Integrated Manufacturing Operations for CPG & Process€¦ · Integrated Manufacturing Operations...

Integrated ManufacturingOperations for CPG & ProcessFilip SchiettecatSiemens Industry Software

PLM Europe 2017Berlin – Estrel Hall C1 I October 24, 2017 – 17h00

Realize innovation.Unrestricted © Siemens AG 2017

Digitalizationchangeseverything

© Siemens AG 2017April 2017 siemens.com

© Siemens AG 201719/06/2017Page 3 Siemens Industry Software

Master Chef in NYC3D-print vacation

memories in chocolate

Coca-Cola enablescustom formulations

from your smartphone

Mondelez enablespersonalized packaging

Digital is transforming the CPG IndustryPersonalizing products



Today’s challenges in the CPG & Process industry

High quality demand High cost pressure

Global and regionalregulatory compliancy

Increasing variety ofproducts and recipes

Fast changing consumerdemands

Global setup – Distributedplants



Our customers have essential requirements –throughout the CPG & Process industry

Security

Speed Flexibility Quality Efficiency



Integrating and digitalizing the entire value chainis key to staying competitive in the future



Creating a Powerful Digital Twin of the entire value chain



Our holistic approach in the CPG IndustrySpecific for process and discrete part of the digital enterprise

Process value chain

Engineering Operation Services3 4 5Productdesign

Process-and plantdesign

1 2

Discrete value chain

Productionengineering

Productionexecution

Services3 4 5Productdesign

Productionplanning1 2


Productionexecution



Producing, filling and packaging a hybrid CPG product requires specific technologies and processes




Productionexecution



Digitalization in the CPG industryProduct Design

Formula Design Package DesignProduct andformula design

Regulatorycompliance

Suppliercollaboration

Trials,sampling &testing

Artworkdevelopment

Packagedesign

Simulation &digitalprototyping

Label designandcompliance



Digitalization in the CPG industryProduction Planning

Creation ofgeneral recipe

Trial runs

Modeling theproductionfacility

Capacitysimulation ofthe plant

Creation of thebill of process

Collaborativeline design

Simulation ofcritical processsteps

Simulation andbottleneckelimination

Modeling & simulating theproduction facility

Planning thefilling & packaging line


Productionexecution





Digitalization in the CPG industryProduction Engineering

Automation designof the process

Automation designof the filling & packaging line

Plant design

Electricaldesign

Automationengineering

Machinedesign

Mechatronicsintegration

Automationengineering

VirtualCommission-ing


Productionexecution





Production PlanningLine Layout

Your Digital Plant isready for use !



Digitalization in the CPG industryProduction Execution

Order execution &integrated quality control

Orderdownload &scheduling

Reporting &qualityexecution

Orderexecution

Energyefficiency

Orderdownload &scheduling

Reporting &qualityexecution

Linemanagement& execution

Energyefficiency


Productionexecution



Order download &scheduling



Digitalization in the CPG industryServices

MindsphereEnergy Analytics

MindsphereSmart Condition Monitoring

EnergyAnalytics

SmartConditionMonitoring

SecurityServices

Drive TrainAnalytics

EnergyAnalytics

SmartConditionMonitoring

SecurityServices

Drive TrainAnalytics


Productionexecution





Use Simulation to achieveforesight in the Virtual World

Summary – The Vision Comes to LifeKey Advantages of Digitalization

Use Big DataAnalytics to gaininsight and drive

continuousimprovement

Seamlesslycoordinate and

control resourcesin the real world


Productionexecution





Manufacturing Operations Management

Production Execution

Role of Manufacturing Operations within the Digital Enterprise– Realize Innovation

TeamcenterVisualization/Graphics Bus (JT + Atlas + Augmented Reality)

Product Lifecycle Mgmt.

DesignEngineering

Simulationand Test

ManufacturingEngineering

LifecycleAnalytics

SLM

Team

cent

er

Run-Time Manufacturing Operations Service Bus

ManufacturingExecutionSystem

QualityExecutionSystem

AdvancedPlanning &Scheduling

EnterpriseManufacturing

Intelligence

Automation / SCADA



Customfunctionality

Customfunctionality

Customfunctionality

3rd partyfunctionality

Siemens Platform Approach for Production Execution

An integrated unified system responds with significantimprovements in Speed, Flexibility and Efficiency

Monolithic MES/MOM approach

Custom Dataintegration

Customfunctionality

Customfunctionality

Custom UserInterface

CustomAlarm/Alert

ManagementCustom KPIs CustomHistorian

CustomReporting

Customfunctionality

Custom DataManagement


Implementation of MOM requires consideration of existinglegacy systems to protect customer’s investments



An integrated unified system responds with significantimprovements in Speed, Flexibility and Efficiency

Customfunctionality

Customfunctionality

Customfunctionality

3rd partyfunctionality MES EMIAPSQuality

Siemens Platform Approach for Production Execution

… and increases the value adding the standard Siemens MOM Portfolio


MobilityComposed applicationsShared services



Manufacturing Operations Management for CPG/Process IndustryCommon Process Model

Logistics Storage

Material Reception &Tank Farm

Manufacturing Operation Management System

Primary Production(Continuous & Batch)

