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7/31/2019 Fleischindustrie En

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Maximize EfficiencyDeliver the Lean Cut


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usiness Goals

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effe


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tivenessWhat does it take to improve operational performance,efficiency and flexibility?

Major changes have occurred in the meat and poultry industry in recent decades. Manufacturers

must be able to rapidly respond to dynamic consumer markets, and to minimize manufacturing

costs. They need to master both the supply chain and distribution networks and optimize quality.

All while simultaneously meeting regulatory requirements.

The need to monitor performance, yield and quality as well as production capacity and producti-

vity is driving the meat and poultry industry to adopt more advanced manufacturing operations

systems. These new manufacturing systems allow comprehensive operational performance

management across processes, resources, lines and plants, enabling efficiency and productivity

improvement and quality. Finding the right enabler to do so is on top of the agenda in more

than one board room.

Siemens understands these challenges, and offers SIMATIC IT for manufacturing optimization.SIMATIC IT is the premier Manufacturing Execution System (MES) for the meat and poultry

industry. SIMATIC IT allows meat and poultry processors to exploit new sources for greater effi-

ciency, and to better manage the product and production life cycle. It delivers consistent quality

by bridging the gap between the supply chain, enterprise business systems and the plant floor.

SIMATIC IT comes with functionality tailored to the specific needs of the meat and poultry

industry, and offers real-time information management, automated information flows, plant

responsiveness and flexibility.

What can we do for you?


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Challenges

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Every day meat & poultry processors face multiple, often contradictory

challenges balancing their delicate production priorities between dynamic

customer order requirements, strict food safety and quality standards,

robust regulatory requirements, and ambitious financial performance

metrics.

Todays consumers are demanding products with guaranteed standards

of taste, safety, consistency, and quality while also expecting new, innova-

tive product and packaging developments. Meat & poultry processors

must balance these consumer requirements with their own goals of finan-

cial performance, regulatory compliance, and brand-image growth and

preservation. In order to meet consumer requirements, differentiate their

products, and expand financial margins, meat and poultry processors

are utilizing increasingly complicated processing technology, including

the application of sophisticated flavoring, marination, battering, cooking

methods, portioning, and packaging. This additional complexity presents

challenges throughout the organization, from the R&D lab through finished

goods packaging. Throughout this fast-paced, dynamic production life-

cycle, meat and poultry producers are challenged to optimize production

efficiency, minimize waste, ensure product quality and safety, and maximize

the use of available resources.

Managing fast-paced production environments while balancing the factors

of financial performance, production throughput and efficiencies, food

quality and safety, and consumer satisfaction requires real-time visibility

and control of the manufacturing process infrastructure. Meat & poultry

producers increasingly seek to deploy technology solutions that provide

robust capabilities in managing real-time production information in order

to optimize throughput and efficiency, ensure complete food safety,

guaranteed quality, and maximize scheduling flexibility across their opera-

tions. They are rapidly discovering that proper implementation of a com-

prehensive; fully integrated Manufacturing Execution System (MES) pro-vides the foundation for control and flexibility they need to meet this

delicate balance of priorities.

Darrel R. Suderman, Ph.D.Dr. Darrel Suderman has a Ph.D. in Food Science and more than 20 years of

hands-on manufacturing experience at leading companies. He is a recognized

international speaker on food and beverage processing and manufacturing

systems.


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Missing the Real ROI: MES as a Case Study

August 11, 2003 AMR Research Alert Bill Swanton, Alison Smith

AMR Research interviewed more than twenty companies thathad implemented MES (Manufacturing Execution Systems)

recently. We found that companies saw three tiers of benefits

from their projects:

Cost reductions

(1x savings in the first year)

Inventory, costs, people, and cycle time.

Process improvements

(3x savings in the second year)

Faster New Product Introduction (NPI), new customer compli-

ance, and data services from better tracking and genealogy.Market improvements

(10x savings in the third year)

Tuning the manufacturing operation to be extremely responsive

to actual demand allows companies to capture market share

without increasing costs.

MES Provides Long-Term Revenue and Market Benefits

Beyond Easy-to-Quantify Operational Cost Savings

July 30, 2003 AMR Research Report Bill Swanton, Alison Smith

The largest benefits of MES come from leveraging the visibility

that MES affords into overarching continuous process improve-

ment and supply chain management strategies. At a fraction of

the cost and time of an ERP initiative, an MES platform provides

visibility into accurate, high-velocity information about produc-

tion performance. This enables manufacturers to recognize and

then seize new opportunities both internally and in the market-

place.

