digital transformation in food and beverage, cpg improving … · 2018. 4. 24. · mtbf details...

The Schneider Electric industrial software business and AVEVA have merged to trade as AVEVA Group plc, a UK listed company.

The Schneider Electric and Life Is On trademarks are owned by Schneider Electric and are being licensed to AVEVA by Schneider Electric.

Digital Transformation in Food and Beverage, CPG

Improving Asset Performance and Reliability

Confidential Property of AVEVA Group plc.

Presented by: Xavier Marfa, F&B Business Development Manager EURA

The Value Driver for Digital Transformation in F&B/CPGValue Propositions across the operational cycles; the production cycle, the assets cycle and the

product cycle

Energy Management & SustainabilityReduce carbon and water impacts, adopt sustainable practices

Improve Operational PerformanceImprove productivity and remove all the wastes from your processes

Improve Asset Performance & ReliabilityReduce Capital and Operation Expenditure needs

Increase Recipe AgilityMeet demands with the right products at the right time

Safety, Quality and ComplianceProtect both consumers and shareholder value. Reduce risk and costs of

compliance and non compliance

• Asset (Visibility): Strategize/Design, Monitor, Analyze, Maintain• Production (Velocity): Prepare, Operate, Inform• Product (Variety)

Improve Asset PerformanceSmart Manufacturing, Smart Supply Chain

• Provides capability for data capturing,

production delay analysis with reasons and

root cause analysis

• Reduction in unplanned outages/downtime

• Improve performance and adherence to plan

• Deliver sustained asset production

performance improvements

• Defer or eliminate capital investment in new

assets (“sweat” the assets)

Business Value:

Our solutions are designed to help to increase

plant performance and asset utilization through

manual and automatic manufacturing equipment

event data collection, efficiency monitoring and

utilization analysis

• Enterprise Asset Performance Management

(eAPM)

• Line Performance / Insight Performance

• Advanced Process Control (APC)

Asset performance: Maintenance strategy is keyPrioritize improvement opportunities and apply the right optimization strategy

Risk-based

Condition

Preventive

Predictive

Pre

sc

rip

tive

Information

The Digital Asset Vision

Looking back…

Model T Ford Toyota Production System

Mass Production

Lean Manufacturing

• Identify “muda” using Value Stream Map

• 5S, SMED, TPM, CI, Deming Cycle…

The Origins of Total Productive MaintenanceThe demands for predictable machine performance in Lean

Manufacturing led to the development of TPM.

Early on, the people at Toyota must have realized that many quality

problems and setup problems originated in poor maintenance

OEE

Overall Equiment Efficency

Targeting OEE – Overall Equipment EffectivenessMeasuring productivity – identifies the % of manufacturing time that is truly productive

Available time

Running timeAvailability

losses

Theoretical Output

Actual OutputPerformance

Losses

Actual Output

Good ProductQuality

Losses

A

B

C

D

E

F

Ava

ilab

ility

Pe

rfo

rma

nce

Qu

alit

y

OEE = Availability x Performance x Quality

= (B/A) x (D/C) x (F/E) x 100%

1. Equipment failure

2. Set up and adjustment loss

3. Reduced speed

4. Idling or minor stoppage

5. Defects in process (scrap)

6. Rework

• It measures the effectiveness of the production

operations / equipment utilization.

• 100% means full capacity

Line Performance

• Based on industry-leading Wonderware MES

• Turnkey OEE package

• Integrated Reporting & Analysis

• Whether your role in the orrganisation

provides timely, accurate & relevant

information

• Ensure peak performance, meet your

operational KPIs

• Offers reason codes, loss deployment, root

cause analysis for production losses.

Predefined User Interface

Work order management

• Accessed by Supervisor.

• Work order creation & assignment.

• Work order details – order

number, quantity, status.

Work order execution

• Work order & Event data entry.

• Start & end work order.

• Visibility of work queue and

production history.

Performance Monitoring

• Monitor over a period (hour, shift,

day).

• Utilization events of the

equipment.

• OEE, including Availability,

Performance & Quality.

