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The Journey to More Effective Packaging Automation
Bryan Griffen Nestlé E&A Engineering Manager
OMAC Packaging Workgroup Chair
The world’s leading nutrition, health and wellness company May 2012
Topics we will cover
• Nestlé: The world’s leading nutrition, health and
wellness company
• PackML: Our packaging automation vision
− The packaging simulation
− Designing a more effective HMI
− A specification for everyone
− Our traveling salesman…
• The value and benefits of implementing PackML
• Conclusions
2 B. Griffen May 2012
Nestlé: The world’s leading nutrition, health and wellness company
Our objective is to be recognized
as the world leader in Nutrition,
Health and Wellness, trusted by
all our stakeholders, and to be
the reference for financial
performance in our industry.
3 B. Griffen May 2012
Nestlé at a glance: key figures
• CHF 109.7bn sales in 2010
• CHF 34.2bn net profit in 2010
• CHF 16.2bn Group EBIT in 2010
• 281,005 employees
• 443 factories
• Factories in 81 countries
• Products sold in more than 140 countries
4 B. Griffen May 2012
1867 1866
1929
1938
1947
1960s
1970s
1980s
1990s
2000s
Henri Nestlé
1866
The Nestlé story – how it all began
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Nestlé products & brands: instantly recognizable
• 10,000 different products
• Around 1 billion products sold every day
• A product for every moment of every day, from
morning to night and from birth to old age
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A brief history of automation and packaging at Nestlé
• Engineering in Nestlé is traditionally process-oriented – we own and
manage our process solutions – We design and automate the key process units
– Rockwell Automation is our solution provider for process automation
• We typically do not own the solutions for the packaging hall – We have a strong focus on materials, aspect and machine capabilities
– No real efforts have been placed on machine automation standards
• Packaging OEMs very often have their own automation platform
specification – Changes to their specified platform increases costs
– No guarantee on performance is given if they must use a different platform
• It is now time to set a new direction…
8 B. Griffen May 2012
Goal: Purchase machines from many suppliers around globe
and integrate them to create a packing line system.
Problem:
◦ No software consistency between machines
◦ No software consistency between like machines from same OEM
◦ Horizontal and vertical Integration is difficult and time consuming
◦ Training challenges for operators and technicians.
◦ Hard to troubleshoot
Solution… Embrace & deploy industry software standards
Why doesn’t the manufacturing machine industry have software
standards like the military, IT world, financial industries, etc.?
9 B. Griffen May 2012
The Wild West of software
Copyright © 2010 Procter & Gamble. All rights reserved.
Nestlé’s vision for packaging automation
• Support sustainable financial performance through reduced total cost of
ownership and increased automation
• Enhance manufacturing competitiveness by improving OEE
• Optimize the control of packaging equipment through:
‒ Implementation of international standards
‒ Realization of horizontal (line) integration
‒ Providing links to vertical MES/ERP systems
• Improve the operational safety of packaging equipment
10 B. Griffen May 2012
The vehicle that will help us realize our vision… OMAC
– Organization for automation and manufacturing professionals, including end-
users, machine builders, and technology providers
– Dedicated to advancing manufacturing capabilities and efficiencies through
identifying common problems, standardization, and improvements to
processes that positively impact the way companies do business
PackML
– Industry standard programming structure that drives a common look and feel
between equipment:
– Defines operational state of a machine (State Model)
– Provides for operational modes (Auto, Manual, Jog, Clean Out, etc.)
– Standard information to/from machines (PackTags)
– Modular coding for re-application libraries and diagnostics
– Foundation for horizontal & vertical machine integration
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• Industry standard (ISA TR88.00.02)
• Software design methodology that leads to: ‒ Common operational look and feel between equipment
‒ Defines operational state of a machine
‒ Provides for operational modes
‒ Standard information to/from machines (PackTags)
‒ Modular coding for re-application libraries and
diagnostics
• Applicable to other types of machine systems
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What is PackML (Packaging Machine Language)
Simulation line layout
Pick and place: Picks up products and
arranges them on a conveyor for the
case packer.
