Applying S95 to a MES Implementation

Danie Tredoux (CCSABCO)

Deon Barnard (EOHMM)

Agenda

► CCSABCO / CCF Business► Project Cheetah► Project Cheetah & MES► The road to the MES implementation

▪ Consult▪ Design▪ Implement

► Project Implementation► Results► Road forward

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Who and What is CCS & the CCF Business► Coca-Cola Sabco (CCS) is a licensed bottler of Coca-

Cola products in 12 African & Asian countries, with the Group Office in Port Elizabeth▪ RSA, Namibia, Mozambique, Tanzania, Kenya, Uganda, Ethiopia,

Sri Lanka, Nepal, Cambodia, Vietnam, Laos► Coca-Cola Fortune (CCF) is part of the CCS business &

operates in South Africa▪ Expected 2009 sales of 7.5 million hectoliters or 66 million cases▪ 14 production lines in 6 plants and 3 sales regions, with 344 SKU’s▪ 23 % of total Coca-Cola sales volumes across 75% of

geographical area of RSA▪ 2,950 permanent employees

Project Cheetah Business Requirements► The existing (old) bottling facility in Bloemfontein did not

allow further expansion in the fast moving PET pack & 15 hectares land was available adjacent to the existing depot in Church Street, Bloemfontein

► Planning started June 2007, first commercial production by 26 November 2008

► A number of good design practices have been introduced in the areas of Efficiency, Energy Management & the Environment. The design objectives include:▪ Site designed to accommodate 6 production lines (future)▪ First line with limited flexibility (2 sizes and 3 packs each)

• 2L @ 22,400 bph, • 0.5L @ 25,200 bph, • 90% mechanical efficiency

Project Cheetah Business Requirements► Design Practices (continued):

▪ Trialing a ceramic roof coating for better thermal protection ▪ High efficiency/yield, low cost, low labour complement▪ Automation of process side & high level of equipment automation▪ Process heat recovery

• Blow moulder heat recovery to environment heating in closure & preform stores, when required

▪ Low energy consumption (near ambient)• High-speed syrup making & filling at temperatures up to 20°C• Cold CIP (with Electro-Chemically Activated water) • Energy efficient Factory Lighting - 30% lower electricity usage than traditional

hi-bay factory lights & better colour of lighting

▪ Separation of waste water streams & effluent pre-treatment▪ Maximized water yield from Water Treatment processes (>90%)

• Nano-Filtration streams recovered with Reverse Osmosis• Filter backwashes recovered & re-utilised

Project Cheetah Business Requirements► Design Practices (continued):

▪ Site ergonomics

Project Cheetah

Project Cheetah

Project Cheetah & MES

► Why include MES in this project?► Cheetah plant was to have a low staff complement► Potential to leverage future benefits of SAP/MES

integration► Improve management information for:

▪ Accurate and real-time management information to allow quicker & more accurate decision making in near-paperless environment from shop floor to top floor

▪ Understand performance drivers better in order to maintain line at >90% Mechanical efficiency

▪ Provide full traceability of production▪ Outsourced, in-line bottle supplier, Boxmore Plastics, measured as

part of the total line▪ An added benefit was improved problem identification at the PLC

level

Project Scope

Implement a MES System for the Production facility (process plant and packing line) at

the Bloemfontein PlantUsing industry best practices

Using the latest product offerings from the Wonderware Suite

And to ensure a totally integrated application with a unified look and feel

Project Approach

► Consult▪ Expose client to MES▪ Expose client to international standards▪ Infrastructure requirements

► Design▪ Develop URS trough a series of workshops with key roll players▪ Integration into rest of plant

► Implement▪ FDS (Functional Design Specification)▪ No big bang approach (phases)▪ Design, validate, configure then Implement

► Handover▪ Match Reports with Excel manual data capture▪ Match Delivered Functionality with URS

Project Approac

h

Consult and Design Phase

► Deliverable: URS (User Requirement Specification)▪ Step 1: Define the project objective, business context

and drivers

▪ Step 2: List the departments and systems to be

employed and deployed

▪ Step 3: List and describe the equipment and processes

▪ Step 4: What are the enterprise functions to be

implemented

▪ Step 5: Analysis of activities for the Production or

Operations department

Design & Implementation Phase

► Develop FDS (Functional Design Document)

► Build Use cases in Supervisor and test with Operator

► Select appropriate Use Case and develop solution

► Commission on site to:▪ Integrate plant information▪ Validate production data against manual log

sheet▪ Enable reporting with Client

Use of S95

► How was S95 used to derive a project solution:

▪ Use the S95 Functional Control Model to map the MES requirement for the project

▪ Within each of the Functional Models use the Appropriate Activity model to map the requirements