By extending production visibility throughout the internal supply

chain, one manufacturer increased profit margins on both highervolumes and higher product mix, all while keeping costs con-

stant. The net effect was to preserve profitability despite lower

sales a universal theme for manufacturers in todays uncertain

economy.

Reprinted with the permission of AMR Research.


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In order to address food safety and quality issues, increase plant performance

and yield optimization, meat & poultry processors want to increase manu-

facturing flexibility, maximize throughput and automate work and information

flows. This requires systems that can enhance manufacturing capabilities.

In highly dynamic markets with increasing consumer and retail demands,

meat & poultry processors need to reduce manufacturing cycle times and

achieve undisputed quality standards. SIMATIC IT can synchronize the plant

and machine-related processes with plant business systems, creating manu-

facturing standardization and driving best practices. This results in optimized

quality and efficiency.

How do you drive efficiency?

Meat and poultry processors must reconcile quality wit

quality and IT systems have to be synchronized within a

production transparency, enable real-time planning an

quality and production-related activities. This will reduc

excellence.

SIMATIC IT coordinates and synchronizes business and

tion exchange between IT manufacturing systems and

SIMATIC IT enables the implementation, execution, syn

flexible modeling environment with automated workflo

Market Respons

Supply Chain

Food Safety a

Yield Optimiz Increasingly S

Requirements

Faster Time-t

Highest Qual

How do you measure performance and leverage rea

Capacity optimization has become a major challenge.

ment and analysis in order to achieve continuous impr

no longer be a black box; real-time performance mana

face a critical need to enable real-time information flo

the production process. Manufacturing systems should

throughput and quality.

SIMATIC IT provides the right information to the right i

decision support and continuous improvement accord

tracing, plant floor resource capacity information, and

shared and leveraged across the enterprise.

Produc

How do you achieve regulatory compliance?

Physical measures of tracking such as paper-based systems or ear tagging may be vulnerable to loss, errors or

even fraud. Information demand from customers in the meat and poultry supply chain is still growing due to

the increased awareness of food safety and greater concern about quality control. These demands result in the

need for adapted IT systems that are able to collect, record and connect data. The FDAs Bio Terrorism Act and

regulatory guidelines such as Country of Origin Labeling dictate that meat and poultry processors implementintegrated farm to fork tracking and tracing systems.

SIMATIC IT can complement traditional tracking systems to include animal and lot tracking from individual farms

through the processing plant and subsequent distribution centers to the consumer point of sale. SIMATIC IT

provides data collection, database management, ingredient and product tracking, production process visualization

and reporting capabilities as an extensive regulatory compliance platform.

Traceability and Genealogy Mark


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anufacturing cycle times. Supply chain, production,

ants. Companies face a critical need to increase

, while acquiring the capability to synchronize all

ut times and result in a high level of operational

processes through a seamless and complete informa-

or, providing interoperability between all systems.

and control of all operations through a uniquely

and Flexibility

cs

urity

egulatory

t

ctations

uction information?

of data and systems allowing data capture, measure-

operational efficiency is a must have. The plant can

key component of enterprise success. Companies

erformance management has to be integrated into

nitor and control essential KPIs including yields,

the right time. It enables the right metrics for critical

usiness objectives defined. Through WIP tracking and

roduct genealogy, real time information can be

ciency

hlightsHow do you integrate quality and production for closed loop control?

Consumers are increasingly concerned with food safety issues, inspiring regulatory bodies to increase require-

ments, laws and regulations. At the same time, manufacturing performance has to be protected. This implies that

quality and production systems need to be seamlessly integrated. It also demands immediate notice of variances

in product quality and integrity. Performing quality controls without the laboratory becoming a bottleneck

requires the ability to schedule these tests and allocate the right resources and equipment beforehand. Optimalefficiency comes when integrating plant operations with quality management systems, and connecting quality

data with production data for extensive decision support.

SIMATIC IT closes the gap between the laboratory and the production allowing in-line testing. SIMATIC IT

completely integrates quality control and assurance into production processes, thereby enabling tracking and

tracing, full product genealogy as well as regulatory compliance through advanced reporting capabilities.

SIMATIC IT also allows the implementation of HACCP principles.

