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Applying S95 to a MES Implementation

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  1. Applying S95 to a MES Implementation Danie Tredoux (CCSABCO) Deon Barnard (EOHMM)

  2. Agenda • CCSABCO / CCF Business • Project Cheetah • Project Cheetah & MES • The road to the MES implementation • Consult • Design • Implement • Project Implementation • Results • Road forward

  3. Microsoft Tech Support Centre At least WW is more advanced

  4. Who and What is CCS & the CCF Business • Coca-Cola Sabco (CCS) is a licensed bottler of Coca-Cola products in 12 African & Asian countries, with the Group Office in Port Elizabeth • RSA, Namibia, Mozambique, Tanzania, Kenya, Uganda, Ethiopia, Sri Lanka, Nepal, Cambodia, Vietnam, Laos • Coca-Cola Fortune (CCF) is part of the CCS business & operates in South Africa • Expected 2009 sales of 7.5 million hectoliters or 66 million cases • 14 production lines in 6 plants and 3 sales regions, with 344 SKU’s • 23 % of total Coca-Cola sales volumes across 75% of geographical area of RSA • 2,950 permanent employees

  5. Project Cheetah Business Requirements • The existing (old) bottling facility in Bloemfontein did not allow further expansion in the fast moving PET pack & 15 hectares land was available adjacent to the existing depot in Church Street, Bloemfontein • Planning started June 2007, first commercial production by 26 November 2008 • A number of good design practices have been introduced in the areas of Efficiency, Energy Management & the Environment. The design objectives include: • Site designed to accommodate 6 production lines (future) • First line with limited flexibility (2 sizes and 3 packs each) • 2L @ 22,400 bph, • 0.5L @ 25,200 bph, • 90% mechanical efficiency

  6. Project Cheetah Business Requirements Design Practices (continued): Trialing a ceramic roof coating for better thermal protection High efficiency/yield, low cost, low labour complement Automation of process side & high level of equipment automation Process heat recovery Blow moulder heat recovery to environment heating in closure & preform stores, when required Low energy consumption (near ambient) High-speed syrup making & filling at temperatures up to 20°C Cold CIP (with Electro-Chemically Activated water) Energy efficient Factory Lighting - 30% lower electricity usage than traditional hi-bay factory lights & better colour of lighting Separation of waste water streams & effluent pre-treatment Maximized water yield from Water Treatment processes (>90%) Nano-Filtration streams recovered with Reverse Osmosis Filter backwashes recovered & re-utilised

  7. Project Cheetah Business Requirements Design Practices (continued): Site ergonomics

  8. Project Cheetah

  9. Project Cheetah

  10. Project Cheetah & MES • Why include MES in this project? • Cheetah plant was to have a low staff complement • Potential to leverage future benefits of SAP/MES integration • Improve management information for: • Accurate and real-time management information to allow quicker & more accurate decision making in near-paperless environment from shop floor to top floor • Understand performance drivers better in order to maintain line at >90% Mechanical efficiency • Provide full traceability of production • Outsourced, in-line bottle supplier, Boxmore Plastics, measured as part of the total line • An added benefit was improved problem identification at the PLC level

  11. Project Scope Implement a MES System for the Production facility (process plant and packing line) at the Bloemfontein Plant Using industry best practices Using the latest product offerings from the Wonderware Suite And to ensure a totally integrated application with a unified look and feel

  12. Project Approach • Consult • Expose client to MES • Expose client to international standards • Infrastructure requirements • Design • Develop URS trough a series of workshops with key roll players • Integration into rest of plant • Implement • FDS (Functional Design Specification) • No big bang approach (phases) • Design, validate, configure then Implement • Handover • Match Reports with Excel manual data capture • Match Delivered Functionality with URS

  13. Consult and Design Phase • Deliverable: URS (User Requirement Specification) • Step 1: Define the project objective, business context and drivers • Step 2: List the departments and systems to be employed and deployed • Step 3: List and describe the equipment and processes • Step 4: What are the enterprise functions to be implemented • Step 5: Analysis of activities for the Production or Operations department

  14. Design & Implementation Phase • Develop FDS (Functional Design Document) • Build Use cases in Supervisor and test with Operator • Select appropriate Use Case and develop solution • Commission on site to: • Integrate plant information • Validate production data against manual log sheet • Enable reporting with Client

  15. Use of S95 • How was S95 used to derive a project solution: • Use the S95 Functional Control Model to map the MES requirement for the project • Within each of the Functional Models use the Appropriate Activity model to map the requirements • Use the Process Segments to define the characteristics • Use the S95 equipment model to derive the plant process flow • Used a S95 naming convention which was implemented in ArchestrA Model

  16. S95 Functional and Activity Mapping

  17. S95 Equipment & Process Model S95 Standard Definitions S95 Expanded Equipment Hierarchy S95 Process Flow Definition

  18. S95 Integration

  19. Reporting Requirements

  20. OMAC&PackML • Design called for : • OEM’s was to deliver a OMAC compliant packaging line • Build a OMAC / PackML enabled application • What was deliver from OEM: • Machine alarm list and running bit • What was done: • Converted basic running / stopped statuses and alarm lists into PackML visualized objects

  21. Scope of Project • Wonderware Performance V3.5 • Wonderware Operations V3.5 • System Platform 3.0 • InSQL V9.0 • Active Factory V9.2 • InTouch V10.0 • Integration of OEM InTouch and ArchestrA objects for Universal Workstation

  22. Topology

  23. Universal Workstation UW • Design called for a single interface (low staff complement) • OEM delivered Touch Panels with InTouch • OEM Developed base standards for visualization using • A2 Objects & • Faceplates • Navigation • MES leveraged these standards for same “look and feel” • Here the power of ArchestrA was leverage to create a single look and feel

  24. Plant Overview Screen

  25. ArchestrA Integration

  26. Wonderware Operations • InTouch used to visualise the operational activities • ArchestrA Objects deployed to interface with plant instrumentation • ArchestrA Objects deployed to interact with Production database • Factelligence component used to configure • Items • Processes • Operations • BOM

  27. Operations Phase 1

  28. Operations Phase 2

  29. Consumption by Entity Report

  30. Genealogy by WO Report

  31. Genealogy by WO Report

  32. Production Yield Report

  33. Wonderware Performance • InTouch was used to visualise the line information • ArchestrA UCO object used to match PLC alarm bits to Reason codes • Use Factelligence component used for: • Processes • Operations • Shift Model

  34. Performance Overview

  35. Performance Drill Down

  36. Performance Drill Down

  37. Production by Shift Report Should be crates

  38. Performance Report: Downtime

  39. Results to date Phase 1 Phase 2 Phase 3 Phase 4

  40. What next? • MES is not a hit and run but an ongoing involvement from business owners • This was a first small step for CCS/CCF and results and benefits are still being analysed and understood • Future step may see InBatch added and OEE & solutions rolled back into other existing plants • Etc….

  41. Questions