Packaging Line Performance System John Coetzee SAB Business Systems Manager Manufacturing Paul Kotzé EOH MES Specialist

Abstract Packaging Line Performance System Faced with the challenge of commissioning a new packaging line in time for the annual summer run on soft drinks, SAB (ABI) turned to line performance for a solution. This solution came with its own implementation challenges, including: OEM coding standards, infrastructure installation and technology maturity. Add 1 part Performance Software to 1 part soft drink line…

Agenda Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary

Business Requirements ► Improve and accelerate line commissioning ▪ Machine performance ▪ Reduce manual capture ▪ Improved accuracy ▪ Reference point vs. OEM reporting ► Serve as a “proof of concept” ▪ OMAC/PackML ▪ OEM interaction ▪ Evaluation of toolset ▪ LMS benefits determination  Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary

Definitions ► OMAC—Organization for Machine Automation & Control ► The PackML standard by OMAC* ▪ Defines line types from standalone unit – fully integrated system ▪ Defines machine states – e.g. running, stopped, paused ▪ Defines a list of tag names, definitions and data sets ▪ Use of these for communication and use of information from machinery to other machinery; and higher-level systems ► ABI – Amalgamated Beverage Industries, the soft drink division of The South African Breweries Limited (ABI) *Source:  Business requirements Project scope OEM Landscape & architecture Implementation Benefits Summary

Project Scope Implement Wonderware MES Performance System V3.4 on the soft drinks line being commissioned at ABI Pretoria ▪ User requirements specification ▪ Filler thin-slice ▪ Develop - ArchestrA to Reporting ▪ Factory Acceptance Test ▪ Commission ▪ Train Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary

Project Scope Additional requirements ▪ Leverage SAP process order/DPR ▪ Adhere to International standards OMAC/PackML* ▪ Adhere to SAB standards HMI & Archestra Naming “DPR” ▪ Interface directly to OEM ▪ Downtime capture Filler Rest of line equipment Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary * abridged

Project background Context ► Existing SAB ABI – SAP PP & QM (“DPR”) ► Previous LMS projects ► OMAC / PackML development ► OEM interaction ► SAB Manufacturing systems Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary

Project background – “DPR”

Project background – LMS Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary

Project background - Context Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary

Project background - structure Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary Garth Basson Business Systems Executive Manufacturing & Supply Chain John Coetzee Business Systems Manager Manufacturing Sandeep Seeripat Business Systems Manager Supply Chain Lucia Beukman Systems Manager Control and Automation Sadie Oberholzer Systems Manager MES Colleen Muller Systems Manager SAP ‘WCM’ Deon Barnard EOH Project Manager Paul Kotze EOH MES Engineer Project team Kivern Singh Process Control Manager ABI - Pretoria

Project background Project details ► Start: August 2008 ► Planned End: September 2008* ► Combined engineering approach ▪ ABI Process Control Manager – Process and Procedures ▪ SAB Manufacturing Systems – Design Guidelines and Standards ▪ EOH Mining and Manufacturing - Engineering Business requirements  Project scope OEM Landscape & architecture Implementation Benefits Summary * PLC datatables and line commissioning delays –> still ongoing

OEM KHS ► Turnkey line delivery – incl: 3 rd party equipment (e.g. Labeller, inspectors) ► OMAC & PLC data structure ► Ibhayi brewery project – 1999/2000 ▪ Data collector ▪ Defined data structure – DB100 ► Challenges ▪ Controller code ▪ 3 rd party supply ► Customers need to drive the standards adoption by OEMs ▪ International open standards ▪ Partnering with OEMs ▪ Partnering with software suppliers Business requirements Project scope  OEM Landscape & architecture Implementation Benefits Summary

Landscape & Architecture Business requirements Project scope OEM  Landscape & architecture Implementation Benefits Summary SAP PP / QM SAP BW Creation of daily production process order Capture of material usages Capture of lost time Consolidated daily production report ArchestrA Machine states Fault codes Packaging Controllers Performance Software HMI – WW Panel Line mimics ↓ Production order ↑ Lost time** ↑ Production quantities** Contextualisation of machine states, fault codes Production volumes Process order delivery tracking ** future

Packaging Process Business requirements Project scope OEM  Landscape & architecture Implementation Benefits Summary Blow Moulder Labeller Filler Blender Caser Palletiser Case Washer Bottles are produced (blown) Bottles get labelled Syrup concentrate blended Returned crates get washed Filled bottles packed into cases Filled cases palletised Bottles filled

Information flow Business requirements Project scope OEM  Landscape & architecture Implementation Benefits Summary

Architecture Microsoft 2008 Hyper V

Design - Methodology ► “DPR”-biased standard ► Common components ► OMAC / PackML standards ► Centralised configuration ▪ Development ▪ Deployment Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Node Deployment Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Software Implemented ► Wonderware ▪ Performance 3.4 ▪ System Platform 3.0 ▪ InTouch 10 ▪ Information Server 3.0 ▪ Historian 9.0 ► Microsoft ▪ Hyper V 2008 – Virtualization Host Node (MES) Virtual Machine (Application Engine/Communication) ▪ SQL 2005/Reporting Services ▪ Windows 2003/Server Platform Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Software Implemented ► Software Toolbox ▪ Siemens S7 300/400 Suite Driver ► ProsCon OPC client ▪ Interface to Palletiser and Caser Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Network & Hardware ► Network ▪ 2 x VPN with 3x managed Switches Control Level 0 Network (2 switches) Supervisor/Business ( 1 switch) ► Hardware ▪ 1 very big server with lots of RAM and processing power……… ▪ 2 x Wonderware Touch Panels stainless steel Filler Blowmoulder Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Application Overview

Machine details

Job Progress

Process Order Handling

Live/Historical Trending

Quadrant Navigation

Reports – Manager

Reports – Reporting Services

Current Status ► Implemented ▪ Automatic logging of machine reasons ▪ Operator created SAP process orders ▪ Operator selected reason codes for filler downtime > 2 minutes ▪ Downtime & production reports ▪ Touch panel ► Outstanding ▪ Detailed line daily report ▪ Some counters and machine speeds Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Current Status ► Future? ▪ Performance Software-SAP interface via MII Upload downtime reasons Download process orders ▪ Formal solution evaluation ▪ LMS approach & business case Business requirements Project scope OEM Landscape & architecture  Implementation Benefits Summary

Benefits ► Downtime reporting ▪ OEM usage ▪ Business usage ► Estimate reject counts/crates on line ► Downtime accuracy ▪ PLC driven ► Openness – OMAC/PackML & S95 Compliance ► Reporting of all micro stops ► Analysis capability Business requirements Project scope OEM Landscape & architecture Implementation  Benefits Summary

► Turnkey supply ▪ SI ▪ 3 rd party equipment ► Engineering approach ► Standards ▪ International – OMAC / PackML ▪ PS requirements – DPR, Interpretation ► Project implementation – during line commissioning ► Ability to interpret in context ▪ Contribution of each machine vs. line ► OEM partnering ► Open standards Business requirements Project scope OEM Landscape & architecture Implementation Benefits  Summary

Questions