Smart Manufacturing in the Food & Beverage Industry
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1 Smart Manufacturing in the Food & Beverage Industry PUBLIC Copyright 2016 Rockwell Automation, Inc. All Rights Reserved. 1
2 Rockwell Automation at a Glance $5.9B FISCAL 2016 SALES 22,000 EMPLOYEES 80+ COUNTRIES WORLD S LARGEST COMPANY DEDICATED TO INDUSTRIAL AUTOMATION AND INFORMATION AUTOMATION SOLUTIONS for a broad range of industries SERVING CUSTOMERS FOR 113 YRS Innovation Domain expertise Culture of integrity & corporate responsibility ABOVE-MARKET GROWTH PRODUCTIVITY INTELLECTUAL CAPITAL VALUE CREATION PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 2
3 Challenges Food and Beverage Manufacturers $ Faster Time to Market Lower Total Cost of Ownership Improved Asset Utilization Enterprise Risk Management Achieve ever-increasing OEE goals Increase throughput Improve food safety Improve yield Address technical skills gaps Facilitate new product introductions Decrease changeover time Improve safety Reduce energy & water consumption Protect IP PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 3
4 Business Risks & Drivers $65B ~ 75% $20B $30M <14 % 21% Automation systems reaching end of life U.S. plants are more than 20 years old Cost of unscheduled downtime 76% of recalls cost up to US Plants completely integrated Suffered a loss of IP in the past year SOURCE: ARC SOURCE: Industry Week SOURCE: ARC SOURCE: GMA SOURCE: Industry Week SOURCE: Kapersky (2014) Realizing Smart Manufacturing has become a business imperative PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 4
5 50B ALERT! NUMBER OF DEVICES ON THE INTERNET BY 2020 SAFE & COLLABORATIVE ROBOTS AI & MACHINE LEARNING PREDICT FAILURES AND REDUCE DOWNTIME WEARABLES & MOBILE DEVICES TRANSFORM WORK FLOWS PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 5
6 Manufacturing and Industrial Enterprises are becoming CONNECTED Intelligent devices that are able to: ANALYZE PREDICT ADAPT SMARTER OPERATIONS PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 6
7 OUTCOMES-BASED DIGITAL TRANSFORMATION OF THE PLANT FLOOR PHASE 1 PHASE 2 PHASE 3 INTEROPERABLE LINE INTEGRATION LINE DIGITIZATION DIGITAL PLANT Improved OEE Informed Decisions Smart Machines Predictive Maintenance Mobility Visibility Collaboration Efficiency PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 7
8 THE CONNECTED ENTERPRISE Enhanced by Contemporary Technologies PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 8
9 SMART MANUFACTURING Leveraging embedded intelligence and new sources of information to connect and optimize the enterprise IMPROVED PRODUCTIVITY IMPROVED TIME TO MARKET REDUCTION IN INVENTORY MITIGATE RISK THE CONNECTED ENTERPRISE PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 9
10 Smarter Machines & Equipment Real-time Data Voltage, Kwh, Running Time, Temperature Information CONTEXTUALIZATION Energy/Product, OEE Knowledge ANALYTICS Predict bearing will fail in 10 hours Wisdom OPTIMIZE More efficient process workflows PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 10
11 Smarter Plants & Operations Yield will meet today s production needs 7100KWh of energy used today ALERT Maintenance Line #1 Time to reach temperature is longer than normal PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 11
12 Strategic Partnerships Full Suite of Industry-Focused Solutions Transactional information: orders, supply network, product design ERP FINANCIALS HR LOGISTICS QUALITY WAREHOUSE IT COMMON SECURE NETWORK INFRASTRUCTURE OT Real-time data: alarms, events, states, energy, diagnostics, INDUSTRIAL THINGS PLCS & SCANNERS MATERIAL & TRANSPORT MACHINES & TESTERS SHOP FLOOR PERSONNEL PRINTERS & LABEL SERVICES PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 12
13 Journey to a Connected Enterprise Business Impact EVALUATE CONNECT COLLECT PRESENT OPTIMIZE What are the most significant challenges in my organization? What KPI s are used to measure performance? What data is needed, from which systems, and define how it could help improve KPI s? Assess current infrastructure for readiness Modernize infrastructure Connect plant equipment & people Must be scalable and flexible Do it securely Data from assets and organize to improve business processes Leverage information from across the plant and enterprise Contextualize it against other data Make it actionable & to make smarter decisions Put it in terminology that s right for the user Correlation & qualitative analysis of the information for process improvement Maximize plant workflow in a coordinated way Make the plant integral to B2B partners PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 13
