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PBWW342 Successful MES Rollout Strategy. Integrated Process Automation & Control Technologies. Agenda. IPACT has implemented a Wonderware MES 4.0 solution that lowers risk, effort, cost and shortens the time to value for clients: Here is how! Introduction Client Overview Project Overview

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pbww342 successful mes rollout strategy

PBWW342 Successful MES Rollout Strategy

Integrated Process Automation & Control Technologies

agenda
Agenda

IPACT has implemented a Wonderware MES 4.0 solution that lowers risk, effort, cost and shortens the time to value for clients: Here is how!

  • Introduction
  • Client Overview
  • Project Overview
  • Rollout Overview
  • Conclusions
slide4

Background and Overview

  • A fresh approach to process and project design
  • Incorporated in 1986
  • Located about 40 miles southeast of Chicago in Valparaiso, Indiana
  • A core group of engineers with an average of 15 years of process experience in a variety of industries
  • Engineered and installed systems world wide

www.ipact.com

slide5

Background and Overview

  • IPACT is proficient in process-related disciplines, ranging from mathematical process modeling and control system design to statistical quality control.
  • IPACT delivers Manufacturing Execution Systems (MES), Product Tracking, ERP integration, Factory Quality Control Systems, Supervisory Control Systems and Process Setup Models.
  • IPACT executes Manufacturing Assessments, Functional Analysis and Specifications, System Design, Development and Implementation
  • IPACT can provide staff support for control applications.

Business Systems,

Finance Systems

  • Plant floor control through integration to ERP systems

Supervisory Control

and

Manufacturing

Information

Plant Automation

Process Control

certifications and experience

Background and Overview

Certifications and Experience

Industries

Disciplines

Project Engineering

Level 1 Automation

Level 2 Automation

Mill Modeling

Statistical Process Control

Production Simulation and Modeling

Enterprise-wide Integration

Motion Control

Device Drivers

Drives

Packaging

Material Handling

Laboratory Information Systems

Manufacturing Execution and Operation Systems

Manufacturing Assessment and Consulting

Instruction and Training

Productivity, Efficiency, Overall Equipment Effectiveness

Automotive

Food

Metals

Pharmaceuticals

Aerospace

Paper

slide7

Background and Overview

Wonderware’s First North AmericaEndorsed System Integrator

To achieve

MES 4.0 Certification!

slide9

Client Overview

  • Plants
    • Make (3)
    • Package (5)
  • Initial Plant Lines
    • Slice (7)
    • Bar (5)
    • Shred (8)
    • Misc (2)
  • Privately Held Company
  • Produce Several Premium Brands
    • Award-winning cheeses
  • Contract Packager for many channels
  • Over 60% of all packaged sliced cheese in North America goes through their facilities
slide10

Client Overview

  • Client wanted more involvement than typical IPACT customer
    • Wanted to be involved in the development process
    • Interest in RAD
    • Plan to take on system support in-house
  • What they are:
    • Experienced, committed engineering and I.T. professionals
    • Closely linked with operations
    • Supported at highest levels of management
  • What they do nothave:
    • Deep pool of resources
    • Heavy ArchestrA development experience
slide11

Goals

  • Improve yield
  • Provide visibility of operations and performance
  • More accurate and detailed tracking (by order) of:
    • Overall line and equipment efficiency
    • Product traceability
    • Product quality and reduce variability
      • Labor
      • Trim
      • Giveaway and Vendor loss
      • Shrink (scrap)
      • Packaging Materials Tracking (deferred to a later phase)
  • Integrate the new MES to the existing SAP
  • Simplify production reporting
  • Track and Trace
  • Performance Measurement – Yield and OEE
  • SAP updates
  • Specifically------->
slide13

Scope

  • Project Scope
  • Initial effort focused on a Packaging Plant
  • Included all line types
    • Slice, Bar, Shred
    • ReBox, ReWork
  • Wonderware MES 4.0/Operations and Performance
  • SAP integration
  • Control Systems integration
  • Case and Pallet labeling
  • Coexistence with legacy SPC system
slide14

Process

  • Initial design and development
    • Generic design that would accommodate future line types
    • Mock-ups, Weekly Calls, On-site visits
    • FAT, SAT, Pilots, Commissioning
    • Remote support
    • Full simulation environments at customer and IPACT sites
  • Pilot first line
  • Refine design based on experience
  • Rollout additional lines of same type
  • Simultaneously address refinement of next line type
  • Repeat!
slide15

Resources

  • Project Resourcing
  • Customer
    • Project Manager
    • Systems Engineers (3)
    • Operations
      • Supervisors (3)
      • Line (4 – 5 each)
  • IPACT
    • Project Manager
    • Technical Lead
    • Engineers
      • (2) Full-time
      • (6) Rotating
converting process
Converting Process

600# Cheese

Loaves

Slices

Packages

Cases

Rework

Pallet

T

T

T

Cheese is pushed through Harp to make loaves

rollout strategy
Rollout Strategy

Shred Line 4

Shred Line 5

Shred Line 6

Shred Line 7

Shred Line 8

Shred Line 2

Shred Line 3

Shred Line Pilot

Bar Line 4

Bar Line 2

Bar Line 3

Bar Line 5

Re-Box Line

Re-Work Line

Slice Line 6

Slice Line 4

Slice Line 7

Slice Line 3

Slice Line 2

Pilot Bar Line

Pilot Slice Line

Slice Line 5

Pilot Slice Line

rollout strategy1
Rollout Strategy

22 Lines

15 Lines

17 Lines

10 Lines

18 Lines

Plant 1

Plant 2

Plant 3

Plant 4

Plant 5

12 months

9 months

9 months

Constraints: Client Resources, Hardware Modification / Installation, Training

slide22

Pilot Strategy

  • Full on-site IPACT support
    • 5 people for first, 2 for second / 5 people from client organization
    • Shred lines are significantly different and will require 2 – 3 Resources similarly approximately 3 people from client organization
    • Appling learning from implementation to implementation
    • IPACT controlled lines for initial starts
    • Monitor transactions, signals, operator actions, etc
    • Minor impact on production schedules
    • GLC coordination critical
    • Operational understanding and direction
    • Operator education and adoption
    • Site Prep, Logistics, Cut to Production
slide23

