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09/06 Title: Batching & Filling – An introduction to the Market & Proposed Strategy Manufacturing Areas: Making & Packing Date: July 2007 Presented by.

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Presentation on theme: "09/06 Title: Batching & Filling – An introduction to the Market & Proposed Strategy Manufacturing Areas: Making & Packing Date: July 2007 Presented by."— Presentation transcript:

1 09/06 Title: Batching & Filling – An introduction to the Market & Proposed Strategy Manufacturing Areas: Making & Packing Date: July 2007 Presented by : Rodger Jeffery & Venus Simmons

2 07/07 1 Scope of Discussion WHY? Motivation & Objectives WHAT? BCS Market & Solutions WHO?End Users – Environment, Business Drivers, Needs HOW?Proposed B&F-BA Portfolio Model SO WHAT?Benefits for End Users & Mettler Toledo

3 07/07 2 The Supply Chain MAKE PACK

4 07/07 3 Motivation & Objectives Top 10 Motivations for this Workgroup (not ranked) - Need a comprehensive portfolio of batch & filling solutions (MTNA) - Competitors (e.g. 920i) solutions eroding customer and distributor base (MTNA) - No current replacement for legacy product (e.g. 9215) (MTNA) - Need a PC based global batch solution (MTE) - Opportunities for growth in small to mid-sized batch and packaging market (MTNL) - Need to develop communication drivers for new terminals for manual batch (BASY) - Need to be able to capitalize on Q.i technology investment across terminals (MTWI) - Need to be able to differentiate MTs solutions portfolio to drive SI & OEM growth (CS&S) - Need to develop common terminology glossary for batch & filling (BASY, MTWI & MOs) - Need new sources of revenue growth (BUSI) 5 Objectives for this Workgroup - Develop B&F (Tools & Solutions) Functional Matrix - Develop B&F Positioning Matrix - Develop path forward for communication drivers for new terminals for manual batch - Develop B&F Glossary - Discuss ways to improve channel Skills/Resource challenges

5 07/07 4 Scope of Discussion WHY? Motivation & Objectives WHAT? BCS Market & Solutions WHO?End Users – Environment, Business Drivers, Needs HOW?Proposed B&F-BA Portfolio Model SO WHAT?Benefits for End Users & Mettler Toledo

6 07/07 5 Batch Control Systems Market – layers by % of units Source: ARC Advisory Group

7 07/07 6 Batch Control Systems Market – by market segment adoption Chemical Pharmaceutical Pulp & Paper Food & Beverage 47.2% 28.4% 8.3% 6.3% Source: ARC Advisory Group 2005 Worldwide Market 3,2 M USD Opportunities for Growth

8 07/07 7 Batch Control Systems Market – by hardware platforms 2005 Worldwide Market 3,2 M USD DCS-based = 53.8% +1% PLC-based = 43.3% -1% PC-based = 3.0% +9% Source: ARC Advisory Group Potential for Partnerships

9 07/07 8 Scope of Discussion WHY? Motivation & Objectives WHAT? BCS Market & Solutions WHO?End Users – Environment, Business Drivers, Needs HOW?Proposed B&F-BA Portfolio Model SO WHAT?Benefits for End Users & Mettler Toledo

10 07/07 9 Fewer plants Complex mix of products per plant Demand for higher quality product & service More difficult to maintain brand loyalty Reduced time to market Global competition Margin & regulatory pressures Growing lack of technical resources Projects align to business strategies & prioritized based on ROA/EVM End Users – Environment, Business Drivers, Requirements

11 07/07 10 Orders PC Resource Planning PC Raw Material Logistics PC Manufact uring PC Product Logistics PC Shipping & Billing PC Delivery PC Produce FAT & Start Up Construct Engineer R & D Innovate Optimize & Maintain Make Pack Manufact uring PC PLC, DCS, Other End Users – Environment, Business Drivers, Requirements Sources: WBF,OMAC,ARC Advisory

12 07/07 11 Manufact uring PC Produce FAT & Start Up Construct Engineer R & D Innovate Optomize Make Pack ERP Manufact uring MES PC PLC, DCS, Other A growing percentage of CEOs view the traditional Manufacturing Supply Chain as a… TACTICAL LIABILITY Complex to Install & Operate Time consuming to implement Not scalable enough, not agile enough Not robust enough Lacks Standardization Generates Process Data (secs, min,hr) Expensive to Own & Operate Business leaders are now investing in ways to return Manufacturing back to a… STATEGIC ASSET Simple to Install and Operate Quick to Implement Scalable (Size, Price & Performance) Robust Use Industry Standards Also generate Business Intelligence Lowest possible Total Cost of Ownership ISA S95 Standard ISA S88 StandardOMAC Standard Business leaders are reinvesting in ways to return Manufacturing back to a… STATEGIC ASSET Simple to Install and Operate Quick to Implement Scalable (Size, Price & Performance) Robust Use Industry Standards Also generate Business Intelligence Lowest possible Total Cost of Ownership Sources – WBF, OMAC & ARC End Users – Environment, Business Drivers, Requirements

