02 plant it_line management systems for filling and packaging plants_michael...

Click here to load reader

Embed Size (px)

Transcript of 02 plant it_line management systems for filling and packaging plants_michael...

  • certified by experience

    2013 ProLeiT AG

    Line Management Systems

    for filling and packaging plants

    Plant iT LMS

  • certified by experience

    2

    Plant Acquis iT

    Extract from our reference list

    Customer Activities

    Weser Gold Plant-wide production data management.

    Use of Plant Acquis iT directly by the customer.

    Danone Production data management via Intranet.

    HTML-supported efficiency analysis.

    Warsteiner Production data management for four bottling lines, incoming order

    processing via Microsoft Excel, Filler Stop Tracker, reporting via interfacing to the

    customer's bottling database.

    Coca-Cola Germany Plant-wide production data management for one PET and

    one bottling line (new plants) respectively, system retrofit on existing bottling plants.

    Grolsch Production data management for 7 bottling lines, integrated incoming order

    processing via SAP, diagnosis (Filler Stop Tracker) and optimization via OEE,

    order-related material identification for raw materials and supplies.

    Bauer Production data acquisition for a milk bottling line, with interfacing to the ERP

    system. Batch tracking from production and material identification in the line.

    Bad Drrheimer Mineralbrunnen GmbH & Co. KG Heilbrunnen,

    Plant-wide use of Plant Acquis iT for bottling lines.

    Line Management Systems, 2013

  • certified by experience

    3

    Plant Acquis iT

    Extract from our reference list

    Customer Activities

    Friesland Campina Use of Plant Acquis iT as a Production Management System;

    current integration of 13 packaging and 4 preparation lines.

    Monitoring of the "Availability", "Performance" and "Quality" indicators, productivity

    comparison of the lines via KPIs.

    Ur-Krostitzer Use of Plant Acquis iT as a Production Management System in glass

    filling. Fault cause allocation via the Filler Stop Tracker. Plant output evaluation via the

    STANLY Status Analyzer. Generation of an order list, including item management with

    integrated reporting.

    KHS Worldwide use of Plant Acquis iT as an OEM solution for production data

    acquisition in bottling plants.

    Line Management Systems, 2013

  • certified by experience

    4

    Plant iT LMS

    System overview

    Line Management Systems, 2013

  • certified by experience

    55

    Production data acquisition

    Plant Acquis iT - system parameterization

    Configuration Manager

    Central engineering environment for

    the complete system

    General administrative information

    Archiving and data removal cycles

    User administration

    Hardware structure of subordinated

    control

    systems

    Messaging structures

    Plant specific communication formats

    Physical plant structure

    Mapping of physical plant structure

    by hierarchical arrangement of

    location keys

    Parameterization of the data points to

    be acquired by using a variety of

    object types

    and allocation to the location keysLine Management Systems, 2013

  • certified by experience

    6

    Weihenstephan Standards

    History of the WeihenstephanerStandards (WS)

    WS 2005

    General part

    WS 2005, Teil 1Physical interface

    specifications

    WS 2005, Teil 2Specification of the

    Interface Content

    WS 2005, Teil 3Data Evaluation and

    Reporting

    WS 2005, Teil 4Approval and Safe

    OperationWS 2000

    Specifications

    Line Management Systems, 2013

    2007 extensions with

    packaging lines

    (during LineMod

    research-project)

    2010 WS Food interface

    contents for meat

    processing companies

  • certified by experience

    7

    Weihenstephan Standards

    Development

    Food Production/Bottling Lines, Packaging

    Standard interface

    Ethernet network

    Communication instructions

    Testtool

    Data evaluation

    Quality assurance

    Batch tracking

    Efficiency analysis

    Data points

    Tagname/

    number

    Data types

    XML device

    description

    Machine Controller

    Line Management Systems, 2013

  • certified by experience

    88

    Detailed view of a filling line with current information on machine states, active

    filling orders and production counters

    Line visualization

    Detail screen filling lines

    Line Management Systems, 2013

  • certified by experience

    99

    Overview of all lines with current information on machine states, filling orders and

