Decreasing life cycle costs while increasing line efficiency!

Optimized Packaging Line - OPL

www.siemens.com/opl
Unrestricted / © Siemens AG 2014. All Rights Reserved.
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 Challenges !!

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Challenges for today’s packaging industry

i m i ze
Min
s t of
co io n a te c e
u c t Cr e d u
prod ase r en cy Re st
c s p a l C o
tra n t a
ig n a per re d uc e T o
De s an d of
er ip
be t t OEM e e r sh
a g ing d en c Own )
pack t ep e n ( T C O
d
plan d u ce
Re cy
c i e n
effi fter
o p a
d r
a r t up
st
Page 3 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.
 Priorities in CAPEX decision process

Invest Initial investment

in Filling & Packaging lines
Capital

Spares Maintenance
Operating cost occurring by
Service Support §
Downtime for service
Energy Downtimes §
Spare parts
§
Training
Training Personal
§
Poor integration
Space
Upgrades §
Line extensions etc.
Extension

Missing awareness that initial investment represent only a small portion of the total "Life Cycle Cost“.

Page 4 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.

Typical structure of filling & packaging lines today

Diversity MIS/MES

Line Overview HMI

Complexity ?????

No Data Data Data

Difficult
Interface Interface 2 Interface n
System-integration
HMI PLC HMI PLC PLC PLC

Topology
Topology
Motion
I/O I/O I/O Control I/O
Difficult Diagnostics Drives Drives Drives
Motors Motors Motors
LV Sensors LV LV Sensors LV Sensors
Asset Costs
Machine 1 from OEM x Machine 2 from OEM y Machine 3 from OEM z

Missing standardization causes high diversity & complexity, and prevents simple line integration.

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Major efficiency loss after OEM’s are leaving site

Phenomena at filling lines causes massive loss of productivity

Line acceptance: OEM leaving

YY%

Potential
savings! XX%

Start of zz ys
commissioning Z yrs

Page 6 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.

 The modular approach of OPL

Line Integration Organisation & Support

§
Interfaces & communication according to §
Technical consulting
international standards §
Training
§
Line visualization §
Service and Support
§
Network diagnostics §
Spare part availability
§
Secure remote access §
…
§
…
… creates transparency
… increases productivity
§
Documentation Ready to run standard applications
… saves life cycle costs and tools:
§
Technical guidelines
§
Specification template §
Motion control (e.g. Top Loading)
§
Hard- & software list §
TCP/IP communication
§
… §
Message handling
§
ProjectGenerator
§
…
Machine Architecture Software Toolbox

Modules can be freely combined according to users needs.

Page 7 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.

 The challenge of standardization & integration

MIS/MES
Module Organization & Support

Module Line integration

§
Line Overview Line Overview HMI
§
Diagnostics Integration
§
Providing Production Data
§
Networks
Module Software Toolbox Standard Standard Standard
§
Data Interface Data Interface Data Interface Data Interface
§
Application HMI PLC HMI PLC HMI PLC

Topology

Topology
Topology
I/O I/O I/O
Module Machine Architecture
Drives Drives Drives
§
Hardware & Software
§
Machine Topology Motors Motors Motors
LV LV LV
Machine 1 from OEM x Machine 2 from OEM y Machine n from OEM z

Modules can be freely combined based on user needs.

Page 8 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.

Module Line Integration –
Line Overview

The Line Overview …

§
shows the entire status of the line(s) at a glance.

§
provides relevant information & diagnostics for
each operator (plant manager, machine operator,
maintenance, service, …).

§
is available on each PC based machine HMI in
the line by using Web Client technology.

The information is based on international standards like OMAC, Weihenstephan Standard & EN60204.

Page 9 Binu Thomas © Siemens Ltd 2014. All Rights Reserved.

 Line Control Unit (LCU)
balancing machine speeds within a line for a optimized usage of your line

Line Visualization

Line Monitoring
Functionality

parametrazing

System
LCU
•
The Line Control Unit (LCU) is an add on
in the supervisory System
•
The machine speed calculation is done in
a separate controller
Line Supervisory Line Controller •
Conveyer systems an be connected and
Application
System controlled in the application
•
Integrated in an existing Line possible
•
Parameter can be optimizes via Plant
ST D I ST D I ST D I ST D I ST D I
Simulation
Interface
(Tag mapping)
3rd party custom
code

Siemens Controller & Drives on line level

Line control can be an add on for better control of the packaging line

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 Module Line Integration –
Providing Production Data

OEE, KPIs, Reporting … Energy data acquisition

LMS (Line Monitoring System) provides: PROFIBUS DP PROFINET

§
OEE, KPIs (standard & custom)
§
Reporting functionalities
§
Shift calendar integration
§
Real time status visualization (WinCC)

Intelligent devices and

measurement equipment

+
Power Management system

=
maximum transparency of the
entire power consumption WinCC powerrate
WinCC screen

An integrated approach with an entry level affordable for everyone – scalable up to MES.

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 Module Software Toolbox –
Project Generator

The Software Toolbox offers function blocks … which can be easily … supporting our
for interfaces & communication… implemented in new or motion control system Simotion
existing projects by using and the
the Project Generator … automation platform Simatic.

Simotion

Simatic S7-300/-400

The OPL Software Toolbox offers manifold standard functions and tools.

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 Module Machine Architecture –
Hard- and Software

Optimization

Plant A Plant B OPL

Hardware Software Hardware Software Hardware Software

PLC 21 3 6 2 3 1

Motion - - 3 2 2 1 Result:
Start:
Reduced variance
Plant audit
HMI 11 5 6 3 3 2 of HW & SW

Drives 6 2 5 1 3 1
Hardware-
Dist. I / O 5 - 3 - 1 list

Software-
Network 4+ - 4 - Optimization3 list

Decreasing parts and software variance leads to easier operation, maintenance, less training and spare parts.

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OPL benefits at a glance

MIS/MES

…saving life cycle costs … creating transparancy … increasing productivity

$ Field Level

Less hard- & software diversity

§ §
Integration of machines/lines in proper §
Limited effort & risk of integration
network topologies (commissioning phase)
Less spare parts variety
§

§
Using international standards §
Lowering of “efficiency drop” effect
Less training for operational & service
§

staff §
Harmonized, OEM independent line
visualization
Less energy consumption due to energy
§

efficient §
High degree of diagnostics
& saving products §
Perfect base to calculate KPI/OEE values &
to connect SCADA/MES systems

§
Easy & fast service & maintenance
§
Reduced downtimes

Decreasing life cycle costs, while increasing line efficiency!

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