▪ Use the Process Segments to define the characteristics

▪ Use the S95 equipment model to derive the plant process flow

▪ Used a S95 naming convention which was implemented in ArchestrA Model

S95 Functional and Activity Mapping

ProductionControl

(3.0)Production Inventory

Control (7.0)

Quality Assurnace

(6.0)

Procurement

(5.0)

Production Tracking

Inventory Tracking

Quality test data

Collection

S95 Equipment & Process Model

Raw Material Storage Liquid Processing Intermediate Product Storage

Process Segment

Process Segment Description:Process Segment Equipment:Process Segment Personnel:Process Segment Material:Process Segment Parameters:Process Segment Dependency:

Filling and Packing

Warehousing

Liquid Processing: Process Segment Table 2

Process Segment

Sugar Dissolving

Process Description

Sugar is fed into the dissolving unit and is dissolved using treated water, the solution is fed into an intermediate buffer tank

Equipment Sugar Dissolver, Intermediate buffer tank, UV Unit

Personnel 1 Operator (syrup maker)Material Treated Water, Sugar, Simple

SyrupParameters

Processing rate, volume / time / order, Brix

Process Segment Dependency

Fed from Bulk Sugar Storage and feeds to intermediate simple syrup tank Storage location 0002 – required quantity moved to storage location 0003

S95 Standard Definitions

S95 Expanded Equipment Hierarchy

S95 Process Flow Definition

S95 Integration

Plant Area Data Type Details

Liquid Processing Plant Completed batch data from MES

Batch Number, Batch quantity, bar code information of ingredients, CIP executed

Liquid Processing Plant Process order from SAP List of scheduled Process Orders with order details

Packaging Plant Completed Process order from MES

Process Order Number, quantity produced, quantity rejected

Packaging Plant Process Order from SAP List of scheduled Process Orders, with order details

Reporting Requirements

Report Type Report focus Details Visibility

Packaging line performanceProcess Plant performance

Per Process order, per time period, per machine

OEE (availability, performance, quality)Reason code Pareto charts (quantity and duration)

History with drill down and Real time

Packing Line status Machine Modes, Machine states

As defined in PackML Real Time

Material Tracking Per Process order, WIP per location

Inventory levels Near Real Time

Order Tracking Per Process Order Status and Progress History with drill down and Near Real time

Traceability By Operator, by Process, by Process Order, CIP

Who made what when on what process and equipment

History with drill down

Genealogy By Material Item, by Process order

What was used to produce

History with drill down

CIP Usage What was cleaned when, how

Routes, tanks washed by whom and to what process

History with drill down

OMAC&PackML

► Design called for :

▪ OEM’s was to deliver a OMAC compliant packaging line▪ Build a OMAC / PackML enabled application

► What was deliver from OEM:

▪ Machine alarm list and running bit

► What was done:

▪ Converted basic running / stopped statuses and alarm lists into PackML visualized objects

Machine Modes

Idle

Automatic

Semi-Automatic

Manual

E-Stop

Machine States

Off

Stopping

Stopped

Starting

Ready

Standby

Producing

Holding

Held

Aborting

Aborted

What Caused the change in state and for how long was it in that state

- User Input- Blockage- Starvation

- Electrical Failure- Mechanical Failure

Scope of Project

► Wonderware Performance V3.5► Wonderware Operations V3.5► System Platform 3.0► InSQL V9.0► Active Factory V9.2► InTouch V10.0► Integration of OEM InTouch and ArchestrA objects for

Universal Workstation

Topology

Universal Workstation UW

► Design called for a single interface (low staff complement)► OEM delivered Touch Panels with InTouch► OEM Developed base standards for visualization using

▪ A2 Objects &▪ Faceplates▪ Navigation

► MES leveraged these standards for same “look and feel”

► Here the power of ArchestrA was leverage to create a single look and feel

Plant Overview Screen

ArchestrA Integration

Wonderware Operations

► InTouch used to visualise the operational activities► ArchestrA Objects deployed to interface with plant

instrumentation► ArchestrA Objects deployed to interact with Production

database► Factelligence component used to configure

► Items► Processes► Operations► BOM

Operations Phase 1

Operations Phase 2

Consumption by Entity Report

Genealogy by WO Report

Genealogy by WO Report

Production Yield Report

Wonderware Performance

► InTouch was used to visualise the line information► ArchestrA UCO object used to match PLC alarm bits to

Reason codes► Use Factelligence component used for:

▪ Processes▪ Operations▪ Shift Model

Performance Overview

Performance Drill Down

Performance Drill Down

Production by Shift Report

Should be crates

Performance Report: Downtime

Results to date

Project Approach

Phase 1

Phase 2

Phase 3

Phase 4

What next?

► MES is not a hit and run but an ongoing involvement from business owners

► This was a first small step for CCS/CCF and results and benefits are still being analysed and understood

► Future step may see InBatch added and OEE & solutions rolled back into other existing plants

► Etc….

Questions