Case Packer: Fills cases with products
and then closes the case.
Case Maker: Erects the case, then
positions the case on a conveyor
ready to be filled.
Wrapper: Places and wraps a quantity
of cartons.
Pick and Place Case Packer
Ca
se
Ma
ke
r
Wrapper
Equipment SensorConveyor
13 B. Griffen May 2012
Three-fold target of the first prototype
Validation of the Horizontal Line Integration Concept
1. Use an international standard as the solution (OMAC/PackML)
2. Make equipment coordination without a line integration PLC
3. Demonstrate that multiple automation suppliers can communicate on a single network and protocol
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Ethernet TCP/IP utilizing a Weihenstephan-based structure:
Current status: Machine-to-machine communications
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Case Packer Case Maker Wrapper Pick & Place
Ethernet TCP/IP
Status/Cmd
PackTags
Status/Cmd
PackTags
Status/Cmd
PackTags
May 2012
Successful points
Use of an international standard solution (OMAC/PackML)
Coordinated equipment without needing a line PLC
Demonstrated that Rockwell, Siemens, B&R and Schneider can communicate on the same network and protocol
Simulation line conclusion
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HMI standards are needed to improve operator efficiency Actual status of individual HMIs for one packaging line...
May 2012 21 B. Griffen
Elevator Caser
Coding filing bag Bag filler VFFS
Check-weigher
Cartoner (CAMA)
Metal detector
Bar code reader Bar code
check
X-ray detector Ink-Jet cartons
Metal detector
finish carton
Ink-Jet case
Many current machine interfaces are not user-friendly and add complexity to run machines
22
• More than 200,000 HMIs are currently
used in Nestlé Factories
• More than 70,000 people involved in
packaging operations worldwide
• All screens have a different aspect and
this creates confusion and hinders staff
flexibility
• A specific training is required for each
equipment, this costs money and takes
too much time
B. Griffen May 2012
A standard HMI solution has been developed Packaging and Automation have worked together to define a standard
look-and-feel for operator interfaces
May 2012 23 B. Griffen
Advantages of using an HMI template: 1. The users interface will be more friendly
2. The operators will be more mobile
3. Gives more diagnostics on equipment
Current status: • Initial HMI specifications is completed
• Currently under internal validation
• Pilot applications are being executed
HMI harmonization will simplify machine operations
24 B. Griffen May 2012
Next Steps: • Integration with PackSpec initiatives from OMAC
• Inclusion in the general URS for packaging
equipment sold to Nestlé
Next steps: On screen diagnostics will reduce downtime and improve efficiency
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Next steps: One safety standard for the entire production plant
Creating an open safety protocol (similar to the PackML concept) enables
increased productivity for the plant
• Cost reduction
• Less down-time
• Higher productivity
• Easy maintenance
Concept under review
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Provide real-time data for:
• Machine/line configuration parameters
• First-fault determination
• OEE calculations
Next steps: Vertical integration into the MES layer
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A general URS with eight modules covers Nestlé’s packaging requirements
1. Procurement module
2. Line integration module
3. Equipment module
4. Safety, health and
environment module
5. Hygienic module
6. General design module
7. Quality module
8. E&A module
- Checklists
29 B. Griffen May 2012
A packaging Equipment is composed of 6 important modules
Fully Integrated Packaging
Electrical
Line Integration
MES
PLC
HMI
Safety
Software
& Hardware
30 B. Griffen May 2012
Electrical specifications were the basis to start the standardization
Content
• Labeling
• Grounding and shielding
• Wiring
• Buttons and alarms management
• Documentation
Status
• Delivered in September 2011, currently in use for all new machine
specifications
• Used as a check-list during the FAT
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Working group :
• Safety, Health and Environment
• Manufacturing Operations
• Packaging
• Engineering
Two tools have been developed :
• Safety specifications
• Safety check-list
Status:
• Safety specifications delivered in November 2011
• Training material currently under development
Safety is a key module for us
