PackML
PackMLThe Science of Machine Software
Adal Tecleab
Procter & Gamble
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Topics
Page 2
Background
Programming Example
Going Forward
Questions / Discussion
1
2
3
4
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G Business
Sales: $83.7B, Net Earnings: $10.8B
61% Sales Outside US
250+ of Worlds Best Known Brands
25 - $1B Brands
1,500+ Packing Lines & GrowingCopyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G Business Needs
Delight more consumers in more areas around the world
Manufacturing translation:
More sophisticated machines purchased and installed globally
Deliver the product and packages consumers desire
Manufacturing translation:
Constant machine modifications and upgrades
Page 4
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Manufacturing Competitiveness
Packaging
Requires:
• More equipment innovations
• Faster machine and line startups
• Production information critical to business(Overall Equipment Effectiveness data)
• To and from OEM machines
• Business information systems
• Reliable systems
• Diverse global workforce
Challenges
• Limited resources
• More complex
machines
• Global coordination
• Engineering
• Manufacturing
• Information Technologies
Page 5
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
The Wild West of Software
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.?
Page 6
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Business Need
Wide variety of software approaches and templates used at P&G
Baby Care study – 60% of start-up issues are software related
Opportunity –
Change software execution to a SCIENCE
Converge on a single, proven industry-standard approach
Page 7
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Software Method Standards
Equipment Operational Methodology
Information Integration
Machine-to-Machine
Machine to/from Enterprise
Equipment Decomposition Methodology
Page 8
PackML(ISA TR088.00.02)
PackTags(ISA TR088.00.02)
Make2Pack(ISA S88 Part 5)
Industry Software Standard
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
PackML Development Timeline
Page 9
2003 2005 2006 2007 2008 2009 2010
First versions of current template are created and installed in manufacturing sites, using S88 11 state model
OMAC template available for download
Current template created using latest PackML Standard, ISA-TR88.00.02
Various revisions and executions across multiple projects…
P&G specifies PackML in equipment specifications
PackML ISA-TR88.00.02
Released
Various revisions and executions across multiple projects…
PackML v2.2Released, includes 10 state model
PackML v3.0Released, 17 state
model
2004
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
PackML Workshops
P&G workshops
North America (June 2010)
Asia (January 2011)
Europe (May 2011)
North America (Oct 2011)
Europe (Oct 2012)
North America (May 2013)
Europe (September 2014)*
Over 400 people trained
Working with organizations on similar industry training
Page 10
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
PackML Benefits
Standard enables:
Simplification through standardization
One time training
Faster startups
Robustness & reliability
Operational consistency
Troubleshoot easier
Consistent tools to track and manage “line performance”
Effective use of our limited engineering resources
Reduced costs!
Page 11
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
What’s in it for the OEM?
Faster Development Time
Greater Reapplication of Programming
Shorter Debug Times & More Robust Programming
Greater Flexibility
Fewer End-User Custom Software Requests
Less Training for both OEM & End-Users
Allows for Greater Focus on Innovation & Machine Capability
Faster
New configurations
New machine concepts
Intellectual Property Still Maintained
Great Customer Selling Point!
Page 12
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Topics
Page 13
Background
Programming Examples
Going Forward
Questions / Discussion
1
2
3
4
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
PackML Tools Make Software a Science
Implementation Guide Planning Project Worksheet Modular Programming Template
Data Flow Score Card
Page 14
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Six Simple Steps
1.
• Decompose machine into Equipment Modules and Control Modules(S88:Make2Pack)
2.• Define PackML Modes and States
3.
• Define machine, equipment, and control module Actions during each mode and state
4.• Define PackTags for line integration and MES functionality
5.• Define Events (and Recipe Setpoints)
6.• Program machine: keep it simple
Page 15
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #1 - Equipment and Control Modules
PLC 1 PLC 2
Page 16
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #2 - PackML Modes and States
Everything needed to make good
product will be automatically
enabled/started. The machine
should automatically start up without
having to manually move or start any
of the modules. Only in this Execute
state will the machine report uptime.
Everything will run like the
producing mode, but the
operators have the ability to
disable any module
manually and force most
solenoids.