Predefined reports

Reports Functions

OEE Analysis OEE performance data & trend

Utilization

Timeline

1 glance understanding of

production events

Utilization by

Entity

Details on availability &

performance events

Production by

Entity

Details on quality events

Line Production Production output data & trend

Utilization

Analysis

Root causes of production losses

MTBF Details & nature of unplanned

stops

MTTR Maintenance & repair

performance

• Derived based on Lean manufacturing / TPM practice.

• Save the time of digging and diving into the ocean of data.

• 8 predefined reports including MTBF and MTTR

Pag

e 11

User ExperienceBased on Feedbacks & Optimized by UI/UX Expert

• Line Performance standard contents are improved in look & feel and usability.

• The contents can be configured and used flexibly to form various layouts / views according to

customer requirement

Entity Overview and WO Execution

Confidential Property of Schneider Electric |

Text: according to attribute

Text: according to attribute

Good Qty

90

Rejected Qty

10Remaining Qty

90

Utilization management

Work Order

Execution

# of

Plants

Complexity/Readiness/Maturity• Assets

• Automation

• Complex process

• Scale

Deploying OEE Solutions

Not easy to Justify Cost &

Effort to Implement MES

OnPrem

Justified

Majority of plants fall

below threshold of either

value or complexity to

justify MES

These are the

companies to

embrace Cloud

solutions

Capability Maturity

Model (CMM) Levels

Deployment Options: FlexibilityOpen and flexible hybrid operating mode offers best of both worlds.

1) Full Cloud

IIoT devices are direct-connected to and

operated from the Cloud (any modules).

2) Hybrid

Some on-premise controls and sources

and some Cloud connected (mixed mode).

3) On-Premise

All controls and software are fully on-

premise. (traditional approach)

Information and Analytics

Application Development Toolkit

Visualization

System Configuration and Standards Management

Real-Time Control and Device Integration

Digital Engineering

Digital Planning and Operations

Digital Asset Performance

Control and Information Management Platform

Industry Value Chain Platform



Visualization



Digital Engineering







Visualization



Digital Engineering







Visualization



Digital Engineering






Typically used by Customers…

• Who are looking to reduce infrastructure, cost and complexity

• Who are looking for a standard approach with fast, frictionless

deployment and pay back

• Who have minimal on-site IT presence

• Whose IT department support cloud-based solutions

• Who are focused on visibility and not requiring tight

enforcement of process - looking for standalone

Utilization/OEE solution

Insight Performance - Customer Value

Insight Performance:

Automatic/manual utilization

and efficiency data collection

Real-time Dashboards:

- Equipment KPI’s

- Utilization/Downtime Events

Reporting with drill down

Analyses

- Equipment comparison

- Equipment history

Insight PerformanceBuild on the Insight platform - powered by Wonderware Online

Edge Computing Device

OEE/Performance

Management App

Historize(Process, Utilization &

Production Event Data)

Edge Device

& App Mgt.

Asset

Registry

Analysis &

Analytics(InSight &

SmartGlance)

Smart

Sensor

Automation

Controller

Smart

Sensor

…

Automation

Controller

…

On-Premise

3rd Party

Apps

Insight Performance ModuleThe Offering

Public Cloud

• Cloud-based OEE/Performance Management App

SaaS - Completely managed and maintained by SE.

• Rapid Application Provisioning

Simple onboarding and configuration process.

• Automatic and/or Manual Data Collection

Flexible data collection options.

• Equipment Monitoring

Utilization/OEE dashboard for Operations Personell

• Advanced Reporting & Analytics

Advanced analysis & analytics provided by Wonderware

InSight & SmartGlance

• Utilization & Production Event Historization

Leverages common “Historization” services as already

utilized by Wonderware Online Process Historian

• On Premise Edge Computing

Robust on premise event store/forward capability and

device/sensor connectivity.


Best practice of improving operational efficiency at lowest TCO

Benefits of Cloud hosted

Software application:

• Eliminates efforts to

create and maintain an

IT infrastructure

• Faster time to value

• Connect multiple

plants:

- best practice sharing

- makes standardization

easy

- scales from small to large

in storage and

performance

New Belgium Grows

Packaging Performance

to Meet Demand

Client:

New Belgium Brewing

Location:

Fort Collins, CO

Ashville, NC

Closing the Loop:

New Belgium is 4th largest craft

brewer supplying America’s favorite

Fat Tire Ale. Production went from

weekly peak 150K Cases to 200K to

meet growing customer demand.

