Post on 17-Apr-2018
The Journey to More Effective Packaging Automation
Bryan Griffen Nestlé E&A Engineering Manager
OMAC Packaging Workgroup Chair
The world’s leading nutrition, health and wellness company December 2012
Topics we will cover
• Nestlé: The world’s leading nutrition, health and
wellness company
• PackML: Our packaging automation vision
− The prototype
− Designing a more effective operator interface
− Where we’re headed next
− Our contribution to the General URS
• Nestlé’s alliance with industry
• The value and benefits of implementing PackML
• Conclusions
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Nestlé products & brands: instantly recognizable
• 10,000 different products
• Around 1 billion products sold every day
• A product for every moment of every day, from
morning to night and from birth to old age
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A brief history of automation and packaging at Nestlé
• Engineering in Nestlé is traditionally process-oriented – we own and
manage our process solutions – We design and automate the key process units
– Rockwell Automation is our solution provider for process automation
• We typically do not own the solutions for the packaging hall – We have a strong focus on materials, aspect and machine capabilities
– No real efforts have been placed on machine automation standards
• Packaging OEMs very often have their own automation platform
specification – Changes to their specified platform increases costs
– No guarantee on performance is given if they must use a different platform
• It is now time to set a new direction…
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THE JOURNEY BEGINS… PACKAGING SIMULATION LINE
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Where we started
2008 Preliminary investigation on automation standards for packaging lines
2009 OMAC / PackML indentified as possible solution for Nestlé
2011 Line simulation prototype commissioned using PackML
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• Packaging Machine Language
• Industry standard (ISA TR88.00.02)
• Software design methodology that leads to: ‒ Common operational look and feel between equipment
‒ Defines operational state of a machine
‒ Provides for operational modes
‒ Standard information to/from machines (PackTags)
‒ Modular coding for re-application libraries and
diagnostics
• Applicable to other types of machine systems
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What is PackML?
December 2012
Validating the line integration concept
The platform is composed of : - 3 Festo modules - 1 Staubli robot - 4 disparate PLCs and HMIs - 1 SCADA (Wonderware)
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Destacking modules
RFID and turning units
Palletization cell
Drilling and transfer units
SCADA system
December 2012
Intellectual Properties Machine Builder D
I/O Machine Network
Intellectual Properties Machine Builder C
I/O Machine Network
Intellectual Properties Machine Builder B
I/O Machine Network
Intellectual Properties Machine Builder A
I/O Machine Network Mac
hine
-leve
l Li
ne-le
vel
OMAC Line Integration Strategy Open protocol for PackML tag
exchange
OM
AC
OMAC State Model
End User
OMAC State Model OMAC State Model OMAC State Model
PackTags PackTags PackTags PackTags
Unveiling of the prototype at Pack Expo
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THE CONTINUING JOURNEY: HMI, SAFETY AND MES
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HMI standards are needed to improve operator efficiency Actual status of individual HMIs for one packaging line...
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Elevator Caser
Coding filing bag Bag filler VFFS
Check-weigher
Cartoner (CAMA)
Metal detector
Bar code reader Bar code
check
X-ray detector Ink-Jet cartons
Metal detector
finish carton
Ink-Jet case
December 2012
Many current machine interfaces are not user-friendly and add complexity to run machines
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• More than 200,000 HMIs are currently
used in Nestlé Factories
• More than 70,000 people involved in
packaging operations worldwide
• All screens have a different aspect and
this creates confusion and hinders staff
flexibility
• A specific training is required for each
equipment, this costs money and takes
too much time
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A standard HMI solution has been developed Packaging and Automation have worked together to define a standard
look-and-feel for operator interfaces
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Next steps: On screen diagnostics will reduce downtime and improve efficiency
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Next steps: Vertical integration into the MES layer for reporting & tracking
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Next steps: One safety standard for the entire production plant
Creating an open safety protocol (similar to the PackML concept) enables
increased productivity for the plant
• Cost reduction
• Less down-time
• Higher productivity
• Easy maintenance
Concept under review
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A general URS with eight modules covers Nestlé’s packaging requirements
1. Procurement module
2. Line integration module
3. Equipment module
4. Safety, health and
environment module
5. Hygienic module
6. General design module
7. Quality module
8. E&A module
- Checklists
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NESTLÉ’S PARTICIPATION TO THE OMAC PACKAGING WORKGROUP
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Who is OMAC?
