the journey to more effective packaging automation griffen.pdf · packaging automation bryan...

The Journey to More Effective Packaging Automation

Bryan Griffen Nestlé E&A Engineering Manager

OMAC Packaging Workgroup Chair

The world’s leading nutrition, health and wellness company December 2012

Topics we will cover

• Nestlé: The world’s leading nutrition, health and

wellness company

• PackML: Our packaging automation vision

− The prototype

− Designing a more effective operator interface

− Where we’re headed next

− Our contribution to the General URS

• Nestlé’s alliance with industry

• The value and benefits of implementing PackML

• Conclusions

2 B. Griffen December 2012

Nestlé products & brands: instantly recognizable

• 10,000 different products

• Around 1 billion products sold every day

• A product for every moment of every day, from

morning to night and from birth to old age


A brief history of automation and packaging at Nestlé

• Engineering in Nestlé is traditionally process-oriented – we own and

manage our process solutions – We design and automate the key process units

– Rockwell Automation is our solution provider for process automation

• We typically do not own the solutions for the packaging hall – We have a strong focus on materials, aspect and machine capabilities

– No real efforts have been placed on machine automation standards

• Packaging OEMs very often have their own automation platform

specification – Changes to their specified platform increases costs

– No guarantee on performance is given if they must use a different platform

• It is now time to set a new direction…


THE JOURNEY BEGINS… PACKAGING SIMULATION LINE


Where we started

2008 Preliminary investigation on automation standards for packaging lines

2009 OMAC / PackML indentified as possible solution for Nestlé

2011 Line simulation prototype commissioned using PackML


• Packaging Machine Language

• Industry standard (ISA TR88.00.02)

• Software design methodology that leads to: ‒ Common operational look and feel between equipment

‒ Defines operational state of a machine

‒ Provides for operational modes

‒ Standard information to/from machines (PackTags)

‒ Modular coding for re-application libraries and

diagnostics

• Applicable to other types of machine systems

7 B. Griffen

What is PackML?

December 2012

Validating the line integration concept

The platform is composed of : - 3 Festo modules - 1 Staubli robot - 4 disparate PLCs and HMIs - 1 SCADA (Wonderware)

8 B. Griffen

Destacking modules

RFID and turning units

Palletization cell

Drilling and transfer units

SCADA system

December 2012

Intellectual Properties Machine Builder D

I/O Machine Network

Intellectual Properties Machine Builder C

I/O Machine Network

Intellectual Properties Machine Builder B

I/O Machine Network

Intellectual Properties Machine Builder A

I/O Machine Network Mac

hine

-leve

l Li

ne-le

vel

OMAC Line Integration Strategy Open protocol for PackML tag

exchange

OM

AC

OMAC State Model

End User

OMAC State Model OMAC State Model OMAC State Model

PackTags PackTags PackTags PackTags

Unveiling of the prototype at Pack Expo


THE CONTINUING JOURNEY: HMI, SAFETY AND MES


HMI standards are needed to improve operator efficiency Actual status of individual HMIs for one packaging line...

12 B. Griffen

Elevator Caser

Coding filing bag Bag filler VFFS

Check-weigher

Cartoner (CAMA)

Metal detector

Bar code reader Bar code

check

X-ray detector Ink-Jet cartons

Metal detector

finish carton

Ink-Jet case

December 2012

Many current machine interfaces are not user-friendly and add complexity to run machines

13

• More than 200,000 HMIs are currently

used in Nestlé Factories

• More than 70,000 people involved in

packaging operations worldwide

• All screens have a different aspect and

this creates confusion and hinders staff

flexibility

• A specific training is required for each

equipment, this costs money and takes

too much time

B. Griffen December 2012

A standard HMI solution has been developed Packaging and Automation have worked together to define a standard

look-and-feel for operator interfaces


Next steps: On screen diagnostics will reduce downtime and improve efficiency


Next steps: Vertical integration into the MES layer for reporting & tracking

December 2012 16 B. Griffen

Next steps: One safety standard for the entire production plant

Creating an open safety protocol (similar to the PackML concept) enables

increased productivity for the plant

• Cost reduction

• Less down-time

• Higher productivity

• Easy maintenance

Concept under review


A general URS with eight modules covers Nestlé’s packaging requirements

1. Procurement module

2. Line integration module

3. Equipment module

4. Safety, health and

environment module

5. Hygienic module

6. General design module

7. Quality module

8. E&A module

- Checklists


NESTLÉ’S PARTICIPATION TO THE OMAC PACKAGING WORKGROUP


Who is OMAC?

