“The accuracy of the downtime reports provided by the Wonderware software solution were so good that even our equipment supplier is using them to troubleshoot its equipment at our plant instead of using manual tracking sheets normally used when servicing the equipment.” John Coetzee SAB Business Systems Manager, Manufacturing Invensys Improves Packaging Line Performance of South African Breweries’ Soft Drink Division Goals • To effectively address the annual summer demand for soft drinks, the plant needed to improve the overall production performance and accelerate commissioning of a new packaging line • The ability to track machine performance, electronic data capture and reporting of measurements were key components to ensuring that the packaging facility operates efficiently Challenges • The facility needed to conform to Pack ML standards to ensure efficient operation of facility manufacturing equipment • The automation system had to work with existing SAP process order applications and daily production reporting facilities • The company wanted to capture all downtime data using the OMAC model of open control technologies for manufacturing applications Solutions and Products • Wonderware InTouch HMI • Wonderware System Platform • Wonderware MES 4.0/Performance Software • Wonderware Historian • Wonderware Information Server Results • Once Amalgamated implemented the PackML standards using the OMAC model and Wonderware software, the company was able to accurately achieve real-time downtime reporting • The company was able to accurately estimate reject counts and crates on the line to implement improvements to the manufacturing line process INDUSTRY: FOOD & BEVERAGE Amalgamated Beverage Industries www.abi.co.za
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“The accuracy of the downtime reports provided by the Wonderware software solution were so good that even our equipment supplier is using them to troubleshoot its equipment at our plant instead of using manual tracking sheets normally used when servicing the equipment.”
John CoetzeeSAB Business Systems Manager, Manufacturing
Invensys Improves Packaging Line Performance of South African Breweries’ Soft Drink Division
Goals• Toeffectivelyaddresstheannualsummer
demandforsoftdrinks,theplantneededtoimprovetheoverallproductionperformanceandacceleratecommissioningofanewpackagingline
• Theabilitytotrackmachineperformance,electronicdatacaptureandreportingofmeasurementswerekeycomponentstoensuringthatthepackagingfacilityoperatesefficiently
Challenges• ThefacilityneededtoconformtoPackML
standardstoensureefficientoperationoffacilitymanufacturingequipment
• TheautomationsystemhadtoworkwithexistingSAPprocessorderapplicationsanddailyproductionreportingfacilities
• ThecompanywantedtocapturealldowntimedatausingtheOMACmodelofopencontroltechnologiesformanufacturingapplications
Solutions and Products• WonderwareInTouchHMI• WonderwareSystemPlatform• WonderwareMES4.0/PerformanceSoftware• WonderwareHistorian• WonderwareInformationServer
Results• OnceAmalgamatedimplementedthePackML
standardsusingtheOMACmodelandWonderwaresoftware,thecompanywasabletoaccuratelyachievereal-timedowntimereporting
• Thecompanywasabletoaccuratelyestimaterejectcountsandcratesonthelinetoimplementimprovementstothemanufacturinglineprocess
INDUSTRY:FOOD&BEVERAGE
Amalgamated Beverage Industrieswww.abi.co.za
Pretoria, South Africa –Assummerrollsaround,thoughtsofbarbequesandfamilyget-togetherscometomind.Andwhatwouldagoodhotdogorhamburgerbewithoutacoldsoftdrinktoquenchahotsummerthirst.Forsoftdrinkmakers,preppingforthisbusytimeofyearentailsreviewingmanufacturinglinestoensuretheyareoperatingatpeakperformance.Thechallengeofcommissioninganewpackaginglineintimeforthisannualsummerrunonsoftdrinkproductscanbedaunting.ButnotforAmalgamatedBeverageIndustries,adivisionofSouthAfricanBreweries(SAB),whichchosetoimplementanewmanufacturinglinebasedonWonderwareautomationsoftwarefromInvensysOperationsManagement.
Amalgamated’smainbusinessgoalwastoaccelerateproductionofitspackaginglinewhichincludedtrackingmachineperformanceparameters,reducingmanualdatacapture,improvingtheaccuracyofmeasurementsandestablishingreferencepointstobetterevaluatethereportsfromOEMsregardingperformanceofitsmachinery.Amalgamated’smachineOEMsuppliersareresponsibleformanagingtheperformanceandcommissioningoftheirequipmentuntilfinalimplementationofthemanufacturingfacility.
