krones Information Technology KITIT Solutions for Optimizing Production

Information Technology

2 | krones KIT

Keeping a Clear Overview

Today, the role of management in the beverages industry is driven by extensive requirements. Fast and accurate decisions are required on a daily basis at different levels of production. These decisions have to be perfectly aligned with corporate strategies, ensure the best possible efficiency and maximize full potential for development.

However, the increasing diversity of products and variation in equip-ment configuration has resulted in a trend towards ever smaller batch sizes – something which has certainly not helped to make the job of deci-sion makers any easier. Furthermore, increased deadline and cost pressures and reduced profit margins have made it essential to optimize the highly engineered production and bottling concept:

■ Identification of savings potential ■ Automatic consolidation of pro-

duction data, thus delivering trans-parency throughout the company

■ Coordination of individual produc-tion orders in the most cost-effec-tive sequence without the need for extensive machine setups

■ Use of standardized facts & figures

krones it – the Tool for Decision Makers

As a system supplier, krones offer a one-stop solution for machine and plant engineering, including informa-tion technology. This ensures that the data flow within the plant and the human-machine dialog are standard-ized and simplified. krones information technology offers added value for users. With the Manufacturing Execution System from krones, a bottling plant re-ceives a comprehensive, standardized platform which links both the indi-vidual machines at field level and the modules at Enterprise Resource Plan-ning System (ERP).

The Benefits at a Glance:■ Industry-specific solution for the

beverages and food industry■ Target-oriented and holistic analy-

ses of the complete plant ■ Provision of data across different

sites as the basis for operational optimization

■ Provision of industry oriented figures for overall production (e.g. Overall Equipment Effective-ness, OEE)

■ Comprehensive and consistent modular solution in accordance with individual customer require-ments

Raw materials, consumable and purchased materials

Production Bottling andpacking Warehouse

Real-time reports

History analysis

Malfunction analysisDownalyseKIT

Large text display

Order management LMS

Network technology NetKIT

Centralinformationsystem

TechnicalreportingReportKIT

ERP enterprise resource planning

Production planning

Maintenance management SIPS

Quality management QualiKIT

Production data acquisition LDS

■ Coordinated hardware and soft-ware from a single source

■ Standardized and highly available network infrastructure

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Coordinating and Organizing – krones LMS

By incorporating material lists and bill of material for all products in the ERP system or the production plan-ning, the LMS order system coordi-nates the complete line on the basis of the individual production batches. The Line Management System takes

the strain off the user by providing up-to-the-minute production infor-mation at the individual touchscreens of the machines. Production data are fed back to the higher level system in order to increase the flow of informa-tion and close the information loop.

Filler

Contiform

Labeller

Packer

Palletiser

Line managementsystem LMS

Recipe andorder system

ERP

Order Y

Order Y

Order preparationOrder Y

Order X completed

Order X

0% 100%

Five Reasons for Using the Line Management System (LMS)■ Increased plant availability■ Coordination of the line as a com-

plete plant with full integration of all individual machines

■ Fast and simple batch changes■ Defined order processing

sequence ■ Tracking & tracing of batches

(TraceKIT)

Features of the Line Management System■ Automatic recipe and batch based

order processing■ Production is specified to bottle

or tank level in order to maximize cost-effectiveness in terms of raw materials, auxiliary materials and other resources.

■ Information about the current batch and subsequent batches on the individual machine monitors on the line

■ Provision of required raw materi-als, auxiliary materials and other resources in just-in-time

■ Evaluation of currently running articles by batch numbers and start/end times

■ Interactive human-machine dialog for fast and effective line operation

■ “Flying-changeover” as the basis for simultaneous processing of multiple bottling tasks on the line

■ Automatic, recipe based adjust-ment of printing and inspection devices

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Gathering Data – Monitoring Processeskrones LDS

krones Line Documentation System LDSIn times of increasing cost pressures, data recording and analysis are essential tools for assessing line efficiency. The krones LDS per-forms this role of automatic data acquisition.

Five Reasons for Using the LDS as a Data Acquisition System■ Securing cost-effectiveness of the

plant through transparency of pro-duction data

■ Central storage of operational data ■ Real-time and historical appraisal

of production performance with standardized visualization and trend displays

■ Acquisition of consumption data for energy and media

■ Documentation of production data required for tracking and tracing

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Real-time visualisation

Data Monitor

LDS reporting Data Report

Features of the Line Documentation System (LDS)■ Acquisition of line data for calcu-

lation of the OEE and the techni-cal efficiency according to DIN standards

■ Acquisition of disturbance data, counters and analog values

■ Secured long-term documentation

DownalyseKIT downtime manage-ment module:■ Provides a quick and reliable rep-

resentation of the complex inter-action of the machines within the line as a complete system

■ Is used for fast identification of potential weaknesses in the line so that specific measures can be implemented in order to improve performance

■ Automatic resolution of all pro-duction downtime in relation to the leading machine in accordance with the fault-cause principle

■ Top-down analysis including ABC assessment on the basis of key performance indicators

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Besides line key figures, the downtime manage-ment module indicates which machines cause leading machine down-times to what extent.