OMAC: The Organization for Machine Automation and Control
‒ Organization for automation and manufacturing professionals, including
end-users, machine builders, and technology providers
‒ Dedicated to advancing manufacturing capabilities and efficiencies
through identifying common problems, standardization, and
improvements to processes that positively impact the way companies
do business
‒ Two main workgroups: Machine Tools and Packaging
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The OMAC Packaging Workgroup (OPW) vision and mission
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Maximizing the business value of packaging machinery through implementing automation standards that lead to
improved flexibility and increased capability, while improving safety, and reducing the total cost of ownership.
To be the guidepost in the packaging industry leading to a more unified automation solution that improves packaging
line efficiencies, reduces the capital and operating costs associated with packaging lines and promotes faster time to
market.
Mis
sion
Vi
sion
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The OPW goals
• We support End User and OEM machine automation choices and
flexibility through greater industry openness and interoperability
• We aim to enhance manufacturing competitiveness by developing
industry-wide standards designed to facilitate packaging line integration
and improve OEE
• We provide tools and methods to optimize the control of packaging
equipment through:
‒ Implementation of international standards
‒ Realization of horizontal (line) integration
‒ Providing links to vertical MES/ERP systems
• We seek to improve the operational safety of packaging equipment
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Mar
ketin
g Te
chni
cal
Increase adoption of the Connect-and-Pack Standards across industry, including End Users, OEMs, Systems Integrators, packaging associations and educational institutions through providing concrete value propositions that positively affect the business and human aspects of the adopting entity.
Develop the technical specifications, tools, and methods which comprise the Connect-and-Pack Standards, and which facilitate attaining the greatest value from packaging automation systems. Work with other industry automation organizations to align standards and methods used in packaging equipment design.
The OPW strategy
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The OPW committees support our strategy Technical Focus:
PackML Continuation of activities related to the standard itself
PackSpec Generate a packaging machinery specification for PackML
PackSoft Collaborate with organizations such as PLCopen & OPC Foundation to enable/ensure compatibility with PackML
PackConnect Work with communication organizations (i.e. ODVA)
PackSafety Development of safety communication protocols
Marketing Focus:
PackAdvantage Communicate the business benefits of PackML
– PackAdopt Work directly with OEM organizations
– PackSyst Work directly with systems integrators
PackLearn Central contact for educational & training institutions
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VALUE & BENEFITS OF PACKML
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Key benefits of compliance to PackML End Users:
• Consistent data and control structure for integration both horizontally (machine-to-
machine) or vertically (machine-to-SCADA/MES)
• Promotes best-in-class solutions focused on innovation
• Reduced total cost of ownership (TCO)
Machine Builders:
• Allows the OEM to select the technology platform that will best suit their needs
• Simplified post-sale support
• Protection of intellectual property
Systems Integrators:
• Consistency when working with multiple automation platforms and OEMs
• Focus on value-added activities such as MES, maintenance tools, etc. instead of
integration concerns
Technology Providers:
• Focus on competitive advantages instead of integration issues
• Open the global market of packaging machines to all Technology Providers (get rid of
the hard specification of one single supplier)
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Members include end users, machine builders, systems integrators and technology providers
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Where our journey has taken us…
• We believe that standardization is imperative to improving our
overall equipment effectiveness; PackML is our standard for
packaging machine automation
• We are fully committed to the PackML strategy, and we continue
to support and develop this strategy through active participation
to the OMAC Packaging Workgroup
• We are developing complimentary tools and specifications for
application as part of our PackML strategy, these include HMI
specifications, communication standards and safety system
integration – all of which are focused on improving the operability
and maintainability of our packaging systems
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Thank you for your attention
How to join OMAC and have your voice heard…
New and renewing End User & Original Equipment Manufacturer annual
membership fees: (http://www.omac.org/content/membership)
• $2,900 – annual sales >$50 million
• $1,900 – annual sales of $5.0 to $50 million
• $900 – annual sales under $5 million
Membership benefits include:
• Access to OMAC Workgroups via direct introduction to Workgroup Chairs
• Access to OMAC best practices and technical guidelines
• One seat on the OMAC technical advisory board (TAB)
• 20% company employee discount to all OMAC conferences and symposiums
• Company logo listed on OMAC website and link to company website
• Listing as an OMAC Corporate Member on OMAC mailings and promotions
• Use of the OMAC and OMAC workgroup logos
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