solutions for adoption of automation technologies in the f...

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National Symposium on

Automation & Digital Transformation of

Food & Beverage Industry26th & 27th February 2016

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K V Rehani

Automation Consultant

Mail ID: [email protected]

Tel: +91 9730018676

Solutions for Adoption of Automation

Technologies

In the F&B Industry

Basics of Modern Industrial Automation

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K V Rehani

Academic:

- B. Sc. Physics Hons., Delhi University 1970

- M. Sc. Electronics , Delhi University 1972

Formerly:

- With Unilever.Head of Control & Automation Group . Worked for 30 years at different locations & positions. Implemented many green field & brown field projects. Developed solutions for many inhouse developed technologies.

- Instrument Er , IFFCO, Phulpur Unit (1979-81), commissioning of Ammonia ,Urea Plants & Site Utilities

- Assistant Instrument Er , Shriram Chemicals & Fertlisers ,Kota (1972-79), had formal training in Instrumentation while working in Ammonia, Urea, PVC, Caustic Soda & Power Plants

Currently:

- Independent Automation Consultant for CPG industry. Pune based

- Advisor to Rockwell Automation for their CPG business & other MNC’s for green field project

- Advisor to innovation led start up groups for young entrepreneurs

Association:

- Senior Life Member. Past President, ISA Pune Section (2013-15)


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Automation Solutions in F & B

Welcome to wonderful world of Automation


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• Manufacturing: Business Perspective

• Challenges of F & B Industries

• Manufacturing Challenges

• Automation Compulsions

• F & B Processes

• Opportunities & Focus Areas

• Challenges & Mitigation Strategy

• Q & A

Agenda

Automation Solutions in F & B


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Manufacturing: Business Perspective

Make DeliverSource

Plan

Supply Chain

Suppliers

Quality

R & D

Manufacturing

Engineering

Administration

Logistics

Warehouse

Value Creation is in Manufacturing ,therefore always in focus.


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Challenges of the F & B Industries.

Availability of products at all times at a price & quality which will help any Industry grow, increase its market share: Changing consumer preferences

Innovations to excite end users & create new marketsStay ahead of competition : Market Share & Sustainability.

Products are Safe & Fresh: Safety & Legislation factors.

Rising raw material & Energy Cost : Productivity & Performance

#


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Manufacturing Challenges

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Productivity

Quality

Safety & Hygiene

Ageing Workforce

Ageing Plants


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Productivity: What can go wrong, Will

How do you increase productivity to keep up with rising demand?stay competitive when cost of raw materials is constantly changing?meet safety norms?become more sustainable & cost efficient?improve performance, increase speed and overall productivity.

Top four areas where technology can increase

production, performance & agility.

Machinery,Materials, Methods & Manpower


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Quality,in Quantity

Investment in Technology as fundamental to growth.How do you accommodate different sizes of products(SKUs) on any given line ?ensure the best chance of maintaining quality & consistency ?innovate with expensive downtime ?What if your equipment could plan for next batch ?

End to end assurance keep quality high and reduce cost by controlling waste & process.

New Mixing Technology gives you ability to change production at short notice without losing impetus.


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Building-in-Safety

Minimizing Risks to operatives with no compromise on

Productions

Enhancing Machine Safety

Safety design, standards & validations

Achieving desired Performance Levels

Injuries in F & B manufacturing represent

around 25 % of all manufacturing injuries

reported.


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Ageing Workforce : How to Defy Ageing ?

Getting skilled manpower is a challenge.Qualified & motivated people are hard to find.

Loss of knowledge /experience is a business threat.

How to minimise downtime in absence of skilled people?

Implement standardised network that require

fewer employees to Manage, Monitor &

Maintain plant assets.


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Ageing Plant: What’s Next for your System?