For purging the fluids. Will
also have automatic control
of flushing tanks for
changeovers.
For homing the axes
that you select
Page 17
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #3 - Actions
Documentation translates directly into PLC code
Basis for training of operations, technicians, process engineers, etc.
Page 18
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #4 – PackTags Setup
Page 19
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #5 – Events and Recipe Setpoints
Define Alarms, Warnings, and PackML Status Events (can be broken
into categories)
Define Recipe Setpoints
Page 20
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Step #6 – Program the Machine
Page 21
Copyright © 2015 Procter & Gamble. All rights reserved.
Old Software New Software % Improvement
# of PLC’s 3 2 33%
# of Programs 48 21 56%
# of Routines 355 117 67%
# of Rungs 4877 2206 55%
# of Tags 5525 2415 56%
# of
Produced/Consumed
Tags
76 35 54%
Memory 2.85MB 5.37MB -89%
PLC #1 CPU Utilization
(L63)99% (task overlaps) 81% (no task overlaps) 18%
PLC #2 CPU Utilization
(L61)65% 53% 18%
PackML
Step #6 – Program the Machine
Old Software New Software % Improvement
# of Alarms 586 325 45%
# of Warnings 264 68 74%
# of Recipe Setpoints 256 113 56%
# of HMI Screens 44 34 23%
# of clicks to change
setpoint aaa from Run
Screen
22 4 82%
# of clicks to change
setpoint bbb6 3 50%
# of clicks to perform
function xxx7 4 43%
Page 22
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Other Examples
Machine B Before and After
Machine C Before and After
Old Software New Software % Improvement
# of Rungs ~8000 ~1100 86%
# of User Setpoints ~300 33 89%
Memory 3.2MB 1.8MB 44%
Old Software New Software % Improvement
PLC Utilization 90% 30% 67%
# of Programs 27 20 26%
# of Rungs 461 383 17%
# of Tags 518 389 25%
Memory 170kB 453kB -166%
Page 23
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Other Examples
Old Software New Software % Improvement
# of Programs 28 9 68%
# of Routines 198 92 54%
# of Rungs 2089 1884 10%
# of UDTs 88 14 84%
# of Alarms 136 217 -60%1
# of Warnings 0 5 -
# of Recipe Setpoints 271 157 42%
# of HMI Screens 52 33 37%
Memory 3.15MB 2.60MB 17%
1Added additional alarms for situations that were never accounted for in old software
Machine D Before and After
Page 24
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Topics
Page 25
Background
Programming Examples
Going Forward
Questions / Discussion
1
2
3
4
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Template Future
Continue to maintain and improve current template
Feedback to design through steering team meetings and website
(packml.pg.com)
Operator and maintenance/troubleshooting training
Continued harmonization with ISA standards (waiting for approval)
Common tool for software development and code creation (PackML Planner)
Education through key networks and tools
OEM, system integrator, and vendor training/support*
Interactive web based training
Studio 5000 v22 and beyond
More object definition beyond typical AOI
Objects better link PLC code with HMI
Page 26
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 27
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 28
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 29
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 30
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 31
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 32
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 33
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
P&G PackML Planner
Page 34
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Machine Control Software Masterplan
Business Need
Majority of machine functions realized through software
Links mechanical and electrical components with process/product performance and quality
Development and support strategies must enable improved productivity, faster speed to market, higher reliability
Vision
Enables flow of resources, training, code, and IP
Reduces software lifecycle costs
Improves reliability and robustness of software
Principles
We manage machine software and capability as a competitive advantage.
P&G and Connect&Develop Partners will maintain software mastery for design of key product transformations.
We standardize software where it makes business sense to increase reliability and reduce costs.
Existing software standards served us well, we only change them based on business need.
We will actively work to improve our templates and library blocks versus deviating to meet project preferences.
Page 35
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Needs from OMAC
P&G needs and wants PackML to succeed in industry
Let’s work together to improve the standard and drive it into
industry.
Page 36
Copyright © 2015 Procter & Gamble. All rights reserved.
PackML
Question / Discussion
Page 37
Copyright © 2015 Procter & Gamble. All rights reserved.