14 Simplify and Accelerate Converged Plantwide Ethernet (CPwE) Deployment ASSESS DESIGN IMPLEMENT MANAGE PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 14
15 IT/OT CONVERGRENCE Enables Collaboration Designed for scale, security and supportability NETWORK IMPLEMENTATION 21 SITES 4x Increase network availability 75% REDUCTION MEAN TIME TO REPAIR Robust modern SECURITY Integrated with IT Network Enhanced Diagnostic Capabilities CPwE based redundant star topology PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 15
16 Offsite Advanced Technologies Support OT Infrastructure as a Service (IaaS) A subscription for plant network, virtual server instance and 24x7x365 infrastructure monitoring ELIMINATED 100% OF CAPEX 24x7 Proactive Support led to 90% Reduction in Troubleshooting Time Virtually Eliminating Network & Server Issues with Redundant Expandable Architecture and a Fully Managed Support Contract PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 16
17 MONITOR & INTERACT WITH IIoT DEVICES, IMPROVE PLANT HEALTH DETECT your smart devices, automatically DIGITIZE the data, allowing work to be done ANALYZE the data perform calculations, transform the data ACT on information, get to the right people, on the right device Immediate value delivered as an Industrial Appliance. Self-contained and FactoryTalk Cloud aggregation options. PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 17
18 100+ DEVICES 23 Action Cards IN MINUTES PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 18
19 CENTRALIZED PROCESS DATA EASILY identify sources of downtime IMPROVED production accuracy by eliminating manual reporting ACCESS to production data used to generate trend reports and analyze specific events PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 19
20 REAL-TIME PRODUCTION DATA ELIMINATED 2,500 HOURS OF MANUAL COLLECTION IMPROVED OEE BY 25% PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 20
21 Brewing 25% Capacity Time of Each Brew Cycle was CUT IN HALF Cut Raw Material Costs by 5% Annually 20 VARIETIES One Million Gallons of Water Saved (predicted) Optimize Brews Real-time PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 21
22 ROCKWELL AUTOMATION SOLUTION CONTROLS AWARD-WINNING HEAT & ENERGY RECOVERY SYSTEM REDUCED Natural Gas Consumption by over 38% DECREASED Annual CO 2 Production by over 3,000 metric tons REDUCED Annual H 2 O Consumption by over 100 million gallons PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 22
23 The added visibility allowed us to see where inefficiencies were happening so we could adjust and refine our process ALARM & EVENTS MONITORING INCREASE UPTIME IMPROVE WORKER SAFETY CUT MAINTENANCE RESPONSE TIME PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 23
24 The ultimate lifecycle story doing it right, rather than a knee jerk reaction. 6 PLANTS WITHIN ENTERPRISE VIEW Allows redeployment of parts REDUCED INVENTORY UP TO 50% MIGRATION PLANNING PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 24
25 The Connected Enterprise for Food & Beverage INCREASE Speed-to-Market OPTIMIZE Quality IMPROVE Efficiency ENHANCE Flexibility MITIGATE Risk ASSESSMENT IMPLEMENTATION DATA COLLECTION & AGGREGATION ANALYTICS & REASONING OPTIMIZATION SECURE PATHWAY FROM RAW MATERIAL TO ACTIONABLE INTELLIGENCE PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 25
26 Attending the Automation Fair event equips you with innovative strategies to help you become more globally competitive and productive with The Connected Enterprise. GAIN in-depth industry knowledge and earn PHD credits by attending forums, hands-on labs, and tech sessions EXPERIENCE the latest technologies and solutions at exhibits from Rockwell Automation and our PartnerNetwork members NETWORK with industry experts and peers PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 26
27 Process Solutions User Group November 12-13, 2018 Philadelphia, PA Join your peers at this interactive 2-day, industry leading event to gain greater insight into the latest process automation technologies. ENLIGHTENED keynotes, technical sessions and hands-on labs that deliver information on the latest modern process automation technologies and techniques INSPIRED customer-delivered best practices to highlight innovative approaches, outstanding ROI, and important successes achieved through Rockwell Automation solutions NETWORK with other process professionals from a broad spectrum of industries PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 27
28 Thank you! PUBLIC Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 28
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