enabling & deploying operational performance

Enabling & Deploying Operational Performance

Rob Aleksa

Procter & Gamble

An Automation Federation Organization

Objective

• Motivate You to Adopt PackML– Technology Suppliers: Embed Directly in Control System– OEMs & End-Users: Apply!!


Discussion Agenda

1. Introduction

2. Challenges

3. Using standards

4. Implementation Strategy

5. Summary


Barry Boehm, Software Engineering EconomicsData from projects at IBM, GTE, and TRW

Typical or Traditional Project

Modular Project & Good Software Methodology

Software Development


How Standards Benefit P&G?

• We buy equipment– Globally– Commercial and customized/unique equipment– Sometimes we’re the OEM– Implication: Integration of many different types of engineering

designs & technology

• Standards– Reduce initial and life cycle costs– Enable P&G and OEMs to focus on innovation– Help in information gathering to drive effective machine

management, utilization, and continuous improvement

“When you do things right, people won't be sure you've done anything at all.”


Software Management Challenge

• Machine systems are increasing in complexity– Many axis of servo drives– Coordinated axis, registration, phasing– Vision system integration– Fault management– Information capture & MES integration– Machine to machine coordination– Global coordination (Engineering, training, maintenance)

• Strategies– Structured, modular object coding– Code encapsulation for reapplication– Consistent software methods across OEM machines– Apply standards

Traditional MechanicalMachine

Flexible and Unique Performing“Electronic” Machine


Information Management Challenges

• Information complexity– Horizontal integration (machine-machine, machine-process)– Vertical integration (production management & coordination)– “Make-pack-and-ship” replaces “make-to-stock”– Regulatory compliance

• Strategies– Apply standard interfaces– Common nomenclature and organization– Modular, structured standard code across machines

– Reduces validation costs

– Simplifies asset verification and management


Typical PLC Software Techniques?


Typical PLC Software Techniques?

NOT FUNCTIONALLY ORGANIZEDNO CONSISTENT TAG STRUCTURE


Templated Solutions


Templated Solutions

INDUSTRY TEMPLATES LEADS TO CONSISTENT & SUPPORTABLE STRATEGY

(Higher Quality Product Logical)


• Covers– Auto Mode State Model (S88

derived)

– Data Definitions (Pack Tags)

• Assists – Derive efficiency information

through Pack Tags

– Maintenance & Trouble Shooting through common approach in Machine Sequence

– Consistent data format makes integration go smoother, adoption of a OEM machine is easier.

PackML

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Maintenance Mode

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PackML - Common Operating Structure


Plant Controls Network

Case Packer

Palletizer

Stretchwrapper

Reporting SoftwareOPC Server

Accumulator

Line

`

Line Controller HMI

PackTags PackTags PackTags PackTagsPackTags PackTags

PackTags

Consistent nomenclature reduces interface complexity

PackTags is about Driving a Data Standard – a Common and Basic Machine Data Record.

PackTags – Common Nomenclature


Standard Software Methodology Benefits

• Users (operators, engineers, managers) learn only one system• Protects future flexibility to grow, the same methods can be re-used• Multiple machine types are interoperable• Integration time is reduced • Uptime is maximized (Common method increases familiarity,

improving ease of maintenance and troubleshooting)• Investment in learning and applying a controller is lessened with

each subsequent purchase• Common network tags among machines are configured identically


Latin American Application


• PackTags used to communicate and interlock.– Example : Cartoner gets jammed and goes to a Stopped State, its Mode Manager communicates to the Labeler

Mode Manager and make the Labeler transition to Holding and then to Held state, until jam condition is cleared.

Process Discrete (Packaging)

Filler

Wrapper

Labeler Cartoner

Storage B

Storage A

LA PackML (Mode Manager)


Methodology Feedback• Clear Functional Specs → Solid

Control System Design• Integrated with P&G systems• Integrated & Holistic Machine View

LA Learnings


P&G Implementation Strategy

• PackML into each Global Business Unit’s practices• Build capability to program, troubleshoot and operate state

based machines• Implementation plan in each Business Unit

– OEM communication method document and expectation when purchasing

– Leverage control vendor training programs and templates– Engineering aids– Leverage into information systems, specifically for OEE calculations

• Ensure continued industry compliance and alignment between End Users, OEMs, and Control Vendors


P&G Results to Date

• Standards– Phased rollout into GBU OEM Machine Specifications– Part of Corporate Global Machine Application Guide

• Implementations– Over 6 on-going machine developments implementing PackML– Over 4 OEM’s plan on using PackML – delivering over 100 machines

globally over the next 3 years– Upgrades planned on existing machines– Multiple installations to date – no negative comments

• Training– Multiple engineering contractors trained on PackML– Formal training earliert

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Implementation Testimonials


GBU Project #1

“In February, a new PLC software on Line 6…. an 8% gain in PR realized. This gain was accomplished using modular code for programming called PackML….”

GBU Project #2

“On the packaging job PackML helped a lot during the startup of the multiple machine modules…. the whole line came up in no time at all. Engineering went faster once the State programming was complete.”

GBU Project #3

“On new machines there is a huge advantage in only learning one programming methodology….”

GBU Project #4

Line 68 Cartoner delivered in April ’07….“Plant E&I loves it.”

Implementation Testimonials


Beauty Care GBU Electrical Specification Packaging and MakingAll machines other than making skids shall follow OMAC guidelines (version 3), including the OMAC state model for automatic operation shown below….

P&G OEM Requirements Are Here!


Our Next Steps

• Continue deployment to new engineers• Develop internal detailed software specification• Develop training video• Work with internal MES partners to standardize on

Machine-to-MES interface using PackTags


Final Thoughts

• Deploy the PackML standards, support future standards and free up resources to innovate

• Standards enable improved operational performance


Questions ?

enabling & deploying operational performance

Documents

effective machine management

efficiency information

pack tagsmaintenance

common approach

structured standard

life cycle costsenable

continuous improvementwhen

packmltechnology suppliers