industry: food & beverage amalgamated beverage industries -...
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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
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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.
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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.
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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.
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