automated craftiness
TRANSCRIPT
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Automated Craft iness H o w a u t o m a t i o n i s h e l p i n g u s b r e w g r e a t b e e r.
John Blystone, PE Electrical & Controls Supervisor Great Lakes Brewing Company
Cleveland, OH
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About Great Lakes Brewing Company
• First modern Craft Brewery in Ohio when opened in 1988 • Still privately owned by founders Pat & Dan Conway
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About Great Lakes Brewing Company
• First modern Craft Brewery in Ohio when opened in 1988 • Still privately owned by founders Pat & Dan Conway • 21st largest craft brewery in the US in 2016 • Produced approximately 162,000 BBL, or just over 5 Million Gallons, last year
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About Great Lakes Brewing Company
• First modern Craft Brewery in Ohio when opened in 1988 • Still privately owned by founders Pat & Dan Conway • 21st largest craft brewery in the US in 2016 • Produced approximately 162,000 BBL, or just over 5 Million Gallons, last year • Available in 13 States, from NC to WI, and Washington, DC • Employ 240 people from restaurant staff, sales, operators, and two lucky engineers • Just added our 6th year-round, Turntable Pilsner • Total of 21 different styles mass-produced throughout the year
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Beer!
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About Me
• 2005 BSEE, specializing in Computer Engineering, from The University of Akron • Dec. 2017 planned MBA, specializing in Executive Management, from Ohio University • Professional Engineer, ISA-certified Controls Systems Engineer, Ohio #78408 • Professional experience includes rubber processing, calendering, precision fluid blending,
material handling • Have worked as consulting engineer, machine builder, and facilities engineer • Became first full-time engineer at GLBC in July of 2013
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Outline
Three questions I want to answer today…
• What is “craft beer” exactly?
• How does automation fit this industry?
• What technologies is GLBC leveraging and how?
+ =
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What is “Craft Beer”?
The Brewer’s Association defines the category using three rules: • Small – 6 million BBL (186 million Gal.) or less per year
(approx. 3% of annual beer consumed in this country)
• Independent – Less than 25% owned or controlled by an alcohol industry member that is not itself a craft brewer.
• Traditional – Majority of their beverage alcohol volume in beer (not cider or flavored malt beverages)
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How does automation fit?
Technology allows for better tools.
Local “manual” micro-brewery (<15k BBL/yr) still uses: • Stainless steel made with modern smelting techniques • Tanks and pipes made with modern automated welding equipment • Valves made with modern CNC equipment • Modern cleaning chemicals and techniques • Modern drives for pumps and temperature controllers for tanks
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How does automation fit?
Technology allows for better tools.
Problems we faced as a large regional: • Lack of data for decision-making • High operator cognitive load leading to errors and process slow-downs • Lack of space to “easily” boost production volume
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How does automation fit?
Critical Questions that helped Determine Automation’s Role
Do we really want our highly-trained & experienced brewers… • Doing repetitive non-value-added tasks • Documenting batch process details by hand • Performing repetitive batch calculations by hand
Likewise, do we want a brewer busy with value-added tasks responsible for… • Time-sensitive process changes that impact quality • Temperature regulation of numerous simultaneous processes that impact quality • Interlocking of various procedures
To the managers, do you want… • Better process visibility • More accurate records • Better equipment utilization • More data to help troubleshoot
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How does automation fit?
Let’s follow my first major automation initiative…
Brewhouse Through-put Optimization (AKA “BTO”)
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How does automation fit?
My 1st Step – Core Upgrades
• SLC 5/05 Step-Forward to 1756-L71 • Still using SLC I/O, zero wiring changes • Allows easy integration of modern drives and I/O
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How does automation fit?
My 1st Step – Core Upgrades
• SLC 5/05 Step-Forward to 1756-L71 • Still using SLC I/O, zero wiring changes • Allows easy integration of modern drives and I/O • Toughest part – software migration. Upgrade tool (RA) or by hand (co-op)
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How does automation fit?
My 1st Step – Core Upgrades
• HMI Upgrade from RSView32 to FactoryTalk View SE • From single computer in wash-down brewhouse to distributed VMWare servers • Thin clients allow for easy restoration of control following hardware failure • Redundant servers provide excellent uptime and data loss prevention
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How does automation fit?
