F³, a new formula for your production processes?

Future Food Factories

Optimized Packaging Line, seamless and integrated automation solutions for packaging

Industry SectorPage 2 F³ - Event Future Food Factory – March 2013

New trends are being born….

Higher flexibilityShort re-equippingtimes, online recipechange

StandardizationReduction “total cost of ownership”

SustainabilityReduction of power

consumption

Consumer behavior is becoming individual

Changing forms and designs

Lower production costs / Global competitionNew challenges for machinery & line construction

Line IntegrationReducing integrationcosts and time

Industry SectorPage 3 F³ - Event Future Food Factory – March 2013

Relation between initial investment and total "Life Cycle Cost“

Initial investment

in Filling & Packaging lines

Spares MaintenanceService

Downtimes

UpgradesTraining

Invest

Capital

Energy

PersonalSpace

Support

Extension

Additional operating cost

occurred by:

poor integration

complex service

increased spare part purchase / storage

elevated training costs

non-optimized energy consumption

How do you optimize your costs in the ‘80% area’?

Industry SectorPage 4 F³ - Event Future Food Factory – March 2013

What does OPL affect?

Standardize the hardware and software to a carefully

selected range of components

Apply a common network topology to the

key components

There are two

key factors which are the basis for optimization –

they must be applied without compromise

1 2

Industry SectorPage 5 F³ - Event Future Food Factory – March 2013

Modular approach of OPL

OPL –

Organisation:Technical Consulting,

Training, support on site, Service and Support, Spare part availability

OPL -

Toolbox:Standardized solutions

for usual repeatingmachine types and tasks (e.g. handling, ect...).Project generatoreasyProject

OPL -

Architecture:„Best Practice“-solutions for automation of typical packaging machines, incl. cabinet design, operating concepts,safety solutions.Based on a hardware list of

perfect fitting components.

OPL -

Line Integration:

Interface between machine level and IT-systems, e.g. line visualization, remote diagnostics, track&trace, …

Industry SectorPage 6 F³ - Event Future Food Factory – March 2013

Typical structure of filling-/ packaging lines today

Challenge of integration

Many plants are currently made up of different products, systems and interfaces fromdifferent suppliers thus creating high diversity & complexity

Missing standardized network structure and machine data interfaces

preventing simple integration of the Machines and higher level systems

DataInterface 2

Machine 1

from OEM x Machine 2

from OEM y Machine n

from OEM z

PLCHMI

I/O I/O

Drives

Motors

LV Sensors

Net

wor

k

Net

wor

kMotion

Control

PLCHMI

I/O

Drives

Motors

LV LV Sensors

PLC PLC

I/O

Motors

Drives

LV Sensors

DataInterface n

Line Overview HMI ????????

No DataInterface

Diversity

Complexity

Difficult

System-integration

Difficult Diagnosis

High Asset Costs

Industry SectorPage 7 F³ - Event Future Food Factory – March 2013

Typical structure of a future filling-/ packaging lines

OPL -

leverages standardization in 4 levels

Level 4

Line Overview visualization

Communications

Diagnostics

Backup & Recovery

Energy Management

Level 1:

Hardware

Software

Level 3:

Network Architecture

Level 2:

Data-Interfaces

Machine 1

from OEM x Machine 2

from OEM y Machine n

from OEM z

Standard DataInterface

Net

wor

k

Motion

Control

PLCHMI

I/O

Drives

Motors

LV

Standard DataInterface

Line Overview HMI

Standard Data Interface

Net

wor

k

HMI

I/O

Drives

Motors

LV

Net

wor

k

PLCHMI

I/O

Drives

Motors

LV

Motion

Control

MIS/MES

Integration

Achieve joint automation and communications standards in order to

integrate the entire plant

exploit the full optimization potential

Industry SectorPage 8 F³ - Event Future Food Factory – March 2013

OPL deliverables

Incremental addition of value-add services

1 2 3

5 64

To support the concept the OPL-team prepared a variety of tools4.

Horizontal

line communication between machines5.

Line overview & diagnostics

library concept improves operator efficiency

6.

Software Toolbox

including communication and technology modules

1.

Selected HW-

and SW-

list

helps to reduce diversity and complexity

2.

Specification

template for end users standardizing

on Siemens TIA equipment3.

Standardized Data interface

based on OMAC supports OEM-independent IT-Integration

Industry SectorPage 9 F³ - Event Future Food Factory – March 2013

OPL deliverables

Incremental addition of value-add services

7 98

To further support the concept, the OPL-team is working to adapt further tools

7.

Power Monitoring based on WinCC Powerrate for Visualization of Energy Consumption

8.

OEE tool LMS (Line Monitoring System) upgradable to Simatic IT MES system

9.

Central diagnostics using Simatic Maintenance Station for WinCC

Industry SectorPage 10 F³ - Event Future Food Factory – March 2013

OPL Benefits

Optimized Packaging Line

is a systematic approach to

reduce complexity and number of variants

reduce training and spare part costs

reduce integration risks and energy consumption

improve productivity, availability and transparency

reduce total cost of ownership

by the consistent usage of

Standardized components

Standardized machine interfaces

Common software modules

Advantages for End users AND Machine builders due to standardization and subsequent cost reductions

Based on international standards like PROFINET and OMAC as well as best practice configurations we provide for our customers

DataInterface 2

Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z

PLCHMI

I/O I/O

Drives

Motors

LV Sensors

Net

wor

k

Net

wor

kMotionControl

PLCHMI

I/O

Drives

Motors

LV LV Sensors

PLC PLC

I/O

Motors

Drives

LV Sensors

DataInterface n

Line Overview HMI

MIS/MES

????????

No DataInterface

DataInterface 2

Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z

PLCHMI

I/O I/O

Drives

Motors

LV Sensors

Net

wor

k

Net

wor

kMotionControl

PLCHMI

I/O

Drives

Motors

LV LV Sensors

PLC PLC

I/O

Motors

Drives

LV Sensors

DataInterface n

Line Overview HMI

MIS/MES

????????

No DataInterface

Machine 1 von OEM x Machine 2 von OEM y Machine n von OEM z

Standard DataInterface

Net

wor

k

MotionControl

PLCHMI

I/O

Drives

Motors

LV

Standard DataInterface

Line Overview HMI

Standard Data Interface

Net

wor

k

HMI

I/O

Drives

Motors

LV

Net

wor

k

PLCHMI

I/O

Drives

Motors

LV

MotionControl

MIS/MES

Inte-gration

Machine 1 von OEM x Machine 2 von OEM y Machine n von OEM z

Standard DataInterface

Net

wor

k

MotionControl

PLCHMI

I/O

Drives

Motors

LV

Net

wor

k

MotionControl

PLCHMI

I/O

Drives

Motors

LV

Standard DataInterface

Line Overview HMI

Standard Data Interface

Net

wor

k

HMI

I/O

Drives

Motors

LV

Net

wor

k

PLCHMI

I/O

Drives

Motors

LV

Net

wor

k

PLCHMI

I/O

Drives

Motors

LV

MotionControl

MIS/MES

Inte-gration

Standardization

Industry SectorPage 11 F³ - Event Future Food Factory – March 2013

Coca-Cola Enterprises

Efficiency and cost improvements in the can as standard