Applying S95 to a MES Implementation
Danie Tredoux (CCSABCO)
Deon Barnard (EOHMM)
Agenda
► CCSABCO / CCF Business
► Project Cheetah
► Project Cheetah & MES
► The road to the MES implementation
▪ Consult
▪ Design
▪ Implement
► Project Implementation
► Results
► Road forward
Microsoft Tech Support Centre
Who and What is CCS & the
CCF Business
► Coca-Cola Sabco (CCS) is a licensed bottler of Coca-
Cola products in 12 African & Asian countries, with the
Group Office in Port Elizabeth
▪ RSA, Namibia, Mozambique, Tanzania, Kenya, Uganda, Ethiopia,
Sri Lanka, Nepal, Cambodia, Vietnam, Laos
► Coca-Cola Fortune (CCF) is part of the CCS business &
operates in South Africa
▪ Expected 2009 sales of 7.5 million hectoliters or 66 million cases
▪ 14 production lines in 6 plants and 3 sales regions, with 344 SKU’s
▪ 23 % of total Coca-Cola sales volumes across 75% of
geographical area of RSA
▪ 2,950 permanent employees
Project Cheetah Business
Requirements
► The existing (old) bottling facility in Bloemfontein did not
allow further expansion in the fast moving PET pack & 15
hectares land was available adjacent to the existing depot
in Church Street, Bloemfontein
► Planning started June 2007, first commercial production
by 26 November 2008
► A number of good design practices have been introduced
in the areas of Efficiency, Energy Management & the
Environment. The design objectives include:
▪ Site designed to accommodate 6 production lines (future)
▪ First line with limited flexibility (2 sizes and 3 packs each)
• 2L @ 22,400 bph,
• 0.5L @ 25,200 bph,
• 90% mechanical efficiency
Project Cheetah Business
Requirements
► Design Practices (continued):
▪ Trialing a ceramic roof coating for better thermal protection
▪ High efficiency/yield, low cost, low labour complement
▪ Automation of process side & high level of equipment automation
▪ Process heat recovery
• Blow moulder heat recovery to environment heating in closure & preform
stores, when required
▪ Low energy consumption (near ambient)
• High-speed syrup making & filling at temperatures up to 20°C
• Cold CIP (with Electro-Chemically Activated water)
• Energy efficient Factory Lighting - 30% lower electricity usage than traditional
hi-bay factory lights & better colour of lighting
▪ Separation of waste water streams & effluent pre-treatment
▪ Maximized water yield from Water Treatment processes (>90%)
• Nano-Filtration streams recovered with Reverse Osmosis
• Filter backwashes recovered & re-utilised
Project Cheetah Business
Requirements
► Design Practices (continued):
▪ Site ergonomics
Project Cheetah
Project Cheetah
Project Cheetah & MES
► Why include MES in this project?
► Cheetah plant was to have a low staff complement
► Potential to leverage future benefits of SAP/MES
integration
► Improve management information for:
▪ Accurate and real-time management information to allow quicker &
▪
▪
▪
▪
more accurate decision making in near-paperless environment
from shop floor to top floor
Understand performance drivers better in order to maintain line at
>90% Mechanical efficiency
Provide full traceability of production
Outsourced, in-line bottle supplier, Boxmore Plastics, measured as
part of the total line
An added benefit was improved problem identification at the PLC
level
Project Scope
Implement a MES System for the Production
facility (process plant and packing line) at
the Bloemfontein Plant
Using industry best practices
Using the latest product offerings from the
Wonderware Suite
And to ensure a totally integrated application
with a unified look and feel
Project Approach
► Consult
▪ Expose client to MES
▪ Expose client to international standards
▪ Infrastructure requirements
► Design
▪ Develop URS trough a series of workshops with key roll players
▪ Integration into rest of plant
► Implement
▪ FDS (Functional Design Specification)
▪ No big bang approach (phases)
▪ Design, validate, configure then Implement
► Handover
▪ Match Reports with Excel manual data capture
▪ Match Delivered Functionality with URS
Consul
t
Hand
Over
Project
Approach
Imple
ment
Design
Consult and Design Phase
► Deliverable: URS (User Requirement
Specification)
▪ Step 1: Define the project objective, business
▪
▪
▪
▪
context and drivers
Step 2: List the departments and systems to be
employed and deployed
Step 3: List and describe the equipment and
processes
Step 4: What are the enterprise functions to be
implemented
Step 5: Analysis of activities for the Production or
Operations department
Design & Implementation
Phase
► Develop FDS (Functional Design
Document)
► Build Use cases in Supervisor and test with
Operator
► Select appropriate Use Case and develop
solution
► Commission on site to:
▪ Integrate plant information
▪ Validate production data against manual log
▪
sheet
Enable reporting with Client
Use of S95
► How was S95 used to derive a project solution:
▪ Use the S95 Functional Control Model to map the MES
▪
▪
▪
▪
requirement for the project
Within each of the Functional Models use the
Appropriate Activity model to map the requirements
Use the Process Segments to define the
characteristics
Use the S95 equipment model to derive the plant
