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WW OPS-08 : Wonderware ExecutionSolutions for the Food and BeverageIndustry
Tom TroyBill SchielTom Giunta
@InvensysOpsMgmt / #SoftwareRevolution
/Wonderware
/InvensysVideos
social.invensys.com
© 2013 Invensys. All Rights Reserved. The names, logos, and taglines identifying the products and services of Invensys are proprietary marks of Invensys or its subsidiaries.All third party trademarks and service marks are the proprietary marks of their respective owners.
Tom TroyBill SchielTom Giunta /Wonderware
/Invensys Operations Management
Introduction of Speakers
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Tom Troy•Director, Operations andExecution Portfolio
Bill Schiel•Director, Global BusinessDevelopment
Tom Giunta•Manager, Food & BeverageBusiness Development
Session Overview
1. Common F&B Initiatives
2. Focus on Packaging
3. Focus on Energy
4. Solution Components
5. How to get started
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*FMCG Companies have many Initiatives!
• Plant Wide OperationalImprovement
• "Make" OperationalImprovement
• "Pack" OperationalImprovement
• TPM- Total ProductiveMaintenance
• Material ManagementImprovement
• PLM to MES Execution
• Utilities/Sustainability/Energy
• Compliance/Food Safety/EHS&S
• Quality Program automation
• Continual Improvement
• ERP Integration
• Business Process Automation
• Multi-Plant Reporting andAnalytics
• Peer System Integration
• LIMS, WMS, CMMS
• Workforce Mobile Enablement
* Fast Moving Consumer Goods includes Food, Beverage, CPG, and many other product categories
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• Plant Wide OperationalImprovement
• "Make" OperationalImprovement
• "Pack" OperationalImprovement
• TPM- Total ProductiveMaintenance
• Material ManagementImprovement
• PLM to MES Execution
• Utilities/Sustainability/Energy
• Compliance/Food Safety/EHS&S
• Quality Program automation
• Continual Improvement
• ERP Integration
• Business Process Automation
• Multi-Plant Reporting andAnalytics
• Peer System Integration
• LIMS, WMS, CMMS
• Workforce Mobile Enablement
Customer Initiative Customer Goal Our Offering- Solution Components NotePlant Wide OperationalImprovement
Improve performance of existing plant assets and capacity.Reduce shrinkage and wasteReduce COGS
Real-time KPIs using IntelligenceMES (all)CEM
Likely need a step-wise approach
"Make" OperationalImprovement
Focus operational improvements in make area includingbatching, mixing, blending, cooking, baking, fermenting
Real-time KPIs using IntelligenceMESBatch ManagementRecipe ManagementFixed and Mobile accessWorkflow
"Pack" OperationalImprovement
Focus operational improvements on fill, pack, and palletize Real-time KPIs using IntelligenceMES
TPM- Total ProductiveMaintenance
The objective of TPM is to maintain the plant or equipmentin good condition without interfering with the daily process.To achieve this objective, preventive and predictivemaintenance is required. By following the philosophy of TPMwe can minimize the unexpected failure of the equipment.
Real-time KPIs using IntelligenceOEECondition Based MonitoringIntegration with CMMSWorkflow
Material ManagementImprovement
Reduce waste and shrink forbulk material receiving, material storage, bi-product bulkload-out, WIP material storage, finished goods.
MES-WorkflowHMI/SCADA
Implement receiving,load-out, internaltransfers inOperations
Corporate Initiatives and Solution Offerings for FMCG
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Implement receiving,load-out, internaltransfers inOperations
PLM to MES Execution Automate the NPI and change management processes Workflow Combination ofEAI for data andhuman workflow forapprovals
Utilities/Sustainability/Energy Reduce energy intensity, water intensity, effluent, solidwaste and emissions. Integrate Co-Gen, solar, wind,biomass
Real-time KPIs using IntelligenceCEM
Compliance/FoodSafety/EHS&S
Automate and integrate SOPs for compliance to internal andexternal regulations
Workflow, IntelaTrac
Quality Program automation Automate and integrate the quality program MES QualityWorkflow, IntelaTrac
Continual Improvement Tools and procedures for Lean, Six-sigma, TPM WorkflowERP Integration Automate interfaces to/from ERP from plant systems
Business ContinuityWEI
Business Process Automation Automate any and all SOPs for any aspect of the operation Workflow, IntelaTrac, MES Operations
Multi-Plant Reporting andAnalytics
Compare KPIs across plants for any measure EMI Intelligence
Peer System IntegrationLIMS, WMS, CMMS
Automate interfaces between systems, including manualactivities
WEI
Workforce Mobile Enablement Provide information access to workers any time and place SmartGlance, IntelaTrac, Intelligenceclient on mobile device, AWF client
Plant Initiatives
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Focus: Packaging OperationsManagement
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What is it?