OMAC: The Organization for Machine Automation and Control

‒ Organization for automation and manufacturing professionals, including

end-users, machine builders, and technology providers

‒ Dedicated to advancing manufacturing capabilities and efficiencies

through identifying common problems, standardization, and

improvements to processes that positively impact the way companies

do business

‒ Two main workgroups: Machine Tools and Packaging

December 2012 20 B. Griffen

The OMAC Packaging Workgroup (OPW) vision and mission

21

Maximizing the business value of packaging machinery through implementing automation standards that lead to

improved flexibility and increased capability, while improving safety, and reducing the total cost of ownership.

To be the guidepost in the packaging industry leading to a more unified automation solution that improves packaging

line efficiencies, reduces the capital and operating costs associated with packaging lines and promotes faster time to

market.

Mis

sion

Vi

sion

B. Griffen December 2012

The OPW goals

• We support End User and OEM machine automation choices and

flexibility through greater industry openness and interoperability

• We aim to enhance manufacturing competitiveness by developing

industry-wide standards designed to facilitate packaging line integration

and improve OEE

• We provide tools and methods to optimize the control of packaging

equipment through:

‒ Implementation of international standards

‒ Realization of horizontal (line) integration

‒ Providing links to vertical MES/ERP systems

• We seek to improve the operational safety of packaging equipment


Mar

ketin

g Te

chni

cal

Increase adoption of the Connect-and-Pack Standards across industry, including End Users, OEMs, Systems Integrators, packaging associations and educational institutions through providing concrete value propositions that positively affect the business and human aspects of the adopting entity.

Develop the technical specifications, tools, and methods which comprise the Connect-and-Pack Standards, and which facilitate attaining the greatest value from packaging automation systems. Work with other industry automation organizations to align standards and methods used in packaging equipment design.

The OPW strategy


The OPW committees support our strategy Technical Focus:

PackML Continuation of activities related to the standard itself

PackSpec Generate a packaging machinery specification for PackML

PackSoft Collaborate with organizations such as PLCopen & OPC Foundation to enable/ensure compatibility with PackML

PackConnect Work with communication organizations (i.e. ODVA)

PackSafety Development of safety communication protocols

Marketing Focus:

PackAdvantage Communicate the business benefits of PackML

– PackAdopt Work directly with OEM organizations

– PackSyst Work directly with systems integrators

PackLearn Central contact for educational & training institutions


VALUE & BENEFITS OF PACKML


Key benefits of compliance to PackML End Users:

• Consistent data and control structure for integration both horizontally (machine-to-

machine) or vertically (machine-to-SCADA/MES)

• Promotes best-in-class solutions focused on innovation

• Reduced total cost of ownership (TCO)

Machine Builders:

• Allows the OEM to select the technology platform that will best suit their needs

• Simplified post-sale support

• Protection of intellectual property

Systems Integrators:

• Consistency when working with multiple automation platforms and OEMs

• Focus on value-added activities such as MES, maintenance tools, etc. instead of

integration concerns

Technology Providers:

• Focus on competitive advantages instead of integration issues

• Open the global market of packaging machines to all Technology Providers (get rid of

the hard specification of one single supplier)


Members include end users, machine builders, systems integrators and technology providers


Where our journey has taken us…

• We believe that standardization is imperative to improving our

overall equipment effectiveness; PackML is our standard for

packaging machine automation

• We are fully committed to the PackML strategy, and we continue

to support and develop this strategy through active participation

to the OMAC Packaging Workgroup

• We are developing complimentary tools and specifications for

application as part of our PackML strategy, these include HMI

specifications, communication standards and safety system

integration – all of which are focused on improving the operability

and maintainability of our packaging systems


Thank you for your attention

How to join OMAC and have your voice heard…

New and renewing End User & Original Equipment Manufacturer annual

membership fees: (http://www.omac.org/content/membership)

• $2,900 – annual sales >$50 million

• $1,900 – annual sales of $5.0 to $50 million

• $900 – annual sales under $5 million

Membership benefits include:

• Access to OMAC Workgroups via direct introduction to Workgroup Chairs

• Access to OMAC best practices and technical guidelines

• One seat on the OMAC technical advisory board (TAB)

• 20% company employee discount to all OMAC conferences and symposiums

• Company logo listed on OMAC website and link to company website

• Listing as an OMAC Corporate Member on OMAC mailings and promotions

• Use of the OMAC and OMAC workgroup logos


http://www.omac.org/content/membership

the journey to more effective packaging automation griffen.pdf · packaging automation bryan...

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