13 07/07 12 Orders PC Resource Planning PC Raw Material Logistics PC Manufact uring PC Product Logistics PC Shipping & Billing PC Delivery PC Produce FAT & Start Up Construct Engineer R & D Innovate Optimize Make BATCH Pack FILL Manufact uring PC Maintain STATEGIC BUSINESS ASSET Simple to Install and Operate Quick to Implement Scaleable (Size, Price & Performance) Robust Use Industry Standards Also generate Business Intelligence Lowest possible Total Cost of Ownership OEM SI OWNER manufacturer or CONTRACT manufacturer End Users – Environment, Business Drivers, Requirements Optimize the Manufacturing Supply Chain

14 07/07 13 Critically Important End Users – Environment, Business Drivers, Requirements Prioritized Review of ALL User Requirements Source: ARC Advisory Group

15 07/07 14 Prioritized Review of ALL User Requirements End Users – Environment, Business Drivers, Requirements Source: ARC Advisory Group

16 07/07 15 Manufacturers require more robust dock to dock batch control system to meet their business needs. They want to be able to invest in commercial off the shelf batch control systems Source: ARC Advisory Group Business Drivers…OPTIMIZE the Enterprise Supply Chain

17 07/07 16 Scope of Discussion WHY? Motivation & Objectives WHAT? BCS Market & Solutions WHO?End Users – Environment, Business Drivers, Needs HOW?Proposed B&F-BA Portfolio Model SO WHAT?Benefits for End Users & Mettler Toledo

18 07/07 17 B&F-BA Model..based on ISA 95 & ISA 88 (ANSI & IEC)International Standards S95 S88

19 07/07 18 B&F-BA Model …based on ISA S88/IEC International Batch Standards Source: S88 part 1

20 07/07 19 Standard Control Strategies (i.e. S88/IEC61512 & OMAC) Standard Data Flows (i.e. SP95) Standard Presentation Standard Documentation (i.e. S88 e-records & recipe models) Resources Analysis Scope Start-up Test Configure Design Reusable Engineering Proprietary API ApproachStandard API Approach Custom One Off Implementation Standards Facilitate Performance B&F-BA Model …Standards & Guidelines

21 07/07 20 Modular Programming saves time & money over Conventional Programming Conventional Programming Modular Programming Program Development4-5 weeks1.5 weeks Program Testing3-4 weeks0.6 weeks Machine Testing3-4 weeks B&F-BA Model …Standards & Guidelines Source: WBF Make2Pack Workgroup

22 07/07 21 Principles of Design 1. Product will follow all current and evolving ANSI and IEC standards on Batch Manufacturing 2. All solutions will use a TABLE BASED RECIPE STRUCTURE 3. All solutions will follow the S88 model for RECIPE TYPES (General, Site, Master, Control) 4. A recipe should be able to SIMULTANEOUSLY START & RUN MULTIPLE PROCESS ACTIONS (phases/equipment modules). However, they are not necessarily managed once started 5. All solutions will support a LIMITED SET OF PHASE CLASSES 6. All solutions will support UNIT CONTROL MODES 7. All solutions should support CONFIGURATION CHANGE LOG IN THE TERMINAL & RECIPE CHANGE LOG IN THE PC 8. The SP88 11 state phase model will apply the states to the appropriate level of control.

23 07/07 22 Batching Portfolio ( ) ENTRY ENTRY+ MEDIUM HIGH HIGH+ formulation ENTRY ENTRY+ MEDIUM HIGH HIGH+ MANUAL manual filling, check-weighing AUTOMATIC filling, dosing batching Single Component Multi Component formulation manual filling, check-weighing filling, dosing batching IND 690 batch IND4... check /R remote batching PLC w/o HMI IND 690 form IND4... check IND 560 fill IND 690 fill IND 690 fill / R IND ??? form/ batch / R IND 560 fill / R IND ??? batch+/ R remote batching with HMI at the PLC FormXP IND690 IND ??? form/R xxx Master data on PC plus remote work terminal Stand-alone terminal IND ??? Remote batching w/o HMI FoW ID30

24 07/07 23 Functional Matrix (6.7.07) Batch Functionality based on location of batch control

25 07/07 24 Functional Matrix (6.7.07) 1. Terminal based Material Transfer tools 2. Terminal based Batch Executive 3. Controller based Batch Executive 4. PC based Batch Executive Four location types: 1234

26 07/07 25 Functional Matrix (6.7.07) Terminal based Material Transfer tools: Terminal is used as a tool for control systems access to weight data Only provides material transfer functionality (target) Relies on some type of communication interface Simplest level of functionality

27 07/07 26 Functional Matrix (6.7.07) Terminal based Batch Executive: Terminal is responsible for execution of recipe(s) Traditionally thought of as stand alone batch product Replacements for LynxBatch, 9215 Limited by amount of I/O & simple manufacturing information

28 07/07 27 Functional Matrix (6.7.07) Controller based Batch Executive: Controller is responsible for execution of recipe(s) Terminal may be used for execution of material transfer phase Strengths lie in I/O control (logical to physical connection) Weakness in production scheduling, recipe management

29 07/07 28 Functional Matrix (6.7.07) PC based Batch Executive: PC is responsible for control execution of recipe(s) Usually relies on controller or terminal for execution of phases (process action) Weakness – I/O control Strengths in manufacturing information, recipe management, production scheduling (access to other PC applications), suitable for Manual & Automatic batch.