process flow
Used a S95 naming convention which was
implemented in ArchestrA Model
S95 Functional and Activity
Mapping
Production
Tracking
Production
Control
(3.0)
Procurement
(5.0)
Quality
Assurnace
(6.0)
Inventory
Tracking
Production
Inventory
Control (7.0)
Quality test
data
Collection
S95 Equipment & Process
Model
Raw Material Storage
Liquid Processing
Intermediate Product Storage
Filling and Packing
Process Segment
Process Segment Description:
Process Segment Equipment:
Process Segment Personnel:
Process Segment Material:
Process Segment Parameters:
Process Segment Dependency:
Warehousing
S95 Standard Definitions
S95 Expanded Equipment Hierarchy
Liquid Processing: Process Segment
Table 2
Process
Segment
Process
Description
Equipment
Personnel
Material
Parameters
Process
Segment
Dependency
S95 Process Flow Definition
Sugar Dissolving
Sugar is fed into the dissolving unit
and is dissolved using treated water,
the solution is fed into an
intermediate buffer tank
Sugar Dissolver, Intermediate buffer
tank, UV Unit
1 Operator (syrup maker)
Treated Water, Sugar, Simple Syrup
Processing rate, volume / time /
order, Brix
Fed from Bulk Sugar Storage and
feeds to intermediate simple syrup
tank Storage location 0002 –
required quantity moved to storage
location 0003
S95 Integration
Plant Area
Data Type
Details
Liquid Processing Plant
Completed batch data from
MES
Batch Number, Batch
quantity, bar code
information of ingredients,
CIP executed
Liquid Processing Plant
Process order from SAP
List of scheduled Process
Orders with order details
Packaging Plant
Completed Process order
from MES
Process Order Number,
quantity produced, quantity
rejected
Packaging Plant
Process Order from SAP
List of scheduled Process
Orders, with order details
Reporting Requirements
Report Type
Report focus
Details
Visibility
Packaging line
performance
Process Plant
performance
Per Process order, per
OEE (availability,
time period, per machine performance, quality)
Reason code Pareto
charts (quantity and
duration)
Packing Line status
Machine Modes, Machine
states
As defined in PackML
Real Time
Material Tracking
Per Process order, WIP
per location
Inventory levels
Near Real Time
Order Tracking
Per Process Order
Status and Progress
History with drill down
and Near Real time
Traceability
By Operator, by Process,
by Process Order, CIP
Who made what when
on what process and
equipment
History with drill down
Genealogy
By Material Item, by
Process order
What was used to
produce
History with drill down
CIP Usage
What was cleaned when,
how
Routes, tanks washed by
whom and to what
process
History with drill down
History with drill down
and Real time
OMAC&PackML
► Design called for :
▪ OEM’s was to deliver a OMAC compliant packaging line
▪ Build a OMAC / PackML enabled application
► What was deliver from OEM:
▪ Machine alarm list and running bit
► What was done:
▪ Converted basic running
Machine Modes
Machine States
Idle
Off
Producing
Automatic
Stopping
Holding
Stopped
Held
Starting
Aborting
Ready
Aborted
SemiAutomatic
Manual
E-Stop
/ stopped statuses and
alarm lists into PackML
visualized objects
Standby
What Caused the change in state and
for how long was it in that state
- User Input
- Blockage
- Starvation
- Electrical Failure
- Mechanical Failure
Scope of Project
► Wonderware Performance V3.5
► Wonderware Operations V3.5
► System Platform 3.0
► InSQL V9.0
► Active Factory V9.2
► InTouch V10.0
► Integration of OEM InTouch and ArchestrA objects for
Universal Workstation
Topology
Universal Workstation UW
► Design called for a single interface (low staff complement)
► OEM delivered Touch Panels with InTouch
► OEM Developed base standards for visualization using
▪ A2 Objects &
▪ Faceplates
▪ Navigation
► MES leveraged these standards for same “look and feel”
► Here the power of ArchestrA was leverage to create a
single look and feel
Plant Overview Screen
ArchestrA Integration
Wonderware Operations
► InTouch used to visualise the operational activities
► ArchestrA Objects deployed to interface with plant
instrumentation
► ArchestrA Objects deployed to interact with Production
database
► Factelligence component used to configure
► Items
► Processes
► Operations
► BOM
Operations Phase 1
Operations Phase 2
Consumption by Entity Report
Genealogy by WO Report
Genealogy by WO Report
Production Yield Report
Wonderware Performance
► InTouch was used to visualise the line information
► ArchestrA UCO object used to match PLC alarm bits to
Reason codes
► Use Factelligence component used for:
▪ Processes
▪ Operations
▪ Shift Model
Performance Overview
Performance Drill Down
Performance Drill Down
Production by Shift Report
Should be crates
Performance Report: Downtime
Results to date
Consult
Hand Over
Project Approach
Design
Phase 1
Phase 2
Implement
Phase 3
Phase 4
What next?
► MES is not a hit and run but an ongoing involvement from
business owners
► This was a first small step for CCS/CCF and results and
benefits are still being analysed and understood
► Future step may see InBatch added and OEE & solutions
rolled back into other existing plants
► Etc….
Questions