Anotherimportantobjectivespecifiedthattheprojectwastoserveasa”proofofconcept”fortheeffectiveimplementationofPackML(PackagingMachineryLanguage)standards,whichareanopensystemofguidelinesusedinthedesignofautomationmachinery.ThePackMLstandardswereestablishedbythePackagingWorkgrouparmoftheOMAC(OrganizationforMachineAutomationandControl)group,aconsortiumofautomationandmanufacturingprofessionalsdedicatedtosupportingthemachineautomationandoperationalneedsofmanufacturing.
“Withoutaccesstovaluableprocessdataitwouldbedifficultforustoevaluatethestatisticswhicharedesignedtoassistthecompanywithdeterminingperformanceimprovementsandascertainwhatpartoftheprojectyieldedthemostvalue,”saidJohnCoetzee,SABBusinessSystemsManagerofManufacturing.
AmalgamatedworkedwithsystemintegratorEOHMiningandManufacturing(EOHMM)whichprovidesfullyintegratedoperationssolutions,MES,enterpriseintegrationandintelligencesolutionstotheminingandmanufacturingindustriesinAfrica.EOHMMdevelopedandmanagedtheprojectparametersincludingcompilingtheuserrequirementsandspecifications,developingandimplementingthefullapplicationcreationofperformancereports,managingfactoryacceptancetesting,commissioningthesystem,andtrainingusersandthetechnicalteamonhowtomanageandmaintaintheapplication.
“Wetookacollaborativeengineeringapproachinvolvingourprocesscontrolmanagerwhoprovidedinputonprocessandprocedures,theSABManufacturingSystemsdivisionwhichconsultedondesignguidelinesandstandards,andEOHMMformanagementofalltheengineeringaspects.Thiscollaborationofeffortsworkedverywellinsuccessfullyimplementingthisproject,”Coetzeesaid.
Challenges and Successes of Collaborative Line Commissioning
Thegreatestchallengeinthesoftwareprojectwasthefactthatitwasbeingimplementedatthesamepackaginglineitwastomonitorwhileitwasbeingcommissioned.Duringcommissioningofanewfactoryline,allfocusandeffortiscenteredonthisprocess.
However,Amalgamatedwaschallengedtoimplementboththehardwarecomponentandthesoftwaresimultaneously.Normally,thehardwarearchitectureofthelineisimplementedfirst,followedbythesoftware--Amalgamatedwantedbothcompletedintandem.
Tosuccessfullyachievethecompany’sobjectivesforleveragingexistingSAPprocesses,conformingtothePackMLstandardandcapturingdowntimedata,AmalgamatedselectedanInvensysOperationsManagementsolutionusingWonderwaresoftware.ThecompanyimplementedtheWonderwareMES/Performance,WonderwareSystemPlatform,WonderwareInTouchHMI,WonderwareInformationServerandWonderwareHistorianapplications.ThecombinationofthesepowerfulsoftwaretoolsenabledAmalgamatedtoachieveitsobjectiveofacceleratingtheproductionofitssoftdrinkmanufacturinglineduringpeakdemandcycles.
ThefoundationoftheAmalgamatedsystemistheWonderwareMES/PerformancesoftwarebuiltontheWonderwareSystemPlatform.Theperformancesoftwarecollects,tracksandcommunicateskeyperformanceindicatorsinreal-time.Thisinformationisthendeliveredtooperatorswhocantakeimmediateactiontocorrectaproblemontheline.BuiltonWonderwareSystemPlatform,theperformancesoftwareishighlyscalableforallSCADA,supervisoryHMIandMESapplications.
Delivering Information to the Right People at the Right Time
WonderwareInTouchHMIisusedforvisualizationofmanufacturingoperations.SophisticatedgraphicsaredisplayedonoperatorscreensshowingstandardizedPackMLinformationtoassesstheoperationalefficiencyofvariousmachinesonthepackagingline.Topreventoperatorconfusion,onlymachineOverallEquipmentEffectiveness(OEE)informationisshown,althoughthefullOEEdashboardisavailableonrequest.