A turn key solution composed of Wonderware Software, Invensysand Partner Services, Ongoing support, hardware as needed
A highly configurable and modular solution that is designed to bereplicated and sustained in multiple plants
Packaging Operation KPIs for equipment, lines, and plants.
Centralized KPIs for multiple plants
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A turn key solution composed of Wonderware Software, Invensysand Partner Services, Ongoing support, hardware as needed
A highly configurable and modular solution that is designed to bereplicated and sustained in multiple plants
Packaging Operation KPIs for equipment, lines, and plants.
Centralized KPIs for multiple plants
What does it do?
Gives Packaging Operation Managers the tools to continuously
improve the performance of their packaging operations
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What kind of results can I expect?
Categories of Quantifiable Improvement• Improved throughput of xx%
• Reduced Packaging material waste
• Reduced use of Cleaning chemicals
• Reduced Lost product or shrinkage
• Increased Energy efficiency
• Reduced Water waste
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Categories of Quantifiable Improvement• Improved throughput of xx%
• Reduced Packaging material waste
• Reduced use of Cleaning chemicals
• Reduced Lost product or shrinkage
• Increased Energy efficiency
• Reduced Water waste
How does it do this?
Connects to key equipment to measure automatically
• Production counts
• Rejects (by type)
• Error codes
• Operating variables
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Connects to key equipment to measure automatically
• Production counts
• Rejects (by type)
• Error codes
• Operating variables
And then…..• Provides information to Baseline current performance and spot opportunities
to improve
• Real-time view of Performance KPIs including OEE
• Monitor for problems and alert those who need to know
Prevent Mistakes by guiding line operators through procedures
including:
• Changeovers
• Replenishment
• Line Startup
• Line Shutdown
Manages Production Problems through Workflows defined by you
• Equipment breakdown
• Process out of control limits
• Quality out of control
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• Provides information to Baseline current performance and spot opportunitiesto improve
• Real-time view of Performance KPIs including OEE
• Monitor for problems and alert those who need to know
Prevent Mistakes by guiding line operators through procedures
including:
• Changeovers
• Replenishment
• Line Startup
• Line Shutdown
Manages Production Problems through Workflows defined by you
• Equipment breakdown
• Process out of control limits
• Quality out of control
Who Uses this solution?
Plant leadership team
Production Manager
Scheduler
Shift Lead
Area operators
Utilities manager
Accounting
Maintenance
Process Engineering
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Plant leadership team
Production Manager
Scheduler
Shift Lead
Area operators
Utilities manager
Accounting
Maintenance
Process Engineering
How do you get started?
Send an email to [email protected] to schedule aconversation with one of our solution specialists.
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Focus: Energy Management
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What is it?
A turn key solution composed of Wonderware Software, Invensysand Partner Services, and Ongoing support
A highly configurable and modular solution that is designed to bereplicated in multiple plants
Energy Performance Indicators for:• Level 1: Primary Utilities at Plant Level: Electricity, Gas, Water, Fuel
• Level 2: Conversion of Level 1 to plant services: steam, compressed air,refrigeration, vacuum, purified water
• Level 3: Consumers of services. Make process, packaging, sanitation
• Level 4: Waste streams. Effluent, emissions, solid waste
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A turn key solution composed of Wonderware Software, Invensysand Partner Services, and Ongoing support
A highly configurable and modular solution that is designed to bereplicated in multiple plants
Energy Performance Indicators for:• Level 1: Primary Utilities at Plant Level: Electricity, Gas, Water, Fuel
• Level 2: Conversion of Level 1 to plant services: steam, compressed air,refrigeration, vacuum, purified water
• Level 3: Consumers of services. Make process, packaging, sanitation
• Level 4: Waste streams. Effluent, emissions, solid waste
What does it do?
