Manufacturing Solutions: The Journey Terence Tan General Manager IAM Wonderware 15 th October 2014 - Holiday Inn, Glenmarie Advance Solutions Seminar: Manufacturing Intelligence – Anticipate the Unexpected by optimizing production and safeguarding your assets
What is MES? Manufacturing Execution Systems (MES) are computerized systems used in manufacturing. MES can provide the right information at the right time and show the manufacturing decision maker “how the current conditions on the plant floor can be optimized to improve production output. MES work in real-time to enable the control of multiple elements of the production process (e.g. inputs, personnel, machines and support services) Source from wikipedia (http://en.wikipedia.org/wiki/Manufacturing_execution_system)
What is MES?
Operations & Execution Portfolio MESA’s 11 Functions of MES Sales & Enterprise Service Resource Management Operations/ Resource Planning Detailed Allocation & Scheduling Status Dispatching MES Document Production Control Units Product Performance Tracking & Analysis Genealogy Labor Maintenance Process Management Management Management Data Quality Collection Management Acquisition Supply Chain Control Management
11 Functions of MES Fully Covered by Wonderware ISA Model ISA Model Sales & Enterprise Level 3 Level 2 Service Resource Management Planning Operations/ Resource Detailed Allocation & Scheduling Status WW Avantis Operations Dispatching MES Document Software Production Control Units WW QI Analyst WW Product Performance Performance Tracking & Analysis Genealogy Software System Platform Labor Maintenance Process WW Management Management Management ArchestrA Enterprise Workflow Integrator Data Quality Collection Management Acquisition Supply Chain Control Management
Wonderware Software Solutions ActiveFactory ERP MES MES Internet Publishing InBatch Operations/Performance Plant Historian IndustrialSQL Web Batch Mgmt System Server Info Server InTouch RT SPC/SQC HMI/SCADA InControl IO Servers Devices Connectivity (Barcode Scanner, PLCs, DCS, AB, Siemens, Omron, etc…) Soft Logic Controllers
How to Implement?
How to Implement? Key Factor MES System
How to Implement? “People” ► Project Team ► Kickoff meeting ► Details System Study ► Define Details Project Scope ► User Requirement Specification ► Project Schedule
How to Implement? “Software Solutions” ► System Design ► Define System Specification ► Define System Architecture ► Define Project Deliverables ► Product Training ► Functional Design Specification
How to Implement? Strategy ► Project Lifecycle ► Project Methodology – PRINCE2 ► Weekly Progress Update ► Monthly Stage Control Review ► Risk Management
Sample of the Project Plan and Activities
How Wonderware Help? ► Certification ▪ Wonderware Certified Support Provider ▪ Wonderware Certified Training Provider ▪ Wonderware Certified System Integrator
How Wonderware Help? ► Customer First Program ▪ Technical Support • Technical Support, Online Case Management and Knowledgebase • Online Training Seminars, Discount on Consulting Services • Emergency Direct/Advanced Technical Support ▪ Software Maintenance • Software Maintenance Releases, Service Packs, Patches and hotfixes • Software version upgrades ▪ Additional Benefits • Wonderware Training • Complimentary Invitation to Customer Events • Dedicated Customer Portal • Technical Account Management Team • Cyber Security Readiness Workshop ▪ Optional Services • Customer First for Solutions • Customer FIRST Cyber Security Maintenance Program • Resident Engineer • Application Clone
How Wonderware Help? ► Wonderware Developer Network (wdn.wonderware.com)
AGENDA Overview of Cobega MES Project Scope Key Factors Why Wonderware? Slide 15
Overview of Cobega COBEGA IS A COMPANY THAT BOTTLES AND DISTRIBUTES Cobega PRODUCTS FROM Cobega works to place itself ECCBC among the best bottlers of the Cobega Coca-Cola system in the world Group and continue being a reference in Daba the Spanish business community for its corporate policies as well as for its excellence in business administration and talent Others management. Slide 16
Overview of Cobega Bottling company and distributor of Coca-Cola Cobega Company products in Catalonia, Aragon, the Balearic Islands and Canary Islands. It also ECCBC Cobega holds a 30% participation in the Portuguese Group business and the 100% in the Iceland’s. Daba Others Slide 17
