Plant-wide Automation - Siemensw3.siemens.com/topics/global/de/partner-programm... · Plant-wide Automation ... Ice Cream, CPG Braumat Brewery Process Automation ... • Business

Plant-wide AutomationTotally Integrated Automation in the Food & Beverage Industry

siemens.comUnrestricted @ Siemens AG 2016

Unrestricted © Siemens AG 2016June 2016Page 2 Joachim Roesler| DF FA AS F&B

Food & Beverage IndustryChallenges are Growing Worldwide

Strengtheningour customers’ competitiveness

Enhance FlexibilityReduce Time to Market Increase Efficiency

• Shorter innovation cycles• More complex products• Larger data volumes

• Reduce energy consumption• Better resource utilization• Higher productivity• High transparency

• Individualizedmass production

• Volatile markets• High productivity

Siemens has the right answers to the challenges of the Food & Beverage industry

Increase Quality

• Closed loopquality processes

• Traceability andintegrated genealogy

• Reliable Processes


Totally Integrated Automation –The basis for future industrial concepts

ƒ Consistent datamanagement

ƒ Global and openstandards

ƒ Uniform interfacesfor hardware andsoftware

Customerrequirements

TotallyIntegrated

Automation

IT Level

IndustrialData Management

IndustrialSecurity

SafetyIntegrated

IndustrialCommunication

Integrated Engineering

PLM

Teamcenter / NX

MES

SIMATIC IT

Services

Plant Cloud Services


TIA@F&B – Plant-wide AutomationStandards and Concepts for an Entire Plant

Plant-wide Automation

Inbound Process/Production Filling/Packaging Outbound

OEM(Machines)

OEM(Process Unit 1…Machine n)

OEM(Machine 1 … Machine m)

OEM(Machines)

Auxiliary Processes: Energy, Water, Steam, Air, HVAC, …

Plant Integration/Line Monitoring + SCADA

Full MES

Production Line Integrationand Control

Dairy,Ice Cream,

CPG

BraumatBreweryProcess

Automation

NahmatSugar

Solutions

Productionsolutions

Edible OilsAnimal Feed

WinCC SESBakery &Confect.

Entire Production Plant

Tota

llyIn

tegr

ated

Auto

mat

ion


Plant-wide AutomationA Modular Approach

Standardized components: Example of a Chocolate PlantMaintenance-Laptop

Power distribution

HVAC

Mixing Milling, Conching Moulding Cooling Packaging

CentralVisualization

WinCC SES(Sequence Execution System)

OEEAnalysis

EnergyMonitoring

Level 4• Energy Management• OEE• Line Monitoring

and Control• Overview Visualization• Diagnosis

Level 1• Hardware• Software

Level 3• Data Interfaces

Level 2• Architecture• Networks


Data Interface 2

Machine 1 from OEM x Machine 2 from OEM y Machine 3 from OEM z

PLCHMI

I/O I/ODrivesMotors

LV Sensors

Topo

logy

Topo

logy

PLCHMI

I/ODrivesMotors

LV LV Sensors

PLC PLC

I/O

MotorsDrives

LV Sensors

Data Interface n

Line Overview HMI?????

MotionControl

No Data Interface

• Diversity

• Complexity

• DifficultSystem-integration

• Difficult Diagnostics

• Asset Costs

Plant-wide AutomationStarts with Standardization

Line integration• Energy monitoring• OEE• Line overview• Network diagnostic

Software Toolbox• Data Interface• Application

Machine Architecture• Hardware Standardization• Software Conventions• Machine Topology Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z

Integration

Topo

logy

PLCHMI

I/ODrivesMotors

LV

StandardData Interface



Topo

logy

PLCHMI

I/ODrivesMotors

LV

Topo

logy

PLCHMI

I/ODrivesMotors

LV

Line Integration


ET 200

Plant-wide AutomationScalable Concept from Field up to Factory Supervisory Level

Automation

Network Industrial Ethernet Profinet

MES

LineMonitoringSystem(LMS)

LineControl

Unit(LCU)

S7-300/400

PDI IF

SIMOTION

PDI IF

S7 1x00

PDI IF

3rd Party

PDI IF

3rd Party

PDI IF

UtilitiesBuilding

PDI IF

LineHMI

KPI/OEE/RCA

EnergyMonito-

ring

Data-analysis,Repor-

ting

SIMATIC B.Data

EnergyData

Mgmt.