Gives Energy Managers the tools to continuously improve the
energy performance of their operation
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What kind of results can I expect?
Categories of Quantifiable Improvement• Reduced energy/water spend per unit of output 5-25%
• Reduced demand charges/penalties
• Reduced effluent charges/penalties
• Direct rebates from energy suppliers and energy service companiesfor demand-response programs and/or peak avoidance
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Categories of Quantifiable Improvement• Reduced energy/water spend per unit of output 5-25%
• Reduced demand charges/penalties
• Reduced effluent charges/penalties
• Direct rebates from energy suppliers and energy service companiesfor demand-response programs and/or peak avoidance
System PlatformSystem Platform
IAS Historian WIS
DAS-PLC
DAS-Modbus
DAS-BACnet
CEMCEM
EnergyUsage
Database
EnergyUsage
Database
CEMObjectsCEMObjects
InTouchfor real-timeview of energyusage
Information ServerClient for usagereports and analysis
Advanced Analytics Clientfor KPIs
How does it do this?
CEMEnergyBrowserPlugin
CEMEnergyBrowserPlugin
CEMEnergyReports
CEMEnergyReports
CEM EnergyAnalyticsWorkbook
CEM EnergyAnalyticsWorkbook
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System Platform
DAS-PLC
DAS-Modbus
DAS-BACnet
BuildingManagement
System
BuildingManagement
System
Meters for:•Electric Power•Compressed Air•Steam•Water•Gas•Chilled Medium
Meters for:•Electric Power•Compressed Air•Steam•Water•Gas•Chilled Medium
CEM
BACnetLonWorks
PLCDCSPLCDCS
PlantInfrastructure
And then…..
• Provides information on baseline energy usage and cost to spotopportunities to improve
• Real-time view of Performance KPIs including EnPIs (energyperformance indicators)
• Monitor for problems and alert those who need to know
• Allocate true energy usage by department, cost center, etc.
• Manages Energy through Workflows defined by you:• Energy use targets exceeded
• Demand Response
• Peak avoidance
• Staged startups of energy intensive equipment
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• Provides information on baseline energy usage and cost to spotopportunities to improve
• Real-time view of Performance KPIs including EnPIs (energyperformance indicators)
• Monitor for problems and alert those who need to know
• Allocate true energy usage by department, cost center, etc.
• Manages Energy through Workflows defined by you:• Energy use targets exceeded
• Demand Response
• Peak avoidance
• Staged startups of energy intensive equipment
Who Uses this solution?
Plant leadership team
Energy Manager
Sustainability team
Cost Accounting (treat energy as a variable cost)
Slide 22
How do you get started?
Send an email to [email protected] to schedule aconversation with one of our solution specialists.
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Solution Components
Products
SupportProductSolution
Infrastructure
Slide 24
SupportProductSolution
Infrastructure
ServicesCollaborate Delivery
Wonderware MES Software: Operations,Performance, Quality
What it does:• Executes Production Orders at each operation• Directs Operators during the operation• Collects production results, material use, process data• Maintains genealogy of materials, operators, equipment• Executes the Quality plan for a production order
Who Uses it:• Production Operations• Quality• CI teams to meet corporate improvement goals
How it adds value to your operation:• Maximum utilization of plant assets to produce to schedule• Maintains quality and product safety• Produces real-time KPIs to support initiatives
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What it does:• Executes Production Orders at each operation• Directs Operators during the operation• Collects production results, material use, process data• Maintains genealogy of materials, operators, equipment• Executes the Quality plan for a production order
Who Uses it:• Production Operations• Quality• CI teams to meet corporate improvement goals
How it adds value to your operation:• Maximum utilization of plant assets to produce to schedule• Maintains quality and product safety• Produces real-time KPIs to support initiatives
Wonderware Corporate EnergyManagement (aka CEM)
What it does:• CEM reads meters for electricity, gas, air, steam, water, chill, and
effluent• CEM relates energy usage to production output to create Energy
Intensity KPIs• CEM provides cost of energy usage for products, processes,
orders, utilities, cost centers….