Quality and Food Safety


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SIMATIC IT

SIMATIC IT Enabler for Manufacturing

Optimization

Due to its modular, object oriented, open and scal-

able architecture, SIMATIC IT enables customers to

standardize processes at a high level, while obtaining

previously unachievable flexibility at the operational

level. This unique approach makes it possible to:

Roll-out solutions smoothly and gradually

Implement changes and enhancements easily

Reuse previously defined business logic to

reduce project duration

Preserve capital investments

SIMATIC IT Cross-Industry Libraries

Libraries offer pre-configured, dedicated functionality

for the meat and poultry industry. With reusable

functions, the SIMATIC IT Cross-Industry Libraries

lower Total Cost of Ownership by providing scalable,

repeatable functionality.

SIMATIC IT ISA-95 Compliance

ISA-95 is increasingly being accepted as the world

standard for Manufacturing Execution that customers

are relying on to secure their investments in MES.

SIMATIC IT not only covers all ISA-95 functions,

but also uses ISA-95 as a blueprint for its product

architecture. As an active Member of the ISA-95

Committee, Siemens continues to contribute to the

further development of the standard.

SIMATIC IT and Totally Integrated

Automation

SIMATIC IT is an integral part of Totally Integrated

Automation (TIA), the Siemens unique common

basis for customer-specific automation solutions thatsatisfies a whole range of automation requirements.

SIMATIC IT benefits from this integration with the

rest of the Siemens product line, thanks to a wide

range of pre-configured objects, ready to be used

without any other engineering effort. TIA allows quick

project implementation, native integration with other

Siemens automation offerings, and compatibility

across different generations of products.


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ERP

SIMATIC IT Framework

SIMATICITProdu

ctionSuite

SIMATIC (control level)

SIMATIC IT Components Material Manager

Order Manager

Personnel Manager

Messaging Manager

Report Manager (optional)

SIMATIC ITInterspec

SIMATIC ITHistorian

SIMATIC ITUnilab

3rd Party

Components

3rd Party Devices

SIMATIC IT Production Suite

The SIMATIC IT Production Suite is composed of the

SIMATIC IT Framework and SIMATIC IT Components.

The SIMATIC IT Framework provides a graphical

environment to model production process, equip-

ment and facilities intuitively, and without the

necessity of programming skills. The graphical pro-

duction model offers a clear understanding of the

plants behavior and visualizes the entire production

status.

The SIMATIC IT Components include basic and

guaranteed MES functions for order management,

material management, product definition manage-

ment, messaging, personnel management, report

management, barcode scanning and data integra-

tion with the plant floor and with enterprise systems

using B2MML.

SIMATIC IT Historian

SIMATIC IT Historian is a collection of software modules

to collect, store and quickly retrieve process and

production information used for Quality Assurance,

Reporting, Certifications, Statistical Analysis,

Performance Monitoring, Down Time Management

(DTM), and Overall Equipment Effectiveness (OEE).

SIMATIC IT Historian may be used on its own, or as

an integrated part of SIMATIC IT.

SIMATIC IT UnilabSIMATIC IT Unilab is the multi-plant Laboratory Infor-

mation Management System (LIMS) that handles all

quality data in the laboratory (samples, analysis,

instruments, etc.) and conforms to all industry and

laboratory standards, including GLP, GAMP, ISO, and

21 CFR Part 11. SIMATIC IT Unilab may be used on its

own, or as an integrated part of SIMATIC IT.

SIMATIC IT Interspec

The Specification Management System handles product specifications for rawmaterials, semi-finished and finished products as well as packaging materials.

This incorporates company-wide specifications as well as individual specifica-

tions for a single plant, supplier or customer.

SIMATIC IT Interspec is the single point of reference for all product specifica-

tions and supports compliance with 21 CFR Part 11. SIMATIC IT Interspec may

be used on its own, or as an integrated part of SIMATIC IT.

SIMATIC IT Report Manager

This optional component of SIMATIC IT offers advanced, fully integrated and

user-friendly reporting functionality. The Report Manager meets regulatory

requirements for ad hoc reporting and offers valuable operational insights.

SIMATIC IT Client Application Builder

Thanks to the data visualization interface of SIMATIC IT Client Application

Builder, all business related information is integrated and aggregated into

reports, enabling better management decisions and supporting regulatory

compliance. These high level financial performance indicators enable increased

competitiveness and promote continuous improvement of business.


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dded Value

SIMATIC IT Framework, Components and Libraries facilitate and

synchronize operations all along the production lifecycle including

material and order management, product definition management,

planning, production, and laboratory information management,

as well as product specification management, tracking, tracing

and production analysis and optimization.

