADALRCPTSCHMSCHEMGRPOMGRVCLACLFEAOPC-UA

SUSUGRRSS

WINFACTORY 4.0 – NEW LICENSE SETUP


On-demand functions

MTS Material Tracking System ADA Advance Data AnalisysLRCP Line RecipeTSCH Time SchedulerMSCH Maintenance SchedulerEMGR Energy ManagerPOMGR Production Order ManagerMBT Batch trace for batch blenders and LybraVCL License for 1 Video ClientVCL5 Licence for 5 Video Clients ACL Alarm ClientOPC OPC-UA ServerAGE Advance Graphics editor (material line)

On-demand services

SUS Software Update Service (annual fee)RSS Remote Support ServiceUGR Upgrade from old software version

WINFACTORY 4.0 – NEW LICENSE ITEMS


New feature

Language11 (Italian, English, German, French, Spanish, Portuguese, Russian, Czech, Polish, Swedish, Chinese

Graphics New interface with vector graphics (SVG)3D graphic Yes Layout Yes with support up to 4 displaysMaterial lines Layout Yes with new layout editorTouch display support Yes (native)

User accounts Yes, with new badge support

Bar code reader New support for material trackingAlarms/log New graphics report

Alarms display New display for alarms (32,42,50“)

e-mail Yes, account option for alarms notificationUpdate Client Update automatic (over the network)PDF reader Yes for machine/device (included by end user)

WINFACTORY 4.0 – NEW FEATURES


WINFACTORY 4.0 – PAGE ELEMENTS


OPC – UAOpen Platform Communications Unified Architecture


CONTROL

SUPERVISION

MANAGEMENT

ENTERPRISE

MACHINE

ERP

Enterprise resource planning

WINFACTORYTYPICAL FACTORY AUTOMATION LAYERS

MESManufacturing Execution System

Winfactory


WINFACTORY 4.0 – OPC-UANEW FACTORY AUTOMATION LAYER SETUP

CONTROL

SUPERVISION

MANAGEMENT

ENTERPRISE

MACHINE

ERP

Enterprise resource planning

MESManufacturing Execution System


OPC-UA – production cell set up

Ethernet

RS485 ModbusRTU


OPC Foundation and Euromap

- February 2017

platform independent interoperability standard - Euromap 77 – link to MES

- Euromap 79 – link to robot

- Euromap 82 – link to auxiliaries


Winfactory 4.0 mobile


Bus/field

control

Lan/Factory Lan

WF4.0 Server

Up to 2/4 display

Client (PC panel)

Alarms

DisplayAlarms Display

(stand alone)

Client WIFI

(windows)

FireWal

l

Client mobile

WINFACTORY 4.0 – MOBILE


Winfactory 4.0 - Energy


MANUFACTURING OPERATIONS

Plastic material

Energy

Plastic product


PRODUCT COSTS

Plastic material represents60% to 90% of the cost

Energy < 15% of the costPlastic product


COST OPTIMIZATION

Continuous improvement

Poor optimization

Rejects ≤ 5%

Inefficiencies ≤ 50%

Plastic material

Energy


ENERGY BURDEN

Less than 10% of the manufacturers know how much energy each device

consumes

Less than 1% measures it

?


ENERGY MANAGEMENT

Split the machinery and equipment setup into predetermined categories

Injection / Moulding Cooling Material Handling

Measure the energy utilized by each category


Energy efficiency is one of the pillars of the SMART

FACTORY

Today’s conventional applications are focused only on

energy supply measuring, without any relation with the

production output

The most common applications are factory based and not

enterprise-wide

WINFACTORY 4.0 – ENERGY


Provide a fully integrated solution with Winfactory 4.0

for energy metering, for each typology (electricity,

natural gas, oil) able to calculate the KPI related to the

production output at enterprise level

WINFACTORY 4.0 – ENERGY


Piovan Cloud

Internet

Smart

Devices

Factory 1

Factory 2

Factory 4

Factory 3

Factory 5

Overall production efficiency

WINFACTORY 4.0 – ENERGY (ENTERPRISE LEVEL)


Thank you GIORGIO SANTELLA

[email protected]

presentazione standard di powerpoint€¦ · 1% feeding 46% dosing 13% others 8% winfactory family...

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