Who Uses it:• Plant Controller to allocated the utility bills to departments,
products, cost centers, etc.• Plant engineer to detect energy waste• CI teams and Energy Manager to meet corporate reduction goals
How it adds value to your operation:• Reduce energy component of COGS• Reduce overall energy spend• Avoid demand charges
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What it does:• CEM reads meters for electricity, gas, air, steam, water, chill, and
effluent• CEM relates energy usage to production output to create Energy
Intensity KPIs• CEM provides cost of energy usage for products, processes,
orders, utilities, cost centers….
Who Uses it:• Plant Controller to allocated the utility bills to departments,
products, cost centers, etc.• Plant engineer to detect energy waste• CI teams and Energy Manager to meet corporate reduction goals
How it adds value to your operation:• Reduce energy component of COGS• Reduce overall energy spend• Avoid demand charges
Wonderware WorkflowWhat it does:
• Creates and Executes SOPs and cGMPs that link people,equipment and systems
• Guides the manual activities in your operation with a completeaudit trail- e.g. manual cleaning, line changeover
• Notifies, escalates, gathers feedback, shows instructions andguidance,
• Reports when, who, and what was done
Who Uses it:• Operations to ensure procedures and policies are followed• EHS&S for safety, regulatory compliance, HACCP• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Capture operation best practices and duplicate shift to shift• Measure procedural productivity to identify and remove bottlenecks• Avoid penalties for energy overuse, effluent or emissions,
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What it does:• Creates and Executes SOPs and cGMPs that link people,
equipment and systems• Guides the manual activities in your operation with a complete
audit trail- e.g. manual cleaning, line changeover• Notifies, escalates, gathers feedback, shows instructions and
guidance,• Reports when, who, and what was done
Who Uses it:• Operations to ensure procedures and policies are followed• EHS&S for safety, regulatory compliance, HACCP• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Capture operation best practices and duplicate shift to shift• Measure procedural productivity to identify and remove bottlenecks• Avoid penalties for energy overuse, effluent or emissions,
Intelligence SoftwareWhat it does:
• Pulls data from any data store: Historian, alarms, productionrecords, batch records, energy database, LIMS
• Uses data to compute and display KPIs across all systems• Highlights deviations to standards for materials, labor, quality,
productivity, energy• Allows drill-down for root-cause analysis
Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Unlocks islands of data and creates actionable information• Automated data collection for team meetings, ops reviews• Fast visibility of deviations to enable fast corrective actions
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What it does:• Pulls data from any data store: Historian, alarms, production
records, batch records, energy database, LIMS• Uses data to compute and display KPIs across all systems• Highlights deviations to standards for materials, labor, quality,
productivity, energy• Allows drill-down for root-cause analysis
Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Unlocks islands of data and creates actionable information• Automated data collection for team meetings, ops reviews• Fast visibility of deviations to enable fast corrective actions
SmartGlanceWhat it does:
• Pulls data from any data store: Historian, alarms, productionrecords, batch records, energy database, LIMS
• Stores extracted data in a secure cloud• Displays information in clear, concise reports and charts• Allows sharing of reports and charts through email
Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Authorized users see operational information anywhere, anytime,
on convenient hand-help devices• See deviations soon after they occur when action can be taken to
mitigate• One interface to all data sources
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What it does:• Pulls data from any data store: Historian, alarms, production
records, batch records, energy database, LIMS• Stores extracted data in a secure cloud• Displays information in clear, concise reports and charts• Allows sharing of reports and charts through email
Who Uses it:• Management Team- Ops, Finance, Engineering, Maintenance• Production Planners• CI teams to Measure, Analyze, Implement, and Maintain
How it adds value to your operation:• Authorized users see operational information anywhere, anytime,
on convenient hand-help devices• See deviations soon after they occur when action can be taken to
mitigate• One interface to all data sources
Conclusion
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