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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AT LEAST W
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DVANCED
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
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