“Becauserawdataisshortonanalysisandfacts,WonderwareMES/Performancesoftwareaddsimportantdetailstotheinformationcapturedbythesystems,”Coetzeesaid.“Thesoftwarealsotracksproductionvolumesandprovidesdetailsontheproductdeliveriestoensurewearemeetingtherequirementsoftheoriginalproductionorder.”
InadditiontoOEEdashboards,anyspecificportionoftheHMIscreenscanbecustomizedtodisplayvariousinformationsuchasdowntime,Paretocharts,linestoppagesincludingdurationandfrequency,jobprogress,andliveorhistoricalperformancetrending.
“BecausethedowntimereportsprovidedbytheWonderwaresystemaresoaccurate,Amalgamated’smachineOEMisusingthemtotroubleshootitsequipmentinsteadofusingthemanualtrackingsheetsnormallyused,”Coetzeesaid.
WiththeimplementationofWonderwareHistorian,Amalgamatedhasaccesstoawealthofhistoricalinformationfromitsproductionprocesses.Asahigh-performance,real-timedatabase,Historianisabletocollectawidevarietyofplantdata,atfullresolutionandveryhighdatarates.
Thisensuresthatdecision-makersatalllevelshavetheinformationneededtodrivevitalproductivityimprovements.ThisinformationissharedthroughouttheorganizationusingWonderwareInformationServerwhichaggregatesandpresentsplantproductionandperformancedataoverAmalgamated’sintranet.
WiththehelpofWonderwareHistorianandWonderwareInformationServer,Amalgamatedhasaccesstoaccuratedowntimeandstoppagereports,canmoreaccuratelyestimaterejectcountsanddeterminethenumberofcratesontheline.Theeliminationofmanualloggingoftheseactivitieshassignificantlyincreasedtheefficiencyoftheproductionfacilitybymakingtheinformationreadilyavailableforbusinessanalysis.
Invensys Open Architecture – Making It An Easy Choice
Today’sMESimplementationsareafarcryfromthe“bigbang”approachofthepast.Wonderwaresoftwaresolutionscanbeinstalledgraduallywithsuccessmeasuredateachstageoftheimplementationbeforecontemplatingthenextstep.WithadherencetostandardssuchasPackML,manufacturersareassuredthatallpiecesofthepuzzlewillactuallyfittogetherandoperateeffectivelyovertime.“Packaginglinehardwareandsoftwaresuppliersusedtoonlyofferproprietarysolutions.ThismadeAmalgamatedverywarybecauseproprietarysystemswouldlockusintoaparticularvendor’ssolution,”Coetzeesaid.“ButsincecompaniessuchasInvensyshaveadoptedopenstandards,wearemoreopentobuythesesolutionsbecauseweknowtheywillhaveinteroperabilityandwillintegratewithothersystems.Sotheironyisthatthetacticofproprietarysystemsthatweredesignedtolockincustomerstoaparticulartechnologyactuallysoldlessthanopensystemswithinteroperability.Thisenablesflexibilityofmanufacturingoperationstoquicklyaddressthechangingdemandsofsoftdrinkconsumers.”
Sogoaheadandopenthatbottleofsodaatyournextpicnicorcookout,becausethankstoautomationsolutionsfromInvensys,softdrinkbeveragemakerAmalgamatedispreparedtosatisfythethirstforfrostybeverageswhenthesummersunblazes.
Invensys,theInvensyslogo,ArchestrA,Avantis,Eurotherm,Foxboro,IMServ,InFusion,SimSci-Esscor,Skelta,Triconex,andWonderwarearetrademarksofInvensysplc,itssubsidiariesoraffiliates.Allotherbrandsandproductnamesmaybethetrademarksorservicemarksoftheirrepresentativeowners.
©2011InvensysSystems,Inc.Allrightsreserved.Nopartofthematerialprotectedbythiscopyrightmaybereproducedorutilizedinanyformorbyanymeans,electronicormechanical,includingphotocopying,recording,broadcasting,orbyanyinformationstorageandretrievalsystem,withoutpermissioninwritingfromInvensysSystems,Inc.
Invensys Operations Management • 5601 Granite Parkway III, #1000, Plano, TX 75024 • Tel: (469) 365-6400 • Fax: (469) 365-6401 • iom.invensys.com
Rel.03/11PNWW-4085
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