Consumer Industry day

Transcription

1 Consumer Industry day What value can standardization bring to you? Name Andreas Pilarski Date 31 st January 2017 PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 1

2 Agenda Demands Standards PackML and RAPID Benefits PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 2

3 Demands Production growth Develop new and existing markets with your products New machines with new automation solution and products Production flexibility Launch new products and tailor made your products to market needs Need more qualified operators and spcialisted workflow Production maintenance Technology don t stand still and needs to be maintained Machines getting more complex and needs higher qualified support Don t think about the problem, think about the solution. German rhyme PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 3

4 Agenda Demands Standards PackML and RAPID Benefits PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 4

5 Standards Standards are the backbone of our society, ensuring the safety and quality of products and services, facilitating international trade and improving the environment in which we live in. From Packaging machinery is increasing in complexity. More machines are including many axes of servo drives, integrated robotics and vision systems, machine fault and performance analysis, and communications for integration with line and production management systems. However, there are no consistent standards for software development -- even between like machines from the same OEM. As a result, operator and technician training and support are becoming increasingly challenging; and horizontal and vertical integration remains difficult and time consuming. (John Blanchard, 2008, ARC Insight # MPH, page 1) PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 5

6 Standards Standards for products CE, TUV, UL, IEEE, CSA. Reduce or eliminate the risk of manufacturer liability Standards for production ISO, FDA, IEOW Guaranties reliability, repeatability and quality Standards for process ISA88, PackML, GAMP Allow review of processes and identify areas of improvement PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 6

7 Agenda Demands Standards PackML and RAPID Benefits PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 7

8 The challenge for YOU Enterprise Systems Including MES Programming PC Line Interface MES Machine-to-Machine Integration Filler Filler Capper Capper Labeler Labeler Casepacker PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 8

9 The challenge for YOU Different machine with different. Operation procedures and concepts Maintenance concepts Automation philosophy Software structure Control technique in the software No or complex solution for modularity PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 9

10 PackML Based on ISA-S88 Batch Control and split into models for Procedural Physical Create by Organization for Machine Automation and Control PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 10

11 PackML Procedural and Physical Model get combined into the Equipment Control Model PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 11

12 PackML Leading to modular design ERECTOR UNIT PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 12

13 What you get from PackML Common programming structure, consistent mode and state definitions that drive a common look and feel between equipment. States (Start-Stop-Run-Idle, 17 available states) Modes (Auto, Manuel, Jog, Clean Out, etc.) PackTags (Data Definitions) Foundation for horizontal & vertical machine integration. PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 13

14 PackML: Operational Consistency PackTags Which state What state should machine be in How long in state Alarms Alarm time stamp PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 14

15 PackML Physical Hierarchy Equipment Decomposition Example Form Fill Seal Bagger Weigh Station Bag Forming Feed Rollers Sealer/Cutte r Unit Form Fill Seal Bagger Equipment Module Weigh Station Bag Forming Feed Rollers Sealer/Cutter Control Module Weigh Scale Lift Servo Bag Gripper Left Servo Right Servo Heater Cutter Servo PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 15

16 ISA S88 Part 5: Make2Pack Adapted from the Batch Industry Equipment Decomposition Machine: Form Fill Sealer Equipment Module: Weigh Scale Equipment Module: Bag Forming Equipment Module: Sealer/Cutter Equipment Module: Feed Rollers Control Module: Infeed Gate Control Module: Scale Control Module: Dump Gate Control Module: Axis Left Control Module: Axis Right Control Module: Heater Control Module: Axis Sealer Control Module: Servo 1 Control Module: Servo 2 PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 16

17 Rockwell Implementation PackML V3 Equipment Control Model Equipment Control Model in Studio5000 PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 17

18 What you get from Rockwell. for PackML implementation Add-on-Instructions HMI Faceplate Easy to use and configurable Established standard in automation PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 18

19 What you get from Rockwell. Power Programming Structure with Command-Condition Interface Best practices in software design Modular and flexible software concept Simplification in machine operation Standardized structure for machine development and maintenance Possibility for standardized rollout of machine improvements PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 19

20 PackML some references OMAC represent end user, machine builder (OEMs) And many more. PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 20

21 PackML future ISA released 2015 TR with new features Rockwell launched Application Code Manager (ACM) which includes Machine Builder Library (MBL) to drive and optimize engineering ACM in conjunction with MBL enable engineering departments to work on common platforms with standardized proven functions Rockwell provide with the MBL a PackML based solution in a fully tested and documented version outside of PowerProgramming Application Code Manager and Machine Builder Library gives you for a common automation environment and productive solution PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 21

22 RAPID Line Integration RAPID is a configurable line control solution with built-in line performance management that provides a flexible approach to integrating discrete manufacturing lines in the consumer product industry, allowing for a single location to setup, control, and analyze the performance of an entire line. Standard data collection interface for line assets The RAPID Equipment Interface "normalizes" all data uniqueness across assets at the equipment level - providing a standard data access model, which keeps the supervisory level standardized, configurable, and repeatable Does not require code rewrite at the asset level Comprehensive test utility to ensure proper execution of OEM equipment prior to startup with test results reporting for verification during FAT Line Control and Performance Management with a common architecture Requires minimal code development to implement a system > configuration based Automatic event and reason code generation for Performance Monitoring > No database setup for events and states or OPC tag mapping required Automation level root-cause provides more accuracy also provides operator input for unplanned events Utilizes single point of access for all control operations, line configuration management, production / performance data collection, visualization, reporting, and analysis Provides actionable information in real time on the plant floor while also providing traditional daily/weekly/monthly historical reports for management / productivity improvement roles Full Ad-hoc reporting environment, simple drag and drop report customization and creation Zero-client for reports and dashboards utilizes HTML5 for support on any device PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved

23 RAPID Line Integration Solution: Defined Tested and Maintained as a System Cannot Build your Own Dedicated View and Performance Management server per plant Delivery Services and Support Delivered by Solutions and Services Business and Licensed Providers only SP/SI Partner selection RAPID System TechConnect Offering PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 23 2

24 Agenda Demands Standards PackML Benefits PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 24

25 Benefits With PackML implementation you have Common machine operation and operators interface Leads to easier machine operation and faster learning Operators more flexible and no learning curve Common structure for machine maintenance Easier to maintain and simplified fault finding Less need of Expert knowledge Common structure for machine application Simplify knowledge sharing and engineering Common structure for development and application improvement Simplify development and reduce risk of implementation PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 25

26 Questions? Rev 5058-CO900D Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.

27 Thank you for your time! Rev 5058-CO900D Copyright 2013 Rockwell Automation, Inc. All Rights Reserved.