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Securing Product Quality – krones QualiKIT

krones Laboratory an Management System QualiKITProduction-oriented IT solutions must be capable of documenting the quality of a batch and presenting it in a manner which can be evaluated, this is the only way to ensure that the stringent requirements in the beverages and food industry can be met. krones QualiKIT is the labora-tory information and management system which delivers all the infor-mation required for quality control and quality assurance.

Features of the QualiKIT Laboratory Information and Management System ■ Verification of production condi-

tions in accordance with HACCP criteria

■ Supports the laboratory manager in the organization of the labora-tory and the laboratory workflow

■ Traceability and archiving of qual-ity related data from laboratory and production, on either a batch or time basis

■ Identification of batches for quar-antine measures

■ Automatic information about required batch blocks and regis-tration of release activities

Sampling Samplearrival

Analyses

Barcodescanning

Resultentry

Validation

Reporting

Sampleplanning

Barcodeprinting

Instrumentinterface

Features of the SIPS Maintenance and Service Module■ Increased line efficiency and plant

service life, thus resulting in lower total cost of ownership

■ Automatically generated schedules and requirements for maintenance and service measures in accord-ance with pre-set parameters (filled system)

■ Open system offering integration of maintenance data for krones machines and third party machines

■ Additional Spare Part Management System module: management and administration system for spare parts in the spare parts storage warehouse with analysis options for warehouse optimization

Machine

LDS

Messagein SIPS

Orderin SIPS

Feedbackin SIPS

Close order

History

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krones Maintenance Management System SIPSMaintenance also plays a key role in the cost-effectiveness of the plant. Preventative maintenance is enhanced by carefully incorporating specific service intervals in the pro-gram according to a schedule based on a recommended number of oper-ating hours. Production planning can be made even more efficient with the aid of krones SIPS, a module for preventative maintenance and servic-ing of all individual machines which ensures high plant availability.

Increasing Plant Availability – krones SIPS

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Compact Data for Technical Reporting krones ReportKIT

Internet based access to identical information formats across factories and sites and standardized evalua-tion tools require the use of a struc-tured and standardized reporting system. The krones ReportKIT uti-lizes the data from the MES modules to generate current, user-oriented reports.

Five Reasons for Using ReportKIT■ Time-saving evaluation options for

production, line and batch data■ User-specific representation of the

data■ Uniform, standardized definition

of key parameters and their calcu-lation for all users

■ Multi-dimensional linking of data (e.g. shift, product, area or site related) with long-term evaluation

■ Document management for cen-tral administration of documents

Features of the ReportKIT■ Fast analyses over long time

horizons■ Representation of relevant, indus-

try-oriented indicators like OEE, efficiency, degree of utilization, quality etc. for defined user groups

■ Decision-oriented gathering and processing of data from the pro-duction process

■ Industry-specific pre-configured dashboards, reports and analyses

Taking the Network as its Basis – krones NetKIT

Industrial Ethernet transports the data: from field level and process/production level to management level. Ethernet LAN and Wireless LAN offer high-availability access and reli-able communications between the plant and the MES solution.

Mobile solutions like handhelds or PDAs (Personal Digital Assistant) allow the reports from the krones IT modules to be called up and control-led from any location. Integrated SMS services allow production relevant data to be forwarded to defined users – regardless of their location.

Virtual Private Network (VPN) offers secure data exchange and access to both various customer sites and – if enabled – between the customer and the machine manufacturer. This enables the implementation of cost-saving teleservice facilities, or alter-natively also networking and cross-functional visualization of lines and sites.

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Production Filling & Packaging Warehouse

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ERP

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Brew-master

Pro-ductionmanager

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Main-tenance

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Service station &Network-managementsystem

Phone

Modem

Operational Network

Router

Back

bone

Manufactoringexecution system

KRONESService

InternetWorld Wide Web

SAP/R3

Firewall

Internet-PortalWEB-servereGate

InternetGateway

DomainServer

WEBServer

MailServer

Officenet

Business Network

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krones agBöhmerwaldstraße 593073 NeutraublingGermanyPhone: +49 9401 70-0Fax: +49 9401 70-2488E-mail: info@krones.comInternet: www.krones.com

Overview of krones IT Solutions:■ Assistance for the plant opera-

tor in order to achieve high plant availability and a reduc-tion of production costs

■ Industry-oriented IT solution for a Manufacturing Execution System (MES)

■ Implementation of the MES solution according standard ISA S95

■ Modules for planning, control-ling, documenting, analyzing and servicing the production operation

■ Connecting link between the enterprise resource planning system (ERP) and the plant level (vertical integration of the systems)

The Expert View – IT-ConsultingConsultancy and individual reviews are a key element of krones infor-mation technology. This is because the analysis of existing bottling and packaging plants and IT systems is the necessary basis on which the machine information can be uti-lized. This allows the data from the machines and any already existing IT systems to be forwarded to or inte-grated in the MES system.Elements of this consultancy service include:■ Analysis of the current situation

with a review of plant compo-nents and a determination of the current IT landscape, also poten-tially across different sites

■ Appraisal of the results of the assessment of the plant and IT structure

■ Development of suitable solu-tion scenarios for best-possible process optimization, taking into account the integration of existing IT systems and the constraints of remaining within the investment budget

■ Realization of the jointly devel-oped solution