Jan

Feb

March

April

May

June

July

Aug

Sept

Oct

Nov

Dec

2011

  • Site 1 Schedule
  • Site 1 Schedule
      • Initial Pilot completed December 2010
      • Currently 15 lines operational, 5 different line types
      • Executing multiple lines per month
      • Several line start-ups have been executed remotely
      • Entire plant – 18 lines, 3 types from inception to completion in 18 months
  • Initial pilot to final rollout - < 12 months

Pilot Soak Period

Rollout Phase Start

Slice Rollout

Bar Rollout

Shreds Pilot

Shreds Rollout

Target

keys to success
Keys to Success
  • Having the right tools / technology
    • ArchestrA
    • Galaxy Object Manager
    • Transaction Simulator
  • Methodology
    • Standardization / Abstraction / Documentation
    • Consistent, Repeatable Process
    • Change management
  • People
    • Customer team engaged
    • Design, Development, Testing, Implementation, Support
the right tools
The Right Tools
  • ArchestrA -
    • Object based, Open Architecture
  • Galaxy Object Manager – GOM
      • System Platform and MES 4.0
      • Replication
      • Design Changes

What else is there to say?

galaxy object manager
Galaxy Object Manager
  • Lowers Cost of Implementation Services
    • How Dramatic?
      • “Normal IDE” benefit is 25% on lines / plants – 3,4….
      • IPACT Model can be as high as 80%
  • Lowers Risk
    • Fewer data entry errors
    • Ability to better handle last minute changes
    • Lower commissioning effort
galaxy object manager1
Galaxy Object Manager
  • Functionality
    • Import / Export of entire Galaxy Object Model including:
      • User defined and third party object
      • All Templates and Instances
      • All User Defined Attributes
      • All I/O Listing
      • All Scripts
        • Scripts can be edited and maintained externally with full search and replace
slide28

The Right Tools

    • Simulation and ‘Virtual Production’
  • Transactional
  • Test end-to-end, including ancillary systems
  • Confirms understanding of production environment
  • Testing and Training
    • Internal
    • Given to Customer
slide29

Methodology

  • Standardization
      • Control Level
      • System Platform Model
      • MES 4.0 configuration (UCO, OCO)
  • Abstraction from Equipment
      • MES PLC
  • System Platform Modeling for Re-use
      • Use of templates, inheritance
      • Up-front design time
      • Build for extension
  • Documentation
      • Configuration Guide
slide30

Jan

Feb

March

April

May

June

July

Aug

Sept

Oct

Nov

Dec

2011

Methodology

  • Consistent Repeatable / Process
    • Initial design and development
      • Generic design that would accommodate future line types
      • Mock-ups, Weekly Calls, On-site visits
      • FAT, SAT, Pilots, Commissioning
      • Remote support
      • Full simulation and test environments both Great Lakes Cheese and IPACT
    • Pilot first line
    • Refine design based on experience
    • Rollout additional lines of same type
    • Simultaneously address next line type
    • Repeat!
    • Each iteration, client took on more responsibility

Start

Actual

Target

Bar Rollout

Shreds Pilot

Shreds Rollout

Updated 08/16/2011

methodology
Methodology

Change Management

  • Management & classification of bugs & enhancement requests
  • Management and testing of enhancements
  • Coordination of development system, sandbox system and live system
  • Implemented in VMware with nearly a dozen different images
people
People
  • Very strong, well organized client team
    • Although not very big, deep – very deep in process knowledge
    • Representing all aspects of organization
    • Executive Sponsor – support, but removes road blocks to success
    • Amazing Project Manager – single point of contact
  • IPACT Team
    • Great Technical Skills
    • Good Support from Wonderware
    • Strong Executive Support
    • Excellent Project Management
struggles challenges
Struggles / Challenges
  • BarcodingSolution needed some configuration memory tweaks
  • Lack of access to SPC application for original pilot
  • Equipment Availability for installation and testing
  • Client’s loss of MES Expert
  • Client’s expectations (ERP “like”) of implementation
    • Co-development
    • On-site development
    • Rollout
  • Changing scope
  • New Line types
  • Modification of infeed
  • Equipment OEE versus Line OEE
  • Simplification of HMIs
conclusions1
Conclusions
  • New Paradigm for MES
    • With the right set of tools, methodology and people, MES implementation can be lower risk, lower cost – shorter time to receive value from the application resulting in higher Net Present Value
    • MES implementation costs don’t need to be a multiple of software licensing but now can be a fraction of software licensing
  • Select a Wonderware Endorsed System Integrator with a track record, tools, process and team that help you achieve success
slide36

Continuing Success

  • The Best measure of customer satisfaction is interest in working with you on future projects:
    • Development of an Office of Excellence to provide support and change management
    • Conveyor Controls Interface
    • PLC support and Development
    • New Printer Interfaces
    • Planning Stages for Subsequent Plants
    • Beginning engagements in “make” plants