Driving Operational Performance
by building Manufacturing
Capability one step at a time…..
Phillip Terlesk
Agenda
Opportunity
Questions
Customer Use
Case
Present State
For Many
Manufactures
Collaborate to
leverage the
Opportunity
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
22
Global population
will exceed 7 billion
BEST IN CLASS DEMANDS
Operating Excellence
More than 70 million
will enter the middle
class
Middle class
adding $8 US trillion
to consumer spend
Compliance
Dynamic Value Creation
$8
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
3
Growth Matrix – Wine is a STAR!
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
4
Growth Matrix – Infant Formula
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
5
Infant Formula / Nutritional Powders
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
6
Value Add will drive growth
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
7
Adding Value will build export $$
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
8
Dynamic Value Creation
Succeeding in a Changing Market Place
Capability To Bring Profitable Products to Market Faster
v
Product Innovation
Raw Materials
Time
People
Chemical / Energy
MANUFACTURING
OPERATIONS
CAPABILITY
Process Innovation
Market Data
Reduce Waste
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
99 9
Agenda
Opportunity
Questions
Customer
Use Case
Present State
For Many
Manufactures
Collaborate to
leverage the
Opportunity
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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10
Questions We Face On a Daily Basis ?
Did we stay within
range on all Quality
parameters during
Fermentation
Did we meet the
CIP targets during
the cleaning cycle?
• Temp
• Time
Have I
completed &
signed off all the
preflight checks
before starting
the new batch?
Are our labels and
packaging material
correct & serialised
Have we set up
our coders
correctly
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
11
Business, IT & Automation Investment
may not be 100% Aligned
Laboratory Information
Management Systems
Manufacturing
Operations
Management
Other Database s
Alarms/Events
Quality
Systems
HMIs
Control Systems
Production
Historians
Performance
Management
Computerized Maintenance
Management Systems
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
12
Building Capability one investment at
a time
ERP
Manufacturing
Operations
Management
Standard
Operating &
Procedures
Change & Asset Management
Manufacturing Intelligence
Process Optimisation
Process,
Packaging &
Safety
Automation
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
13
Deliver the correct Information
Plant Mgmt.
For the Executive


Production
Quality
Engineering
Operator
Costs, schedules, production output
Financial indicators, sustainability
For the Production Manager