Results:

We’re Closing the Loop to

help New Belgium Brewing:

• Increase Efficiency

• Improve Maintenance

• Expand Packaging

Capacity

• Avoid New Capital

Investment

Production Volume

33% MorePer week (50K Cases)

20% Increase OEEin 2 yrs

50% LessUnscheduled Downtime

%

• Optimising process operation with conventional control is challenging:

• Time delays prevent accurate adjustment

• Control actions interact with each other

• Disturbances are frequent

• Optimum conditions are unknown

• Lots of manual operation, operator’s experience dependent

• Product quality measurements are infrequent

• Conventional Control works to ensure in-specification product, yet in-specification does not equal to

optimization

• Due to the Conventional Control we need to sacrifice other KPIs to make sure it is in-specification

F&B Industry Pain Points in Process Optimization

APC for F&B – Comparison with Conventional Control

To make it simple:

Takes into account every kind of variables and

parameters which can influence an equipment or

an installation…

in order to understand/modelize process

behavior

And based on this, it is able to anticipate

process reaction due to any perturbation we

can deliver updated signal

Signal is always managed/based on the

difference between measured variable

and setting.

Powder Moisture %

Atomiser current

Air heater steam valve position

Exhaust fan speed

Dynamic Model

of Dryer

Outlet air temperature

Outlet air RH%

Dryer Feed Rate

Inlet Air Temperature

Inlet Air Fan Speed

Fluid Bed Temperature

Fluid Bed Air Flow

These are manipulated

automatically by APC

Controlled Variables (measured)Manipulated Variables

Ambient Air

Humidity

These are monitored and

controlled by Advanced

Process Control, in closed-loopDry Matter

contents

Feedforward Variables

Page 24Confidential Property of Schneider Electric |

APC - Automated Closed Loop Control

• Moves the operating process closer to multiple constraints at the same time

• Allows operation to be closer to operating limits by reducing variations

• Improves quality

• Increases operating profit

Advanced Process Control has two primary

functions:

1. Minimize process variability

2. Consistently push the operating point

towards optimum operating point without

violating product quality

E.g. Dryer:

Maximum product

moisture limit

E.g. Dryer:

Minimum outlet

air temperature

limit

“Normal”

process

variability

Optimum

operating point


Advanced Process Control

Maximum unit throughput:

determined by ambient

conditions, feed dry matter,

etc

Favourable swing in ambient

temperature

Operator-preferred

operating point (infrequent

changes, significant

margin)

“Lost opportunity” captured by



operating point (frequent

changes, reduced margin)


APC - Challenging the Constraints

Applicable on any process / equipment that has some or all

of the following characteristics:

• Prolonged time delays between action and response

• Slow dynamic response

• Multivariable interaction or constraints

Apply at: milk powder, coffee, tea, eggs, cereal, spices,

flavorings, starch and starch derivatives, vitamins, enzymes,

stevia, nutraceutical, colorings, etc.

All complex regulating

processes with significant

energy consumption

Industrial Oven Industrial Autoclave Grain Drying

Evaporator and Dryers

Pasteurizer

Equipment

Liquid Processing

Solid Processing


APC Application in F&B

FrieslandCampina

Optimizes Spray Dryer

Operations

Client:

Friesland Campina

Location:

Netherlands

Closing the Loop:

FrieslandCampina is the world’s sixth

largest dairy company, with an annual

revenue of 11.3 billion euros. With

facilities in 32 different countries,

FrieslandCampina’s products find

themselves in 100 different countries.

They are partnering with us for spray

dryer optimization utilizing our

predictive process control.

Results:

We’re Closing the Loop to

help the FrieslandCampina:

• Improve throughput and

quality

• Maximize production by

minimizing downtime

• Achieve significant year

on year savings

Dryer produces

8 Tonnes/HrOf Product

10% ThroughputAverage increase with zero product

quality violation

Achieved ROI in

< 2 months€

%

Questions?


digital transformation in food and beverage, cpg improving … · 2018. 4. 24. · mtbf details...

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