Obsolescence

Lack of support from OEMs

Expensive downtime

Have a Migration Strategy & choose

right partner


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Achieving Agility: Operational Efficiency

When reviewing opportunities for improved operational efficiency by evaluating entire production cycle spectrum-from raw material receipts to finished goods,four key areas to evaluate every stage:

Machinery: Right first time & improved first pass quality.Material : Accurate recipe control to minimise wastageMethods: Using correct tools & most efficient process.Manpower: Right skills for operators, no unnecessary activity


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Automation Compulsions

Globalization :

Collaborative Manufacturing

Manufacturing information integrated with Supply Chain Visible Factories, Shop to Top Floor

Plant Wide Optimization

Benchmarking: Internal / External

Increased focus on Energy, Environment & Sustainability


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Automation Solutions in F & B manufacturing

Batch : Integrity & Traceability

Managing Supply Chain

Packing Line Integration : Driving Productivity

Smart Manufacturing


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Raw Material

Receipts

Ethernet Network

MAIN SERVER

MaterialTrack Server

Data Base

Logix

SCADA

•Visual Inspection

•GRR Generation

•Barcode Generation

•Store Location

Assignment

Barcode

Printer

Cordless

Barcode

Reader

• Sampling in

to Bar-coded

bins

• Analysis

Results entry

in to system

mapped to

sample

Cordless

Barcode

Reader

•Store at

Assigned area

•Show Status

(lights)

•Guide

Material Issue

•Validate

Material Issue

•Guided

unloading

• Status

Display

• Track Tank

Status

• Validate

Delivery from

Right Tank

•Barcode Barrels

•Display Barrel

Status

•Validate

Dispensing

•Tag Issued

Containers

QC/LAB RM Solids

Major

RM Liquids

MajorLiquids

MinorPowder

Minor

Mixer

AreaHolding Tanks &

Packing Area

Packaging

Material Storage

• Guide, Validate

Dozing as per

Batch Sheet

• Link Batch to

material Used

•Monitor

Operator

•Prompt Operator

• Validate Correct

Additive Mixing

•Monitor and

Guide Operator

• Guide and

Monitor Xfer to

Holding tank

•Store at

Assigned area

•Show Status

(lights)

•Guide

Material Issue

•Validate

Material Issue

• Display

Batch nos

• Prompt

Batch change

• Packaging

Line

Messaging

•Production Planning

• Batch Sheets/schedules

•Monitor Progress

•Reporting

•Data Logging

DeviceNet

Batch Integrity & Traceability


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Automation Solutions: Asset Productivity

OEE

Line Integration

Performance Reliability

Intelligent Equipment

Remote Support

Integrated Architecture


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What is Overall Equipment Effectiveness (OEE)?

Quality% = Total – Scrap

Total

Performance% = Total * Ideal Cycle

Running Time

Availability% = Running Time

Available Time

Overall Equipment Effectiveness (OEE) =

Availability x Performance x Quality

One Shift

Available Time

Running Time

Production @ Rated Speed

Good Production

Sc

he

d

Un

ava

il

Lost Capacity

Do

wn

ti

me

Sp

ee

d

Lo

ss

Sc

rap

Scheduled Unavailable Time

Breaks, meetings, maintenance, etc.

Downtime

Breakdowns, setups, changeovers

Speed/Cycle Time Loss

Reduced speed, cycle time variation

Quality Loss

Rejects, scrap

Key Performance Indicator

(KPI)

Time Loss Causes

OEE

Available Time = Shift time –Unavailable Time


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Line Integration

Insist on OMAC Guidelines compatible machine

design


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Automation – keeping pace with changing requirements


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Scalable Control Solution

Regulate

Optimize

Control

Predict

Single

LoopMultiple

Loops

Process

UnitMultiple

Units

Plant-wide

Value-Add

Area

Span of ControlStand Alone

Cluster

Centralised Panels

Stand alone pkg lines

SCADA

PLC’s,DCS,

Control Network

Remote access

& Data sharing

Enterprise

PLC’s,DCS,

Control Network

Remote access &

Data sharing with

ERP thru MES


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Strategy and Vision

Vision

World Class

Yesterday

Quality Performance

GAMP & PackML Simplicity

Information Enabled

Integrated Architecture


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Control Solution Selection

#

Have a strategy for adoption of Technology.

Start small, think big.

Do not reinvent the wheel

Invest in manpower & skill development


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K V Rehani

[email protected]

ISA Pune Section

Automation Consultant: KVR Consulting

solutions for adoption of automation technologies in the f...

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