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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“.

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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

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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.

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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.

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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.

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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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