Industry 4.0 / PackML @ Arla FoodsLenze PackML Webinar / 20th June 2016Arne Svendsen, Arla-IT MES & AutomationReferences: Dennis Brandl, Visionaire/Open StandardsBryan Griffen, Nestlé & OMAC Chair

Agenda

1. Arla Foods - Global Dairy Foods Manufacturer

2. Industry 4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A

3 May 20233

Who am I ?

1957: Wendelbo1980: M.Sc. EE(P) + Computer Science1980-1991: PLC firmware and SCADA software development1990-2002: CIM-consultant (Computer Integrated Manufacturing)2002 - now: Head of Corporate MES & Automation team

(Part of Arla Global-IT)

Contact: Arne.Svendsen@ArlaFoods.comLinkedin: https://dk.linkedin.com/in/arnesvendsen

Arla Foods Introduction

13,500+FARMER OWNERSFROM 7 COUNTRIES

70 Production Sites(EU, US,CHN)

MILK INTAKE12,5+ BILLION KILO

19,000+COLLEAGUES

10 BILLION EUROREVENUE

PRODUCTS SOLD IN100+ COUNTRIES

Our vision: Creating the future of dairy to bring health and inspiration to the world, naturally

Arla Foods Introduction1000’s of Variants - Arla Brands & Private Label

Business EnvironmentCooperative business since 1880

Cooperative dairy business - 1880 -> 2016

Business EnvironmentA global supply chain today

• 70+ Production Sites, 50+ Distribution Centers• Sales worldwide

Business EnvironmentStrategic Focus

• Networked supply chain, fast moving consumer goods/cool chain

• A history of Mergers & Acquisitions• Organic growth is the strategy now• Partnering in Manufacturing &

Distribution

• Core business: Product Innovation, Supply Chain & Distribution

• Non-core: Partnering with specialised service-providers

Agenda

1. Arla Foods - Global Dairy Foods Manufacturer2. Industry 4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A

Industry 4.0 - high levelOne (of many) views

The 1st (Steam) The 2nd (Ford T) The 3rd (www, PC) The 4th Industrial Revolution

Internet of Things (IoT)”DIGITAL”

New Business Models

INDUSTRIAL Internet of Things (IIoT)Digital / Smart ManufacturingINDUSTRY 4.0

The good old www: Internet (of People)

Industry 4.0 - high levelTechnologies – and Connectedness

• (New) Technologies• Connecting Anything• => New Business

Models• Sharing economy• “Everything” as a

service

Connectedness & New Business Models

BILLIONS AND BILLIONS OF DEVICES

• Already there are sites under construction with 500,000 devices

May 25, 2016 12

Reference: Dennis Brandl

INTEGRATION NIGHTMARES• Today the average worker in an modern plant

interacts with over 30 smart devices per day• in the near future this will be over 300 to 3,000

smart devices per worker

• Integration is already the hardest part of any new system

• Over 70% of the effort on a typical project• Just for dozens of systems and hundreds of devices

May 25, 2016 13

Reference: Dennis Brandl

UNINTENDED JOB SECURITY• Be Smart• Or integration will become a generational project

• A 100,000 device refinery takes 5-10 years to get up & running, a 1,000,000 device will take 50-100 years

• Train your kids/grandkids in automation & control

May 25, 2016 14

Reference: Dennis Brandl

BUT STANDARDS WILL SAVE US, RIGHT?

XKCD.COM

May 25, 2016 15

Reference: Dennis Brandl

Agenda

1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A

Mapping to Arla Business needsTODAY: Connected, yet still hard work.

Distribution

CenterDistributio

nCenter

Dairy

DairyDairy

SAP - Business IT system

Mapping to Arla Business needsTODAY: Connected, yet still hard work.

Technologies:- Automation- RFID, scanners- Printers- Wireless LAN

- AGVs- Robots- Inline measure- Analytical dev.

Dairy

Functions:- Prod.Orders- BOM/Recipes- Collect ”all” data

- Traceability- Quality- Reporting- Analytics

DATA

MES

- AGVs- Robots- Inline measure- Analytical dev.

Technologies & Devices- Automation- RFID, scanners- Printers- Wireless LAN

SAP - Business IT system

Mapping to Arla Business needsIn I4.0 terms, the solution is:

Functions:- Core Realtime (remain on site)- Core Non-Realtime -> Cloud- Non-Core function -> ext. Service

FACTORY

Technologies/Sensors/Devices

Arla InternalBIG Data

Arla StrategicInnovation Center

EnergyOptim.