30 07/07 29 Functional Matrix (6.7.07) Batch Executive functions: Manufacturing information: scheduling, recipe management, tracking/tracing, production analysis Manufacturing operations: recipe execution, arbitration, execution at unit and/or phase level Manufacturing process control: phase control, interlocks, exception handling Process Instrumentation: material feed control, process measurement, special operations (user interface, custom)

31 07/07 30 Scope of Discussion WHY? Motivation & Objectives WHAT? BCS Market & Solutions WHO?End Users – Environment, Business Drivers, Needs HOW?Proposed B&F-BA Portfolio Model SO WHAT?Benefits for End Users & Mettler Toledo

32 07/ Primary Benefits for End Users Not Important Critically Important Customer Investment Drivers/Benefits Source: ARC Advisory Group

33 07/ Benefits for Mettler Toledo Delivers a comprehensive portfolio of batch & filling tools and solutions to the channel Defends existing customer and distributor base from attack by competitors Allows the channel to go after small to mid-sized batch and packaging opportunities Globally harmonizes MTs manual/automatic batch & filling solutions for the first time Capitalizes on existing Q.i technology investment (exclusivity last for ~12 more years) Differentiates MTs solutions portfolio to drive SI & OEM growth Delivers a common terminology glossary for batch & filling applications Provides opportunities for MOs to increase existing, or access new revenue growth May eventually deliver a PC based small to mid size global batch solution

34 07/07 33

35 07/07 34 DRAFT ONLY TOOLS & SOLUTIONS …completing the batch and filling range GMP (Standards Based e.g. S88) Batch / Fill Integrated Solution Traditional Batch / Fill Manual Stand Alone Solutions OEM / SI Integration Tools MT Channel Solutions IND560 IND780Fill Q.i Batch Compact + Q.i Batch + $1,500 $3,800 $10,900 > Q.i pro + (12chn & Network ) Q.i lite + (12chn) Q.I compact + (2chn) IND780 IND690 IND560 Panther C710/750 T600 $750 $500 $6,211 > $3,988 > $3,200 > $2,300 > $2,100 > $1100 > $795 > $27,500 > T600C710/750Q.bATCHcompactIND780IND560 Q.bATCH Full Q.i material transfer capability + Limited Q.i material transfer capability ~ IND690 Sys Fill $? Traditional (Non Standards Based) Batch / Fill Integrated Solution Traditional (Standards / Non Standards Based) Batch / Fill Automatic or Semi-Auto Stand Alone Solutions IND690 Q.iMPACT

36 07/07 35 DRAFT ONLY TOOLS & SOLUTIONS …completing the batch and filling range Traditional (Non Standards Based) Batch / Fill Integrated Solution Traditional Batch / Fill Manual Stand Alone Solutions OEM / SI Integration Tools MT Channel Solutions IND560 ~ IND780 ~ XXX Q.i Batch Compact + Q.i Batch + $? $2,000 $1,500 $? $4,300 $3,800 $10,900 > XXX IND780 XXX IND560 IND331 IND131 XXX $750 $500 $6,211 > $3,988 > $3,200 > $2,100 > $1 600 > $1100 > $695 > $495 > $27,500 > T600C710/750Q.bATCHcompactIND780IND560 Q.bATCH Full Q.i material transfer capability + Limited Q.i material transfer capability ~ GMP (Standards Based e.g. S88) Batch / Fill Integrated Solution Traditional (Standards / Non Standards Based) Batch / Fill Automatic or Semi-Auto Stand Alone Solutions

37 07/07 36 DRAFT ONLY TOOLS & SOLUTIONS …completing the batch and filling range Traditional (Non Standards Based) Batch / Fill Integrated Solution Traditional (Standards / Non Standards Based) Batch / Fill Automatic or Semi-Auto Stand Alone Solutions Traditional Batch / Fill Manual Stand Alone Solutions OEM / SI Integration Tools MT Channel Solutions IND560 ~ IND780 ~ Formweigh? Recipe Fill Formweigh? Recipe Fill Q.i Batch Compact + Q.i Batch + $? $2,000 $1,500 $? $4,300 $3,800 $10,900 > IND780 + (Q.i pro 12Network ) IND780 + (Q.i lite 12) IND780 + (Q.i compact 2) IND780 ~ IND560 + (Q.i compact 1) IND560 ~ IND331 IND131 C710/750 Repl ~ T600 Repl ~ $750 $500 $6,211 > $3,988 > $3,200 > $2,100 > $1 600 > $1100 > $695 > $495 > $27,500 > T600C710/750Q.bATCHcompactIND780IND560 Q.bATCH Full Q.i material transfer capability + Limited Q.i material transfer capability ~ GMP (Standards Based e.g. S88) Batch / Fill Integrated Solution


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