02 plant it_line management systems for filling and packaging plants_michael...
date post
26-Jan-2017Category
Presentations & Public Speaking
view
464download
0
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
