1. Benefits of Using the OMAC Packaging Standards Dave Bauman OMAC

2. Dell Desktop Computer Canon Printer Fuji Digital Camera HP Scanner/ Printer/FAX Industry Standards provide lots of choices - Cost - Performance

3. Operator Interface Programming PC Realtime Information System Casepacker Filler Capper Labeler Install standard OEM machines & easily configure them into an integrated packaging system

4. Business Objectives Lower Engineering Costs –Easier integration of packaging machines Lower Capital Costs –Buying standard packaging machines Faster Project Schedules –Buying standard machines –Easier integration

5. Agenda Options for Line Integration Prior to OMAC Packaging Standards OMAC Packaging Group (OPW) –Background on OPW –OPW Subgroups & Accomplishments Line Integration with OPW Standards Benefits How to Learn More About OPW

6. Option1: Convert OEM’s to User Preferred Supplier Machine Purchase Cost 100% Time 1990 2000 Control Platform Change Mechanical System Control System Traditional Mechanical Machine Flexible and Unique Performing “Electronic” Machine OEM Conversions to Preferred Supplier are: -Expensive -Cause schedule delays

7. Option 2: Standard OEM Equipment & Integrate Together Operator Interface Programming PC Realtime Information System Casepacker Filler Capper Labeler Custom Code Custom Code Custom Code Custom Code Custom Code Custom Code This option adds: - Significant engineering integration cost - Schedule delay

8. Formation of OMAC Packaging Workgroup Exploratory Meeting – PackExpo 1999 –Users participating included P&G, Hershey, General Mills, Nabisco OPW Formed at ARC Forum Feb, 2000 Mission: Provide a forum where users, machine builders and technology suppliers work together to achieve the benefits of advanced packaging automation Adopted the

9. Pack Teams PackConnect –Standardized Networks PackML –Common Machine Language PackSoft –Standarized Programming PackAdvantage –Making the Business Value PackLearn –Packaging Automation Education

10. PackConnect - Standardized Networks Multi-vendor motion bus w/ packaging profile (egs. SERCOS, Profidrive) Multi-vendor controller to controller motion bus

11. PackML Machine State Model PackML V3.0

12. PackML Mode Manager PackML V3.0 Multi-Mode Capability

13. PackTags – Control Tags Tag NameTag DescriptorData Type PML_Cur_ModeCurrent ModeByte PML_Cur_StateCurrent StateByte PML_Cur_Mach_SpdCurrent Machine SpeedReal PML_Mat_ReadyMaterial ReadyBinary PML_Mat_LowMaterials LowBinary PML_Trans_TriggerTransition TriggerStructure PML_ResetPackage ResetBoolean PML_Cntrl_CmdControl CommandInteger

14. PackTags – Information Tags Tag NameTag DescriptorData Type PML_Mode_TimeTime in Current ModeTime PML_Cum_Time_ModesCumulative Time in All ModesTime PML_State_TimeState TimeTime PML_Cum_Time StatesCumulative Time in All StatesTime PML_Seq_NumberSequence NumberInteger PML_Reason_CodeReason CodeInteger PML_Reason_IndexReason IndexInteger PML_Reason_TextReason TextString PML_Reason_Code_SuppSupplemental Reason CodeBinary PML_Cur_Spd_SelCurrent Speed SelectedInteger PML_Mach_Design_SpdMachine Design SpeedReal PML_Prod_ProcessedNumber Products ProcessedInteger PML_Defect_ProdNumber Defective ProductsInteger PML_Rework_ProdNumber Re-workable productsInteger PML_Mach_CycleMachine CycleInteger PML_Prod_RatioProduct RatioInteger

15. PackTag Item Specification Example Current State: Tag Name: PML_Cur_State Data Type: Byte Tag Descriptor: Current State Comments: The response is one of a restricted set of integers that define the current state. These states are one of the following: 0Undefined 1Off 2Stopped 3Starting 4Ready 5Standby 6Producing 7Stopping 8Aborting 9Aborted 10Holding 11Held

16. PackSoft and PackAL PackAL is an application library of functions Defines high level functions Number of technology providers are building PackAL into their products including: –Siemens –Beckhoff –Bosch Rexroth

17. PackAL Functions Machine FunctionMachine Communication Wind / Unwind Axis (constant surface velocity, csv mode) Wind / Unwind Axis (constant torque, ct mode) Dancer Control Registration Registration_Correction Indexing Batch Counter PLS (Digital CAM Switch) Override JogAxis Flying Sync Gear_In with dynamic Gear Factor Motion Command Positioning with oriented stop PackML Machine State Model FB PS_Send, PS_Receive PS_CommRequest PS_Indicate PS_CommRespond PS_CommConfirm PS_CommTerminate PS_Publish PS_Subscribe

18. PackAL Example Function Block use Tag Names of OMAC PWG –Mandatory IO variables and optional IO variables –Reference variables allow for various technology implementations –Use of specific OMAC PWG tag names –FB can be called in any language (LD, FBD, SFC, ST, IL of IEC61131, C, etc.) PS_Wind_csv AXIS_REFAxis AXIS_REF BOOLExecuteInVelocityBOOL REALVelocityErrorBOOL REALSpoolRadiusErrorIDWORD SRadius_REFSRadius MC_DirectionDirection REALMin_S_Radius REALMax_S_Radius REALAcceleration REALDeceleration REALJerk

19. Packaging Line Integration with OPW Standards Operator Interface Programming PC Realtime Information System Pack ML Pack ML Casepacker Filler Capper Labeler Pack ML Pack ML Pack ML Pack ML This approach - Significantly reduces line integration - Shortens project schedule

20. OMAC Packaging Workgroup Automation Survey (April 2006) Over 60% of pkg. lines not networked Over 2/3 of pkg. lines have no reliability data collection 7% of pkg lines are integrated to ERP Systems 20% of users specify the OPW Guidelines –Major reason for not using OPW Guidelines is not familiar with them Most users only use ladder logic programming Summary of survey on OPW website (www.omac.org/packaging)www.omac.org/packaging

21. Why Join the OMAC Packaging Workgroup Line Integration –PackConnect can help Reliability –PackML can make this much easier ERP Integration –PackML can help here Better programming implementation –PackSoft can help

22. Business Benefits Lower Engineering Costs –Easier integration of packaging machines Lower Capital Costs –Buying standard packaging machines Faster Project Schedules –Buying standard machines –Easier integration One user company expects $15 million savings

23. Information on OMAC Packaging Workgroup Stop at Automation Federation Booth here at ISA OMAC Packaging Workgroup CD here or at booth PackExpo –Oct 29 th – Nov 2 nd Chicago’s McCormick Place –(7) Demos in the OPW Booth Participation from (17) different vendors Demonstrating OPW Guidelines –PackExpo demo brochure here or at booth OMAC Packaging Workgroup Website www.omac.org/packaging Contact : Dave Bauman - OMAC Technical Director dbauman@omac.org

24. Thank You