Leveraging Standards - Map Your Show · Expo 2014-17. Harmonizing Integration • Consistent connection to an MTPI product • Pack ML as the backbone of PI device logic • Nearly

Leveraging Standards to Improve Productivity

The Drive for StandardizationJay Joyner

Controls Engineer Manager

Procter & Gamble

OMAC Board

PackML to the Industrial Internet

OMAC - 2017 PACK EXPO Innovation Stage Copyright © 2017. All rights reserved.

Strong, global leadership from OMAC member companies drives automation standards

2OMAC - 2017 PACK EXPO Innovation Stage Copyright © 2017. All rights reserved.

PackML is a standardized methodology for organizing & programming discrete machines

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PackML

States

Execute, Held,Suspended…

PackTags

Which state?How long in state?Alarm Events?

Modes

Producing,Maintenance,Manual

• Packaging Machine Language

• Industry standard (ISA TR88.00.02)


We have created templates & guides to assist with PackML specification & implementation

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• The OMAC PackSpec Template provides a standardized framework specifying packaging machinery

• The P&G programming template has been updated to comply with the new revision of TR88.00.02

• The Arla Foods Unit/Machine Implementation Guide helps to simplify the design and implementation of PackML


We have developed several tools to assist with PackML development

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• PackTag_Builder from Bosch-Rexroth is a configurator for PackTagsbased on PLCopen® XML import & export standards

• Light tree management directly indicates the machine state

• The Nestlé HMI template defines the navigation and standardizes the look-and-feel of the machine interface


We are collaborating with OPC Foundation to define an open communication protocol

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• OPC UA provides a vendor agnostic solution to communicate PackML states, modes and PackTags to any machine


We have shown the value and benefits of implementing PackML

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Technology Providers Facilitates market

requirements Drives innovation Improves product and

application supportability

Drives common user specifications Promotes modular designs Improves code reusability Improves machine supportability Protects intellectual property

Machine Builders

System Integrators Reduces customization Reduces integration time Improves supportability Focus on value-added tasks

Improves speed to market Consistent data and control structure for

horizontal & vertical integration Reduces integration cost, time & variability Reduces system life-cycle cost, MTTR, etc.

End Users


Our automation systems are diverse, but must liaise to facilitate integration

• Inside the box certainly needs to be proprietary. Outside the box we need an open standard used by everyone. This will allow:

– Data exchange– Machine interface/coordination– Safety monitoring

• OEMs can simplify integration by eliminating proprietary architectures at the system level, and instead using open standards.

8OMAC - 2017 PACK EXPO Innovation Stage Copyright © 2017. All rights reserved.

Let’s Hear from an OEM and End User about their Experiences with PackML

• Church & Dwight Co. Inc.• Andy Knerr - Senior Research Engineer• Joe Giambrone - Associate Machinery Specialist

• Mettler Toledo• Tom Dorward - Product Manager

OMAC - 2016 PACK EXPO Innovation Stage Copyright © 2016. All rights reserved. 9

Leveraging Standards to Improve Productivity

End User Benefits of PackMLAndy Knerr

Senior Research Engineer

Joe GiambroneAssociate Machinery Specialist

Church & Dwight Co., Inc.OMAC MEMBERS

PackML to the Industrial Internet

It Isn’t Rocket Science…

• Pre-PackML Workshop, Chicago - 2017

Or is it…

• Post-PackMLWorkshop

PACER

• Purpose

• Agenda

• Conduct

• Expectations

• Roles/Responsibilities

Agenda

• Church & Dwight Overview

• PackML Strategy

• PackML Use Example

• Recognizing Trends

• Next Steps

Church & Dwight Team

• Doc Bullard – Director • 12 years with C&D

• Paul Redwood - Program Engineer• 8 years with C&D• OMAC Board of Directors

• Tom Barlics – Program Engineer • 15 years with C&D

• Andy Knerr, CPP - Senior Research Engineer• 8 years with C&D• OMAC Technical Advisory Board

• Joe Giambrone - Associate Machinery Specialist• 7 years with C&D

Church & Dwight Team

• Packaging Machinery Group (PMG)

DISCLAIMERWe are NOT Controls Engineers and we will not pretend to be…

• but… feel free to email [email protected] if you are looking for a controls job

mailto:[email protected]

C&D Overview

• Most may know us by the brand name “Arm & Hammer”

Our FLAGSHIP Power Brand - 1 of 10 11


1846

2001

2001

2001

2001

2005

2006

2012

20172011

Church & Dwight PackML Strategy

simplicity.

