Driving operational performance by building manufacturing capability one step at a time
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Driving Operational Performance by building Manufacturing Capability one step at a time…. Phillip Terlesk. Agenda. Global population will exceed 7 billion. Best In Class Demands. Operating Excellence Compliance Dynamic Value Creation. More than 70 million will enter the middle class.

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Driving operational performance by building manufacturing capability one step at a time

Driving Operational Performanceby building Manufacturing Capability one step at a time…..

Phillip Terlesk


Agenda

Agenda


Driving operational performance by building manufacturing capability one step at a time

Global population will exceed 7 billion

Best In Class Demands

Operating Excellence

Compliance

Dynamic Value Creation

More than 70 million will enter the middle class

Middle class

adding $8 US trillion

to consumer spend

$8


Growth matrix wine is a star

Growth Matrix – Wine is a STAR!


Growth matrix infant formula

Growth Matrix – Infant Formula


Infant formula nutritional powders

Infant Formula / Nutritional Powders


Value add will drive growth

Value Add will drive growth


Adding value will build export

Adding Value will build export $$


Driving operational performance by building manufacturing capability one step at a time

Dynamic Value Creation

Succeeding in a Changing Market Place

Capability To Bring Profitable Products to Market Faster

v

Product Innovation

Raw Materials

Time

MANUFACTURING

OPERATIONS

CAPABILITY

People

Process Innovation

Chemical / Energy

Market Data

Reduce Waste

9


Agenda1

Agenda

  • Opportunity

  • Questions

  • Present State For Many Manufactures

  • Collaborate to leverage the Opportunity

  • Customer Use Case


Questions we face on a daily basis

Did we stay within range on all Quality parameters during Fermentation

  • Did we meet the CIP targets during the cleaning cycle?

  • Temp

  • Time

Questions We Face On a Daily Basis ?

Are our labels and packaging material correct & serialised

Have I completed & signed off all the preflight checks before starting the new batch?

Have we set up our coders correctly


Business it automation investment may not be 100 aligned

Business, IT & Automation Investment may not be 100% Aligned

Laboratory Information Management Systems

Other Database s

Alarms/Events

Manufacturing

Operations

Management

Quality Systems

HMIs

Control Systems

Production

Historians

Computerized Maintenance Management Systems

Performance Management


Building capability one investment at a time

Building Capability one investment ata time

ERP

Manufacturing

Operations

Management

Standard

Operating &

Procedures

Change & Asset Management

Process Optimisation

Manufacturing Intelligence

Process, Packaging & Safety Automation


Deliver the correct information

Deliver the correct Information

Plant Mgmt.

  • For the Executive

  • Costs, schedules, production output

  • Financial indicators, sustainability

  • For the Production Manager

  • Schedule, track production activity

  • Way production is running, ways to improve

Production

  • For the Quality Manager

  • How product was made, ensure compliance

  • Ways to improve product and yield

Quality

  • For the Engineering / Maintenance Manager

  • Keeping plant running

  • Predicative maintenance, asset optimization

Engineering

Operator

  • For the Operators

  • Monitoring process to keep production running

  • Identifying relationships to optimize the process


Agenda2

Agenda

  • Opportunity

  • Questions

  • Present State For Many Manufactures

  • Collaborate to leverage the Opportunity

  • Customer Use Case


Collaborate to prioritise objectives align capability

Collaborate to PrioritiseObjectives & Align Capability

Line & Site Specific

Reports

&

KPI’s

Performance Focus

High level

Business

Objectives

People

Quality / Yield

Execution

Innovation

Compliance

Processes

Throughput

Business Drivers

Align Capability

Material

Energy

Equipment

xxx $$$ xxx


Agenda3

Agenda


Apc industry use case

APC & Industry Use - Case

Phillip Terlesk

Sales Executive


Rockwell improves manufacturing processes

Rockwell Improves Manufacturing Processes

Enhance Profitability through:

  • Improve Product Quality

    • Minimize variability

    • Reduce deviation from specifications

  • Increase Production

    • Unlock capacity Maximize throughput

  • Reduce Manufacturing Costs

    • Use less energy per unit of output

    • Maximize yield

MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value


Model based applications approach

Model-based Applications Approach

A Hybrid Model explains or emulates

the behavior of a process.