Secondary Production(Packaging/Bottling, Palletizing)

Warehouse &Distribution

Finished Goods ProductionTransformation into SemiFinished Goods

Delivery toWarehouseSupplier Incoming Materials

Supplier ITSystems



Integrated Manufacturing OperationsThe 6 Pillars of our Configurable MOM Solution Portfolio

Integrated Manufacturing Operations

Order Downloadand Scheduling Order Execution Quality

ExecutionProductionReporting

Product Tracking& Genealogy

ManufacturingIntelligence



Order Download and SchedulingProduction Optimization by detailed scheduling

Order Download andScheduling§ Orders download from ERP

§ Order scheduling by standardor specific algorithms

§ Manual update of schedulingdata

§ Scheduled orders ready to bedispatched in production



Order Execution§ Coordination of automatic and

manual tasks

§ Batch engine integration

§ Quality enforcement duringproduction

§ Synchronization of Batchexecution with quality

Order ExecutionProduction Process Integration and synchronization



Production ExecutionIntegration and synchronization of Production & Quality Process

Production Execution§ Production operations and

quality operations go handin hand.

§ Coordination of automaticand manual tasks

§ Batch engine integration

§ Orchestrated Qualityoperations duringproduction

§ Alignment on qualityspecifications andprocesses is key



Quality Execution§ Manage the quality data &

workflow in laboratories andplants, optimizing datacollection, analysis andreporting

§ Support off-line and at-linetesting in laboratory and onmanufacturing floor

§ Support for complex testplans/methods definition andexecution in different contexts

§ Deviation Management

§ Quality Reporting

Quality ExecutionOrchestrated testing to ensure proper product quality



Production Reporting§ Production Order Tracking

(times, material quantities,equipment units)

§ Actual production datacompared with Estimatedscheduling data

§ Electronic Batch Report

Production ReportingProduction Visibility on all the operational details



Product Tracking &Genealogy§ “Backward genealogy”: Raw

Materials used for oneFinished or Semi FinishedLots

§ “Forward genealogy“: Finishedor Semi Finished Lotsproduced using one RawMaterial Lot

§ Full Product recall capability torapidly assess the impact of acontaminated material

Product Tracking & GenealogyEnsure Compliance through full product tracking



ManufacturingIntelligence§ Deliver Production KPIs based

on real data collection

§ Analysis and drilldown intoOEE KPIs

§ MES data contextualization

§ Platform independentvisualization

§ Easy and intuitiveconfiguration of newdashboards

Manufacturing IntelligenceEfficient analysis of Production KPIs



Siemens Manufacturing Operations Management PlatformEnables standardization across plants

SIMATIC IT UA



Configure your operator screens and manufacturing processesA key differentiator for our platform

Engineering of end-user screen throughMash-Up Editor

Using the configured operator screen to seematerials and the track & trace info

CONFIGURATION RUNTIME



Configure your tasks and manufacturing processesGraphical Work Orchestration to link task and processes together

Work Orchestration§ Configure tasks for your

specific processes

§ Define the sequence of tasks

§ Easily orchestrate individualtasks or task sequences bymeans of a graphical workflow

§ Establish ManufacturingOperations Catalogs for yourcompany

§ Platform independentvisualization

§ Easy to maintain

§ Easy to upgrade



Manufacturing Operations Management for CPG & Process IndustryFrom “Points of Pain” to Business Benefits

Vertical integration to connect ERP and Automation Systems

Integrate Quality and Production

Product and Production Traceability

Process raw data into Key Performance Indicators (KPIs)

KPIs analysis for stakeholders

Implement ERP Production Orders

Increase efficiency

Increase Product Quality

Compliance to regulations

Process Visibility for Continuous improvement

Realtime asset and production monitoring

Optimize production timeOptimized use of available resources

Timely and proper execution for both automatic and manual tasks



Holistic Digital Twin

What is our Special Sauce?Digital Twin

Gain foresight bysimulating products,people, processes andresources interacting inthe virtual world

Gain insight bymatching real-worldperformance to yourdesigns so you can

drive continuousimprovement



This is what you gain

Security

Speed Flexibility Quality Efficiency



Great Wall Wine Yantai Co Ltd –Consistently highest quality with MESBusiness benefits• Data availability for responsiveness and informed decisions• Aggregation of data on all aspects affecting the end product• Standardization of the entire production process• Improved efficiency and quality• Fewer process errors• Traceable production information

Production executionSIMATIC IT

Proof from Practice

Production executionSIMATIC IT R&D Suite

Grupo Campari -Key steps towards the Digital EnterpriseBusiness benefits• Unified repository for all (approximately 21,000) product

specifications, accessible via Web to internal stakeholders• Standardization of contents, collection and validation processes.• Integrated management of analysis on products, incoming goods

acceptance process and release to production• Acquisition and management of

plant efficiency and performancedata with real-time reporting tools



Digital Enterprise Suite –Realize your digitaltransformation

Make thefuture yours.



Thank you !Danke !

siemens.com/mom

Filip SchiettecatHead of Industry Management CPG / Process

SiemensDigital FactoryProduct Lifecycle [email protected]

siemens.com/industrysoftware

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