    production counters

    Line visualization

    Overview states and filling orders

    Line Management Systems, 2013

  • certified by experience

    10

    Analysis of faults

    Machine operating states

    Line Management Systems, 2013

  • certified by experience

    11

    Analysis of faults

    State analysis filling line

    Line Management Systems, 2013

  • certified by experience

    12

    Analysis of faults

    Fault analysis

    full day

    restrict time range

    Pasteur valve failure

    Time selection

    Line Management Systems, 2013

  • certified by experience

    13

    Analysis of faults

    Detailed downtime analysis

    Time range

    three days

    Line state

    Operating: Filling

    Failure

    labellerdowntime

    Line Management Systems, 2013

  • certified by experience

    14

    Analysis of faults

    Detailed downtime analysis

    Equipment

    failure

    line/filler

    Bottle washer

    Filler stop all

    error causes

    Filler

    Time range

    three days

    Line Management Systems, 2013

  • certified by experience

    1515

    Production reports

    Daily report

    Quantities (movements of raw material, counter values), limit violations, standard

    deviations

    Batch report

    Article-/ product data, start and end time, filled product (saleable units), QM-relevant

    data

    Shift report

    Filled products per shift, change over times, downtimes, line efficiencies and KPIs,

    faults

    Filling report

    Filled articles per week, accumulated view, comparison week/month/year

    Inspection report

    Number of test runs/test bottles, detected, sum of ejected goods

    Line Management Systems, 2013

  • certified by experience

    16

    PDA Krostitzer brewery

    Manual input shift report

    Line Management Systems, 2013

  • certified by experience

    17

    PDA Krostitzer brewery

    Shift report

    Line Management Systems, 2013

  • certified by experience

    18

    PDA Krostitzer brewery

    Report sorting empty goods

    Line Management Systems, 2013

  • certified by experience

    19

    PDA Krostitzer brewery

    Inspection report

    Line Management Systems, 2013

  • certified by experience

    2020

    Management of filling orders

    Overview filling orders, grouped by filling line and calendar week

    Manual input and corrections

    Bill of material

    Job list

    Example

    Line Management Systems, 2013

  • certified by experience

    2121

    Start filling order in different order areas

    Detailed information e.g. for material provision

    Job list

    Start filling order

    Line Management Systems, 2013

  • certified by experience

    2222

    Start filling order in different order areas

    Detailed information,

    e.g. Best before, production counter

    Job list

    Start filling order on touch panels in the line

    Line Management Systems, 2013

  • certified by experience

    2323

    Management of Bill Of

    Materials based on

    Material Master Data

    received from SAP

    Groupable views of

    BOM

    Usage of BOM in order

    management with

    adjustment of

    component quantities

    Materials management

    Parameterization of Bill of Material

    Line Management Systems, 2013

  • certified by experience

    2424

    1. Scan location (where)

    2. Scan material-ID (what)

    3. Optional display process

    instruction

    4. Verify, release and log

    Materials management

    Identification - Verification if right material is used?

    Example:

    Labels

    W-LAN

    Scanner

    Display product-relevant

    data (e.g. EAN 128) LMS Server

    Line Management Systems, 2013

  • certified by experience

    2525

    Materials management

    Verify packaging material per filling order according to BOM

    Confirmation material provision

    Display material info for operator

    Line Management Systems, 2013

  • certified by experience

    2626

    Machine-Stop-Tracker

    OEE = Overall Equipment Effectiveness

    OEE is a method to understand and improve the behaviour of a process by

    evaluation of production stops

    Basic OEE formula:

    OEE = Availability rate x Performance rate x Quality rate

    Process of OEE data evaluation

    Define production times in the shift planning

    Evaluation of heartbeat signals of the main machine to identify production stops

    Assignment of error source and error cause to production stops by manual input in the

    Machine Stop Tracker tool

    User input of rework amounts as well as changeover timing in the dashboard overview

    Store information in the database to calculate OEE rate