EquipmentOptim.

IT-systemsSupport

NON-coreService

Offerings

ERP

<-Faster Connect

Mapping to Arla Business needsWhat to consider, implementing I4.0

PARTIAL CONCLUSION:• Decision: Which NON-core functions - to be bought as a service• Cloud solutions: Costs move from CAPEX to OPEX• INFORMATION strategy • IT Security

Agenda

1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of

PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A

PackML - A real-world example (1:8)Build faster Packaging lines

ONE Business SolutionERP

ONE Production SolutionMES/Manufacturing Operations Mgmt.

ONE Automation SolutionProcessAutomation

ProductionAutomation

PackagingAutomation

• Adopted ISA95 in 2002 for SAP/MES integrations• Corporate MES-solution, implemented on 50+ sites• ISA88 Library in place for Process Automation• Since 2013, focused on faster integration of

production and packaging lines.

PackML - A real-world example (2:8)Cheese Production Line – example

ON THIS ONE CHEESE PACKAGING LINE: 9 units, from 7 suppliers, from 4 countries

PackML - A real-world example (3:8)The PackML ”USB” connector

• Arla has no large technology center. We build packaging lines, mainly by integrating standard units from our industry

• Challenge is to integrate units into a working line• Faster, faster, faster

LINE Control

PackML

LINE Control

PackML PackML

PackML - A real-world example (4:8)Cheese Production Line – example

PackML as interface to Units

PackMLPackML

PackML - A real-world example (5:8)Making it easy for the operators !

3 May 202328

Packaging Line Implementation – IMPROVED ..

Timeline

AnalysisPhase

Implementation phase

Timeline

ContractSigned

Analysis

Implementation phase

Site Installatio

n

FATtest(s)

Site Installation

SAT test (s)

Improved Production TimeTime to Market

PackML - A real-world example (6:8)Business Value

Success items: Specification (forward to contract) much faster Works across all automation (PLC) platforms Test suitcase for remote FAT testing Data => Business information from day-1 Harmonised Operator interfaces!

OEESEE also ARC article:

PackML - A real-world example (7:8)Business Value

Machine Project Time Cost Prod.TimeSpecification -> Sign Contract ++ +Integration tests (FAT & SAT) ++Training (Operators & Maint.personnel) ++Commisioning (”burn in”) +

Operations (5-8 years ?) Time Cost Prod.TimeMaintenance (time to repair) +OEE / Optimisation +Training (Operators & Maint.personnel) + +Line changes/New units /New products + ++ ++

PackML - A real-world example (8:8)Gathering momentum for PackML

• P&G and Arla Foods offer their company standards documents on OMAC website for unrestricted use (based on OMAC membership)

• Company and platform-independent OMAC Best Practice Guide is in progress. For end-users and Machine builders to get started. Nestlé is actively supporting this as well.

Agenda

1. Arla Foods - Global Dairy Foods Manufacturer2. I4.0 overview 3. Mapping to Arla Foods’ Business needs4. I4.0/Plug & Play - real world example of PackML5. How I4.0 will become success - for all of us6. Conclusions7. Q&A

For Industry 4.0 to get successConnectedness need Protocols

Send Mail

Write English

Prequisite:Agree language

Receive Mail

Read English

”The Internet takes care of the rest ...”

For Industry 4.0 to get successWhat the Internet does for you...

An IP adress

PhysicalInfrastructure

WAN/LAN/Wireless

IP Protocol

Mail protocol

Language

An IP adress

PhysicalInfrastructure

WAN/LAN/Wireless

IP Protocol

Mail protocol

LanguageThe Internet

For Industry 4.0 to get successPackML – showing the way !

PackML is a good example of a high level ”DOMAIN” Protocol of I4.0• An agreed common language, and lower levels taken care of

PackagingLine Control

An IP adress

Machine unit

An IP adress

Physical InfrastructureWAN/LAN/Wireless

OMAC PackML

Physical InfrastructureWAN/LAN/Wireless

OPC UA OPC UA

OMAC PackMLIIoT

OPEN Standard ProtocolsPackML in this case

Copyright © 2016 OMAC. All rights reserved.

OMAC - OPC Foundation Collaboration

Bryan Griffen, OMAC Chair

The Need for Standards in Packaging Automation

Wednesday, May 25, 2016

37Copyright © 2016 OMAC. All rights reserved.

Complexity and standards: case study #1

Lack of standard brings complexityto an inherently simple system!

38Copyright © 2016 OMAC. All rights reserved.