“Programming Code Soup”PackML Clarity

Execute

Recent Install Example – York, PA

• 17 machines• 11 OEMs

• 1 Integrator • Only 3 PackML machines

Church & Dwight Product Acquisition

• “Best Tube Filling Start-Up Ever” – Mike Boyer

Church & Dwight PackML Strategy

Current PackML Install Base

PackML Installed Example

RFQ Assessment

• Current RFQ

60% 30% 10%

RFQ Assessment

RFQ Assessment

• Update RFQ - leverage PackSpec

60% 30% 10%33% 33% 33%

Next Steps

• Continue Controls Development Training

• RFQ Update

• Identify Potential Partners, such as

• Demonstrate benefits

• Gain alignment and establish momentum

• Roll-out retrofits and upgrades

• Present, Promote and Educate

THANK YOU

Leveraging Standards for the Future

Harmonizing DataTom Dorward

Product ManagerMettler Toledo

OMAC TAB

PackML Bridge to Industrial Internet


Mettler Toledo Product Inspection Division

PCEZwingenberg Germany

HI-SPEEDIthaca, NY USA

GARVENSGiesen Germany

SAFELINEManchester UK

SAFELINE EAGLETampa, FL USA

SAFELINE X-ray Royston UK

Vision Inspection & Serialization X-ray & Metal Contaminant Detection Checkweighing & Product Handling

CI-VISIONChicago IL, USA

Preparing for Industry 4.0, IoT and IIoT

• The Challenge: Getting Data ready for the • Product Inspection devices produce data…..lots of

data.• Part of a packaging line that is also producing

data.• PackML provides common definitions for machine

and process data


Cloud

As part of the X-series development

At the request of a major customer

At the request of a major customer

At the request of major customers

The evolution was largely driven by customer requirements – for Checkweighing, a general need for a method to communicate line status. For the others, as a requirement for continued customer support

The PackML Progression – A Path to Industry 4.0

Metal Detection Vision InspectionCheckweighing X-Ray

2010 2013 20152006-07

Recv'd customer guides

Attend OMAC meeting

Joined OMAC

First State Model Demo

Demo's at Pack Expo 2014-17

Harmonizing Integration

• Consistent connection to an MTPI product• PackML as the backbone of PI device logic• Nearly identical interfaces

• Combination of defined PackML structure and PI Structure• An identical common section of data

• Driving the state• Changing modes• Changing parameters• Monitoring events• Requesting production stats

• A device specific section• Common look, individual data• Structure of production stats

Metal Detection Production Data

Checkweigher Production Data

Excerpt from above"The intent was to make every packaging machine report its operational status the same way, independent of the machine type. As an analogy, PackML is for packaging equipment what Morse code was for the telegraph."

Evaluation of our products

• Four solutions, for four inspection disciplines, developed in four organizations, in three countries -what are the chances that the solutions are all designed and look the same?

• Standard Interpretation and implementation

• Assess the state of the products -

For each solution, are we compliant with ISA TR88.00.02?•MTPI Checkweighing, Metal Detection, X-Ray and Vision•Where there are gaps, fill them

How do the solutions vary within the set?•Is there a best practice within the solutions?•Write a guide for best practices

Evaluate the instruction sets for all solution•Can integration be done with the instructions?

Exercise the instructions by constructing a physical model•Test the theoretical model

PackML - a basis for future development, IoT, and Industry 4.0

PackML as a common "spine" for all machine communications

Applies to Fieldbus, OPC, ProdX – any future products with machine-state data

Use common fundamental inputs to identify States in a consistent manner

Establish common definitions for shared Modes and Tags

Propose inspection-specific Modes and Tags of interest to the industry

Why

Standardized Customer Interface for MTPI products – reuse of code

Less "unnecessary invention"

Less training required – engineers, service personnel, support personnel, Integrators and Customers

Faster development time and greater reliability

Documents

Leveraging Standards - Map Your Show · Expo 2014-17. Harmonizing Integration • Consistent connection to an MTPI product • Pack ML as the backbone of PI device logic • Nearly