My 2nd Step – VFD Upgrades
• Upgraded to PowerFlex 525 drives • Built-in Ethernet/IP communications to new L71 for greater abilities • Built-in Safe-Torque-Off improved safety function • Freed up existing digital and analog I/O for other uses
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How does automation fit?
My 3rd Step – I/O and Sensor additions
• L71 allowed Ethernet/IP I/O additions • New pre-run heat exchanger panel • Basement utility monitoring panel (co-op designed, built, commissioned) • ArmorBlock I/O for valve position feedback • New hot liquor / hot water control skid
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How does automation fit?
My 4th Step – Software!
• 1st goal – lighten operator cognitive load • Automated grain-out sequence (17 step “manual” procedure to 1 button)
• Relies on torque feedback of 525 rake motor drive to determine when “empty” • Used same feedback to minimize equipment wear by limiting torque
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How does automation fit?
My 4th Step – Software!
• 1st goal – lighten operator cognitive load • Automated send-down temperature and flow control from brewhouse to fermenters
• Improved response and more consistent average temperature • Far less threat to yeast in fermenter, far fewer “re-pitches”
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How does automation fit?
My 4th Step – Software!
• 1st goal – lighten operator cognitive load • Automated lautering process
• Very complex process, many input and output variables • Greatly decreased lautering time variability, increased wort consistency
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How does automation fit?
My 4th Step – Software!
• 1st goal – lighten operator cognitive load • Automated brewer calculations for ERP records (sadly not automated data transfer)
• Improved data accuracy leads to better decision making • Discovered it acts as leading indicator of various failures and process problems
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • Co-op designed, built, and commissioned utility panel
• Monitored plant air pressure, used for troubleshooting
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • Co-op designed, built, and commissioned utility panel
• Monitored plant air pressure, used for troubleshooting
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • Co-op designed, built, and commissioned utility panel
• Monitored plant water, hot water, hot liquor, compressed air, incoming power, etc…
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • Co-op designed, built, and commissioned utility panel
• Monitored safety indicators
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • FactoryTalk View Alarms & Events Server • HMI server access locked down, PLC-side alarms allows co-ops to write and maintain
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • FactoryTalk View Alarms & Events Server • HMI server access locked down, PLC-side alarms allows co-ops to write and maintain
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • “Bread Crumbing” to lead operators to location of faults
Before…
Valve YV-26901 is Faulted! Without “bread crumbing”…
Wouldn’t know it unless you happened to see it blinking on the “Gas Block” screen.
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • “Bread Crumbing” to lead operators to location of faults
After…
Valve YV-26901 is Faulted! “Bread Crumbing” leads you to the problem.
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • FactoryTalk Analytics for Devices (AKA “Shelby”) BETA tester • Gave us hardware analytics on the 29 out of 31 Rockwell-based systems without them
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How does automation fit?
My 4th Step – Software!
• 2nd goal – add analytics for troubleshooting & decision making • FactoryTalk Analytics for Devices (AKA “Shelby”) BETA tester • Gave us hardware analytics on the 29 out of 31 Rockwell-based systems without them • Ease of implementation incredible, immediately pointed us to two failed PLC batteries and one
bad Ethernet cable (duplex hunting)
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How does automation fit?
My 4th Step – Software!
• 3rd goal – add dashboards for management and non-operators • FactoryTalk ViewPoint installed, special screens developed
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How does automation fit?
My 4th Step – Software!
• 3rd goal – add dashboards for management and non-operators • FactoryTalk ViewPoint installed, special screens developed
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How does automation fit?
My 4th Step – Software!
• 3rd goal – add dashboards for management and non-operators • FactoryTalk ViewPoint installed, special screens developed – on tablets!
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How does automation fit?
All combined…
• Short introduction to John Boyd
• Colonel, US Air Force
• Fighter pilot, Pentagon consultant
• Inspired the “Lightweight Fighter Program” which spawned the F-16 and F-18
• Bachelor’s degrees in economics and industrial engineering
• His theories were key to the ‘91 invasion of Iraq
• Perhaps best known for his OODA loop theory
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How does automation fit?
All combined…
• Boyd’s OODA Loop
• Observe • Orient • Decide • Act
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How does automation fit?
All combined…
• Key to success is ability to make repeated good decisions quickly
Rockwell Automation’s
Integrated Architecture is helping us achieve that success
Sustained sales growth over past 3 years despite being “at capacity” in
2014 thanks to decreased downtime and increased
automation and throughput.
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How does automation fit?
Any Questions?