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.

39Copyright © 2016 OMAC. All rights reserved.

PackML is our standard for packaging equipment automation

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)

40Copyright © 2016 OMAC. All rights reserved.

Collaboration with OPC Foundation to define an open communication protocol

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

41Copyright © 2016 OMAC. All rights reserved.

Strong, global leadership from member companies drives automation standards across industry

Visit the OMAC website here.

42Copyright © 2016 OMAC. All rights reserved.

Next gen packaging lines will be natively capable of full integration via PackML & OPC UA

PackML

PackML

PackML

PackML

PackMLPackTagsOPC UA

network

Tag Database,Historian, etc.

MES Apps

PackML

Mapping to Arla Business needsOPC-UA – Basic I4.0 Protocol

Manufacturing Execution Processes/Functions ...

MilkIntakeArea

Main ProductionAreas

Filling /PackagingAreas

Semi/FinishGoods WarehouseAreas

OPC UA Basic I 4.0 Protocol

OPC UA

PackML PackMLPackML

I4.0 I4.0 I4.0

ProcessOptimisation

OEEDetailScheduling

Track &Tracing

ProcessOptimisation

OEEProcess

OptimisationOEE

OPC UA

SAP Business SystemData Warehouse

For Industry 4.0 to get successEnd users requirements to I4.0

1. Standardisation bodies (and there are many) must cooperate closely to define generic, OPEN Standards.

2. The end user requirements are: ”any application” to “any device” communication

Wrap-upConclusions

• Industry 4.0 is less about (new) technologies and more about Connecting & New Business Models– and doing it fast, maintainable, upgradable

• PackML is a clear case of Standardisation BenefitsCost reduction, faster projects, harmonised interface, operator efficiency, higher uptime. Its ready – use it!

• I wanted to give you a background for understanding the ”Protocol challenges” of I4.0.(We, the end users, do NOT want to get caught - having to choose between proprietary platform communities in the Manufacturing space)

Q&A

Your are always welcome to contact me at:Arne.Svendsen@ArlaFoods.comhttps://dk.linkedin.com/in/arnesvendsen

Further studies

47

Arla PackML interfaceOMAC - Organization for Machine Automation and Control

48

Arla PackML interfaceTR88.00.02

Machine buildersUnit control program

TR88 Model

Machine buildersUnit control program

TR88 Model

”Upper IT-system”

TR88/PackML

ISA88/Part-5(Make2Pack)

49

Arla PackML interfacePackML Statemodel

3 May 202350

Arla PackML interface PackML is a part of the Arla standard purchase contract

50

Commissi

oni

ngContract

Time

Overall Interface demandPackML

Specification

Interface details defined

PackML SDS

Specificat

i

onOffe

rHOT

OPac

kML

FAT

PackMLtest suitcase

Arla PackML interface PackML implementation as of 1st of January 2015

Delivery

and

installat

ion

SAT

Valid data from day 1

SETUP

UNIT

TEST SUITCASE• 22 mandatory tests• 3 optional tests

TEST SUITCASE UNIT

52

Arla PackML interface Test suitcase

05/03/2023

Arla PackML interfaceMachine builder training

3 May 202354

• Intro• Arla Foods• Arla Production IT• Arla PackML interface• Arla PackML OEM implementation• Next step (Industry 4.0, IoT...)

Agenda

3 May 202355

Arla PackML OEM implementation PackML State Manager

56

”Upper” IT system

Solution 3

PackML

”Upper” IT system

Solution 2

PackML

Gateway PLC

PackTagsSocket TCP/IP

Socket TCP/IP

”Upper” IT system

Solution 3

Gateway

PackML

Socket TCP/IP

Arla PackML OEM implementation Interface solutions

”Upper” IT system

Solution 1

”Upper” IT system

Solution 1

”Upper” IT system

Solution 2

PackML

PackTags

Arla PackML OEM implementation Interface requirements and Specification for Units - PackML

57

Selected Mark type

Unit type

Connection type Specification in section

☐ Type #1

PackML State model simulator

7 Configuration of PackML State model simulator

☐ Type #2

PackML State model simulator

7 Configuration of PackML State model simulator

☐ Type #3

TCP/IP Socket communication

8 Configuration of PackML unit

Arla PackML OEM implementation PackML “Lite” – type 1 & 2

58

Arla PackML OEM implementation PackML “Lite” – type 3

59

Arla PackML OEM implementation

60

TR88.00.02 specification of minimum set of PackTags

Arla PackMLLine Controller