1.200 employees 12 M ILLION PEOPLE 1 1 MILLION 3 P LANTS 3 P ALLETS / YEAR 440 SKU’ S 20 270 50 H ECTARES 50 Brand Names MILLIONCASES/YEAR 80.700 C LIENTS 21 PACKAGINGLINES Slide 19
AGENDA Overview of Cobega MES Project Scope Key Factors Why Wonderware? Slide 20
They called it the ICEBERG Project… Slide 21
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“ THEHIDDENFACTORY ” … but it has been completed Slide 23
Scope Work Orders planning on bottling 24h lines (Download and Manage) Labour management InTouch Operations Performance OEE, MTBF, MTTR… WO Execution (Track&Trace) CIP’s , Format Changeover and TPM Workflow Integration with SAP PM SAP Raw material consumptions Energy efficiency CEM Quality Intelligence Reporting Slide 24
Scope System Platform 25k/12k 49 InTouch for SP • 36 in WW Panel PC • 13 for Cobega’s Workstations 298 equipments supervised • 92 Operations Entities • 98 Performance Entities 400 PoE of CEM 91 Wonderware Workflow users 20 Intelligence Concurrent users 5 Intelligence Analytics clients Slide 25
How it works Production Plan 24h CEM Work Orders to the bottling Lines InTouch/ WOPS Work Order Execution Workflow SAP Slide 26
Workflow Example Workflows in a Work Order Line 12 – WO1 – Cola – Cans 33cl – 30.000 u. Running Time A - 00:00’20’’ – WO Verification Pending Time Cheklist before start a WO CIP done Raw Materials availability Right number of Operators available and capable to run this equipment TPM tasks already completed Line Status Slide 27
Workflow Example (TPM) Workflows in a Work Order Line 12 – WO1 – Cola – Cans 33cl – 30.000 u. E - 00:40’00’’ – Task Management (TPM) Task Management ( Total Productive Maintenance ) Pending tasks are shown to the operator through InTouch, including step-by-step guide All relevant information is registered: task fulfillment, time and operator There are several types of tasks Slide 28
WO’s trace in real time for Planners and Line Supervisors Slide 29
KPI’s monitoring in real time by areas Slide 30
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AGENDA Overview of Cobega MES Project Scope Key Factors Why Wonderware? Slide 33
1. What are they looking for? Clearly identify WHICH are they real needs • Increase OEE • Reduction of • Support TPM • SAP/R3 Reduce Production Costs Integrate Info between Non- • SMED • Coordination • Production Improve Process Mgt Conformities production planning • Energy tasks (Numetrix) Increase Assets Consumption • Coordination • Wastewater Availability • Labor Costs Production/M Treatment systems aint/Quality • Maintenance • Syrups Costs Production *SMED: Single Minute Exchange of Die Slide 34
2. Where is the Return On Investment? • Increase OEE • Increase OEE • Reduction of • Reduction of • Support TPM • Support TPM • SAP/R3 • SAP/R3 Reduce Production Costs Reduce Production Costs Integrate Info between Integrate Info between Non- Non- • SMED • SMED • Coordination • Coordination • Production • Production Improve Process Mgt Improve Process Mgt Conformities Conformities production production planning planning • Energy • Energy tasks tasks (Numetrix) (Numetrix) Increase Assets Increase Assets Consumption Consumption • Coordination • Coordination • Wastewater • Wastewater Availability Availability • Labor Costs • Labor Costs Production/M Production/M Treatment Treatment systems systems aint/Quality aint/Quality • Maintenance • Maintenance • Syrups • Syrups Costs Costs Production Production Slide 35
2. Where is the Return On Investment Reduction of Non- Energy Support to TPM Conformities: Consumption • Avoid BOM • Assets • Labor hand mistakes consuming dedicates to without WO, CIP , gather info Maintenance … CEM Workflow Operations *BOM: Bill Of Materials Slide 36
3. Avoid White Paper Syndrome The Team cannot start the project “from the scratch” We must have knowledge and experience about the Software to be used But it is even more important to “SPEAK THEIR LANGUAGE”: H I -C ONE Syrup T ORQUE K AIZEN LEAN SKU’s A SEPTIC K ISTERS Slide 37
4. Methodology MES project Specification Specification • 300 PoEU • 5 alarms/equipment Project Project • 1.000 PoEU • 500 alarms/equipment Functional Specifications and Methodology Slide 38
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