Soft Sensors


Pavilion8 model predictive control

Pavilion8 Model Predictive Control

Controller executes at 5 sec to 1 min intervals


Soft sensors virtual online analyzers or voa

Soft Sensors (Virtual Online Analyzers or VOA)

Neural Networks

  • Replace sparse, or infrequent, feedback from Lab or analyzer

ProcessData

Product Quality

output

VOA

Calcs

Process Parameter

LabData

… neural networks can fit

general non-linear relationships

artificial neuron with

weight parameters

Heat and Material Balances

input A

input B

Traditional Empirical Correlations


How apc enables operational objectives

How APC Enables Operational Objectives

Minimize operational variance

Reduce Variability 30 – 50%

CV

DV

Achieves Uplift - closer to spec or performance limit whilst managing the process within constraints and safety margins

BENEFIT $

Transition effectively

SPECIFICATION OR LIMIT

CV

KEY TARGET

BEFORE MODEL PREDICTIVE CONTROL

Follow operational plan

WITH MODEL PREDICTIVE CONTROL

AND OPTIMIZATION

CV

The Business Value is

Achieved by

“raising the bar”


Operator interaction with a standard regulatory control system

PLC/DCS

PID

PID

PID

Operator Interaction with a Standard Regulatory Control System

?!?!?

Step A,D,B,C

Process

Lab


Operator interaction with amodel predictive control system

PLC/DCS

PID

PID

PID

Operator interaction with aModelPredictive Control System

Production

Target

Soft

Sensor

Pavilion8

MPC

Process

Lab


Milk powder processing

Milk Powder Processing

  • Farm Cows

  • Tankers / Rail

  • Raw Milk Silo Storage

  • Separation into skim milk and cream

  • Standardization to specifications by combining skim milk, cream, and lactose or permeate

  • Falling Film Evaporation

  • Spray Drying

  • Powder Packing


Dairy solution

Dairy Solution

Production Landscape

Receiving Area & Raw Milk Silos

Future Automation Landscape

ERP

Milk Separation into Skim Milk & Cream

ERP

MOM

CPGSuite

Quality

Standardization to specifications by combining skim milk, cream, and lactose or permeate / Milk Treatment

Utilities

Pavilion Fat / Protein

Optimisation

Milk Treatment

Evaporation / Drying / Fluidbed

Pavilion Moisture Optimisation

Powder Drying

Rockwell FT Historian - Reporting and Tools

Packaging /Logistics/Mass Serialisation

CPG Suite Labeling / Serialisation

Packaging

Plant Pax - Visualisation

SCADA

Controls &

Safety

Plant Pax - Logix


Scope for both protein fat optimisation pavilion8 dryer evap mpc

Scope for both Protein & Fat Optimisation & Pavilion8 Dryer & Evap MPC

Butter Processing

Permeate / Lactose etc

Cream

Hot Air

Pavilion8 Protein & Fat Optimisation Analysis – this overview

Wholemilk

ProcesScan™ FT

Separation Pasteurization

Standardizing Streams

Standardized buffer Storage

Rockwell’s MPC Solution-Dryer & Evap Optimization

Rockwell - Protein & Fat Optimisation Solution

Product In

8-15% solids

Pavilion8 MPC Dryer & EvapOptimisation

Solids In

Hot Air

Product Out

45 -55% solids

Cold Air

Powder Out

HP Pumping

Drying


Dairy standardisation solution

Dairy Standardisation Solution

  • Rockwell’s Pavilion8 Model Predictive Control (MPC) platform provides a closed loop standardising solution with superior targeting of final powder Fat and Protein composition.

  • Minimising giveaway of protein and fat in the standardisation process optimises yield providing substantial financial benefit.


Dairy standardisation solution performance and visability

Dairy Standardisation Solution Performance and Visability


Visualisation performance metrics

Visualisation: Performance Metrics

Distribution curve comparison (mean & standard deviation) against baseline

Accepted moisture lab value against specification limit and controller target

Moisture benefits, control performance & how hard moisture is pushed

Standard deviation improvement against baseline

Downloadable & accepted moisture lab values report

Cp – how good is distribution within limits: Cpk – how centre is the distribution within limits

A key Differentiator

31


Dairy standardisation solution benefits

Dairy Standardisation Solution Benefits

  • Composition variability reduction of 50% or greater

  • Tight compositional control allows fat and protein targets to be driven to the specification minimums.

  • Superior final powder compositional targeting.

  • Performance visualisation facilitates proactive decisions


Questions

Questions?


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