Schedule, track production activity

Way production is running, ways to improve
For the Quality Manager

How product was made, ensure compliance

Ways to improve product and yield
For the Engineering / Maintenance
Manager

Keeping plant running

Predicative maintenance, asset optimization
For the Operators

Monitoring process to keep production running

Identifying relationships to optimize the process
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
14
Agenda
Opportunity
Questions
Customer
Use Case
Present State
For Many
Manufactures
Collaborate to
leverage the
Opportunity
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Collaborate to Prioritise Objectives & Align
Capability
Line & Site Specific
Reports
&
KPI’s
Performance Focus
High level
Business
Objectives
People
Quality / Yield
Processes
Throughput
Business Drivers
Align Capability
Execution
Innovation
Compliance
Material
Energy
Equipment
xxx $$$ xxx
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Agenda
Opportunity
Questions
Customer
Use Case
Present State
For Many
Manufactures
Collaborate to
leverage the
Opportunity
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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17
APC & Industry Use - Case
Phillip Terlesk
Sales Executive
Rockwell Improves Manufacturing Processes
Enhance Profitability through:
- Improve Product Quality
Minimize variability
Reduce deviation from
specifications
- Increase Production
Unlock capacity Maximize
throughput
- Reduce Manufacturing Costs
Use less energy per unit of output
Maximize yield
MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
19
Model-based Applications Approach
Analysis
A Hybrid Model explains or
emulates
the behavior of a process.
Soft Sensors
Optimization
Prediction
Control
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20
Pavilion8 Model Predictive Control
Controller executes at 5 sec to 1 min intervals
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Soft Sensors
(Virtual Online Analyzers or VOA)
Neural Networks
 Replace sparse, or infrequent,
feedback from Lab or analyzer
Process
Data
Lab
Data
VOA
Calcs
Product Quality
Process Parameter
artificial neuron
with
weight parameters
Heat and Material Balances
outpu
t
… neural networks can fit
general non-linear
relationships
H RXN  H Ferm  H Feed  H Recirc
Traditional Empirical Correlations
input
A
input B
EtOH  f H RXN 
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
22
How APC Enables Operational Objectives
Minimize operational variance
DV
Reduce Variability 30 – 50%
CV
Achieves Uplift - closer to spec or performance limit whilst
managing the process within constraints and safety margins
BENEFIT $
Transition effectively
CV
Follow operational plan
CV
KEY TARGET
SPECIFICATION OR LIMIT
BEFORE MODEL
PREDICTIVE
CONTROL
WITH MODEL PREDICTIVE CONTROL
AND OPTIMIZATION
The Business Value is
Achieved by
“raising the bar”
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
23
Operator Interaction with a Standard
Regulatory Control System
?!?!?
Step A,D,B,C
PID
Lab
PID
PID
PLC/DCS
Process
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Operator interaction with aModel
Predictive Control System
Production
Target
Pavilion8
Soft
Sensor
MPC
PID
Lab
PID
PID
PLC/DCS
Process
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Milk Powder Processing
•
Farm Cows
•
Tankers / Rail
•
Raw Milk Silo Storage
•
Separation into skim milk and cream
•
Standardization to specifications by combining
skim milk, cream, and lactose or permeate
•
Falling Film Evaporation
•
Spray Drying
•
Powder Packing
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Dairy Solution
Production Landscape
Future Automation Landscape
ERP
Milk Separation into Skim Milk & Cream
Evaporation / Drying / Fluidbed
Packaging /Logistics/Mass Serialisation
Utilities
Quality
Standardization to specifications by
combining skim milk, cream, and lactose
or permeate / Milk Treatment
Rockwell FT Historian - Reporting and Tools
Receiving Area & Raw Milk Silos
CPGSuite
ERP
MOM
Pavilion Fat / Protein
Optimisation
Milk Treatment
Pavilion Moisture
Optimisation
Powder Drying
CPG Suite Labeling /
Serialisation
Plant Pax - Visualisation
Plant Pax - Logix
Packaging
SCADA
Controls &
Safety
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Scope for both Protein & Fat Optimisation
& Pavilion8 Dryer & Evap MPC
Butter Processing
Permeate
/
Rockwell
- Protein
& Fat Optimisation Solution
Cream
Wholemilk
Separation Pasteurization
Lactose
etc
Standardizing Streams
Rockwell’s MPC Solution-Dryer & Evap
Optimization
Product In
8-15% solids
Standardized buffer Storage
ProcesScan™ FT
Hot Air
Product Out
45 -55% solids
Solids In
Hot Air
Cold Air
HP Pumping
Powder Out
Drying
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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Dairy Standardisation Solution
• Rockwell’s Pavilion8 Model Predictive Control (MPC)
platform provides a closed loop standardising solution with
superior targeting of final powder Fat and Protein
composition.
• Minimising giveaway of protein and fat in the standardisation
process optimises yield providing substantial financial
benefit.
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
29
Dairy Standardisation Solution
Performance and Visability
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Visualisation: Performance Metrics
Accepted moisture lab value against specification limit
and controller target
Moisture benefits, control performance & how hard
moisture is pushed
Distribution curve comparison (mean &
standard deviation) against baseline
Standard deviation improvement against
baseline
Downloadable & accepted moisture lab
values report
Cp – how good is distribution within
limits: Cpk – how centre is the
distribution within limits
A key Differentiator
31
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
31
Dairy Standardisation Solution Benefits
• Composition variability reduction of 50% or greater
• Tight compositional control allows fat and protein targets to be
driven to the specification minimums.
• Superior final powder compositional targeting.
• Performance visualisation facilitates proactive decisions
Copyright © 2013 Rockwell Automation, Inc. All rights reserved.
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