OrderMana-gement

MaterialMana-gement

ERPconnec-

tivity

SIMATIC IT

WinCC


Plant-wide AutomationStep-by Step Approach

Planning

Implementation

Operation

Line Integration

Organization

Architecture

Tools

Consulting to optimize specificationand accomplish standardization

Provide standardized PLC data blocks,HMI libraries and LMS configurations

Implementation support to OEMs

Partner community to support systemintegrators in performing projects

Specific training for operators

Project coordination to seamlessly coordinateOEM – SIEMENS – End User

On-Site support with trained local staffduring commissioning

A |

B |

C |

D |

E |

F |

G |


Plant-wide Automation – Line Monitoring SystemThe right functionality for all different users

OEM• Weihenstephan and OMAC integration• Easy-to-use data interface

Engineering/System-Integration• Only one system house for Line Integration projects• From shop floor components through SCADA up to MES integration

Machine and Line Operator• Higher visibility of performance issues• Optimized system support to localize areas of improvement within the line

Line Supervisor/Maintenance• Standardized KPI system for high transparency• Online and offline analysis to understand machine behavior

Top Management• Multi-line performance analysis and benchmarking• Business reporting to support management decisions


Plant-WideAutomationoffers

1 | Well-defined interface data blocksfor OMAC and Weihenstephan(including Documentation, Guidelinesand examples for HW and SW)

2 | Templates for Operator Panelobjects and pictures

3 | Support through standardSiemens channels

Plant-wide Automationfor OEMs

How can I simplify the PLC data interface?How can I reuse programs in other machines?

• Quick and easy engineeringof data interface withoutchanges in the machine program

• Implementation with examplesand interface data blocks down-loaded from Siemens’Online Support Internet

• Reduction of test- andcommissioning times

• Support available 24/7

TIA@F&B reduces time and risk tointegrate machines data interfaces


1 | Libraries for HMI objectscan be re-used other projects

2 | Easy-to-use configuration toolsfor Line Monitoring System (LMS)

3 | Standard data interfaceensures correct, consistent data

Plant-Wide Automation for System IntegratorsProject delivery with clearly defined value and fixed costs

How can I lower the engineering costs?How can I meet my end customer’s cost and performance targets?

• Configuration tools withimport/export capabilitiesallow to reuse configurations

• Libraries with predefined objectscan be used as templatesfor now or other projects

• Standardization reduces risk andimplementation costs

TIA@F&B supports cost-efficientand reliable implementation



1 | Detailed real-time informationabout machine downtimes

2 | Online information about pro-duction quantity and quality

3 | Machine information screenswith detailed KPI’s

Plant-wide Automationfor Line Operators

What is the status of my machines?Am I on target with production demands?


• Optimized usage of machinesby real-time monitoring ofline and machine status

• Full integration of all datain one system enables operatorsand saves HW costs

• User-friendly interface withstandardized objects

• Fast access to all information

TIA@F&B makes machine and lineoperators more efficient


1 | Asset Performance Analysis

2 | Root Cause Analysisto find the real reason for downtimes

3 | Monitoring and extensiveReporting for further data analysis

• Supports the responsible peoplewith all relevant data for fastdecisions

• Easy visualization and lesstime-consuming analysis of KPI’s

• Reduction of downtimes byidentifying root causes andscheduling preventive maintenance

• Predefined and easily to configurereports for detailed analysis

LMS supports efficient and fastanalysis of data

Plant-wide Automationfor Line Supervisors and Maintenance

How can I analyze data from different points of view?How can I find the real reason for performance deviations?



1 | Multi-Line Analysisbased on customizedScorecards and Dashboards

2 | Detailed Analysisof KPI’s andproduction parameters

3 | Business Reportingto support management decisions

• Business Reporting(integrating data fromshop floor up to business systems)

• Cost control and identificationof cost savings by continuousmonitoring (also in multiple plants)

• Current data also supportsthe investment decision process

With SIMATIC IT you canprepare the right decisions andsupport continuous improvement

Plant-wide Automationfor Top Management

How can I compare different lines with each other?How can I find material-related issues?



Selected HW & SW Specification templates Guidelines and documents

Plant-wide AutomationSupport and Deliverables

Reduces diversity and complexity inproduction process, filling and packaging

Supports optimization and standardizationof the automation equipment

Network design, Interface descriptions, etc.simplify implementation

Ensures interoperability accordingto international standards

Free of charge downloads for PLC andHMI templates and data interface block

Enables fast, easy andreliable implementation

Standardization Online support Training


Plant-wide AutomationBenefits at a Glance

• Reduced diversity inhardware and software

• Less spare parts variety• Lower assets costs• Less training for

operational and service staff• Less energy consumption• Better resource utilization

• Integration of machines/linesin proper network topologies

• Using international standards• Harmonized, OEM-independent

line visualization• High degree of diagnostics• Calculation of KPI/OEE values

to analyze line efficiency• Foundation for MES systems

to support management decisions

• Limited effort and risk of integration(commissioning phase)

• Lowering of “efficiency drop” effect

• Easy and fast service and maintenance• Reduced downtimes

Time

Pro

duct

ion

effic

ienc

y

Field Level

MIS/MES

$Decreasing life cycle costs, while increasing line efficiency!

… reduced life cycle costs … more transparency … increasing productivity


Thank you for your attention!

www.siemens.com/food-beverage

Joachim RoeslerIndustry DevelopmentDF FA AS Food & Beverage

siemens.com

Documents

Plant-wide Automation - Siemensw3.siemens.com/topics/global/de/partner-programm... · Plant-wide Automation ... Ice Cream, CPG Braumat Brewery Process Automation ... • Business