From Global to Local Design

Management of product diversity and

fast market response

SIMATIC IT Interspec formulates, manages

and distributes both enterprise-wide as plant

and customer specific product specifications

for raw materials, semi-finished and finished

products as well as packaging material. Thanks

to the integration with the ERP system, it

can also hold the extensive list of co- and

by-products and list them in the BOM.

Download Orders

Leverage the potential of your

IT infrastructure

SIMATIC IT allows bi-directional dataexchange with enterprise business systems,

including ERP and WMS systems to providebetter manufacturing visibility and to pro-

vide the necessary tight link between the

ERP level and the plant floor. This integra-tion allows synchronization of all activities,

avoiding bottlenecks and reducing non-pro-ductive work as well as the risk of data

inconsistencies.

Plan and Map Resources

Optimize throughput, production flexibility

and asset utilization

SIMATIC IT offers the maximum degree ofplant information and performancemeasurement necessary for compliantdelivery and monitoring of critical controlpoints defined in the HACCP plan. Usingreal-time data, SIMATIC IT optimizesresource utilization and throughput whileincreasing the flexibility necessary to makeadjustments during production.


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SIMATIC IT along the Production Lifecycle

Test

Seamless integration of QA/QC processes

SIMATIC IT Unilab is a market-leading

Laboratory Information Management

System (LIMS) to manage laboratory work-

flow and samples. Analysis and analysis

results can be integrated automatically into

the processing workflow and included in

HACCP reports as a proof of regulatory

compliance, without causing any delays due

to waiting for test results.

Analysis and Optimization

Continuous improvement of performance

and quality

SIMATIC IT Historian enables the definition

and calculation of Key Performance Indica-

tors (KPIs) such as WOG yield, debone yield,

moisture content, giveaway and quality in

order to measure business performance. It

provides Management with the tools neces-

sary to analyze and report on the data, thus

creating a useful information source andproviding possibilities for improving manu-

facturing performance and quality.

Define Processes

Enforce standard procedures but

accommodate plant uniqueness

SIMATIC IT enables the central definition ofprocesses and procedures, yet takes into

account local plant resources and con-

straints. This enables consistent and homo-

geneous production procedures throughout

various plants for better standardization,

and lower operating costs. It also has the

ability to easily modify and control manu-

facturing procedures according to local

plant requirements and new production

and product needs.

Produce

Coordination and synchronization of

all operations

SIMATIC IT coordinates all activities needed to

drive and optimize production in real time and

to improve quality while at the same time

shortening time-to-market through more effi-

cient production procedures. Significant cost

savings will be the direct and immediate result

of first-time-right production, quality tests with

the earliest possible recognition of non-compli-

ance and if necessary automatic and appro-

priate responses to out-of-spec conditions.

Track and Trace

Genealogy and regulatory compliance

SIMATIC IT enables the tracking of every

material movement and offers full

upstream and downstream genealogy,

including extensive reporting capabilities

as well. It enables the meat and poultry

industry to react in a timely manner to

requests from regulatory bodies as well as

to limit liability in food safety scares and to

preserve brand quality and image.

Analyse

GlobalDesign

LocalDesign

MapResources

DefineProcesses

DownloadOrders

Test

Produce

Track &Trace

Optimize


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More flexible, efficient and faster

SIMATIC IT continues the success story of TIA (Totally IntegratedAutomation). SIMATIC IT is a scaleable system, enabling total integration

and full support of existing industrial standards with a component

based approach.

SIMATIC IT Framework synchronizes, analyzes, coordinates and

optimizes production. Heterogeneous applications can be integrated

to better manage the complexity of production data and processes.

SIMATIC IT Components provide superior manufacturing functionality,

such as Laboratory Information Management, Production Performance

Management, Material Management and Product Specification

Management. These components can be coordinated by SIMATIC IT

Framework, or used as independent applications.

The proven interaction of the different components leads to higher

efficiency and quality, and protects your investments in existing plant

resources and systems.

Where do we go from here?

More information:

[email protected]

www.siemens.com/simatic-it

Competence Center Food & Beverage:

www.siemens.com/food

Competence Center Food & Beverage (US):

www.sea.siemens.com/foodbev

Siemens AG

Automation and Drives

w w w . s i e m e n s . c o m / s i m a t i c - i t

SIMATIC IT is a registered trademark of Siemens AG.

If trademarks, brand names, technical solutions and similar are not specifically

mentioned, this does not mean that they have no protection.

The information provided in this manual contains merely general descriptions

or characteristics of performance which in case of actual use do not always

apply as described or which may change as a result of further development

of the products. An obligation to provide the respective characteristics shall

only exist if expressly agreed in the terms of contract.

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