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A physical prototype will help us to validate the line integration model
This platform will be composed of : - Festo modules
- Staubli robot
- 4 vendors PLCs and HMIs (Siemens, Rockwell,
Schneider and B&R)
- 1 SCADA (Wonderware)
Goal of the prototype : - Communicate M2M
- Implement line supervision
- Fully implement OMAC state model
- Evaluate the HMI template
- Implement stoppage reason codes for MES
Timing : - Commissioning in week 21 (this week)
- OMAC line integration implementation guide
(addition to P&G guideline) planned for September
34 B. Griffen May 2012
Benefits of PackML for end users
• Benefits of implementing a standard ‒ PackML & PackTags are part of an international standard
‒ Consistent data and control structure to share information both horizontally
(machine to machine) or vertically (machine to SCADA/MES)
‒ Easier line integration and startup
• Enhanced operations ‒ A consistent state model enables common engineering platform for all
machines within a packaging line
‒ Common look and feel for HMI requires less training
‒ Standardized interface and predefined PackTags enables easy integration
with factory standard HMI/MES
• Business benefits ‒ Promotes best-in-class solutions focused on innovation
‒ Reduced total cost of ownership (TCO)
38 B. Griffen May 2012
Benefits of PackML for OEMs
• Improved development cycle ‒ Control platform independent, allowing the OEM to select the technology
platform that will best suit their needs
‒ Greater reapplication of reusable, modular programming modules that work
for a variety of End User
‒ Less customized code to test
• Improved customer delivery ‒ Reusability of proven software reduces time to market
‒ Easy integration and startup at customer site, especially when working with
other OEMs and Systems Integrators
‒ Simplified post-sale support due to consistency from End User to End User
• Business implications ‒ Allows for greater focus on innovation & machine capability
‒ Intellectual Property still maintained
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Benefits for Systems Integrators
• Reduced engineering effort ‒ Consistent data and control structure for bringing in information from multiple
OEMs and serving it up to End User SCADA/MES systems
‒ Consistency when working with multiple automation platforms and OEMs
‒ Consistent structure enables concurrent engineering
‒ Reusable, modular programming modules applied for a variety of End Users
• Enhanced offerings ‒ Focus on value-added activities such as MES, maintenance tools, etc. instead
of integration concerns
‒ Ability to develop “standardized” integration packages that result in
reapplication of code and bigger margins
• Improved delivery ‒ A single protocol means less worry about start-ups, faster commissioning, etc.
‒ Less service calls for integration concerns that may not have been discovered
during start-up
May 2012 40 B. Griffen
Benefits for Technology Providers
• Development strategies ‒ Wider range of discrete machine applications by using an industry standard
(ISA TR88.00.02 plus S88 Part 5) instead of a propriety solution
‒ Easy integration of control systems into an existing environment
‒ Reduce the efforts in developing multiple networks and protocols
‒ Concentrate on innovative technologies
• Business implications ‒ PackML standards are becoming widely accepted by End Users, Technology
Providers and OEMs
‒ Show competitive advantages instead of discussing integration issues over
and over again
‒ Open the global market of packaging machines to all Technology Providers
(get rid of the hard specification of one single supplier)
‒ Internal efficiency and consistency when training engineering and customer
support teams, as well as for on boarding of new engineers
May 2012 41 B. Griffen
What we have learned in our journey
• We believe that we have found a solution to improving the
overall effectiveness of our packaging lines – PackML
• We have shown that horizontal communications can be achieved
with disparate control platforms using PackML standards
• We are building a platform for testing the vertical integration to
the MES systems using PackML standards
• We are fully committed to the PackML strategy, and we are
moving towards specifying this as a required standard from our
packaging vendors
“It’s good to use a common language. Now we can all understand each other.”
– Christian Chatel, Schneider Electric
42 B. Griffen May 2012
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