Industry 4.0 / ISATR88 PackML Implementation @ Arla Foods

1. Industry 4.0 / PackML @ Arla Foods
Lenze PackML Webinar / 20th June 2016
Arne Svendsen, Arla-IT MES & Automation
References:
Dennis Brandl, Visionaire/Open Standards
Bryan Griffen, Nestlé & OMAC Chair

2. Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. Industry 4.0 overview
3. Mapping to Arla Foods’ Business needs
4. I4.0/Plug & Play - real world example of PackML
5. How I4.0 will become success - for all of us
6. Conclusions
7. Q&A

3. Who am I ?
1957: Wendelbo
1980: M.Sc. EE(P) + Computer Science
1980-1991: PLC firmware and SCADA software development
1990-2002: CIM-consultant (Computer Integrated Manufacturing)
2002 - now: Head of Corporate MES & Automation team
(Part of Arla Global-IT)
Contact: Arne.Svendsen@ArlaFoods.com
Linkedin: https://dk.linkedin.com/in/arnesvendsen
03 July 20163

4. Arla Foods Introduction
13,500+
FARMER
OWNERS
FROM
7 COUNTRIES
70 Production
Sites
(EU, US,CHN)
MILK INTAKE
12,5+
BILLION KILO
19,000+
COLLEAGUES
10 BILLION EURO
REVENUE
PRODUCTS
SOLD IN
100+ COUNTRIES
Our vision:
Creating the future of dairy to bring health and inspiration to the world, naturally

5. Arla Foods Introduction
1000’s of Variants - Arla Brands & Private Label

6. Business Environment
Cooperative business since 1880
Cooperative dairy business - 1880 -> 2016

7. Business Environment
A global supply chain today
• 70+ Production Sites, 50+ Distribution Centers
• Sales worldwide

8. Business Environment
Strategic Focus
• Networked supply chain, fast moving
consumer goods/cool chain
• A history of Mergers & Acquisitions
• Organic growth is the strategy now
• Partnering in Manufacturing & Distribution
• Core business: Product Innovation, Supply Chain & Distribution
• Non-core: Partnering with specialised service-providers

9. Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. Industry 4.0 overview
3. Mapping to Arla Foods’ Business needs
4. I4.0/Plug & Play - real world example of PackML
5. How I4.0 will become success - for all of us
6. Conclusions
7. Q&A

10. Industry 4.0 - high level
One (of many) views
The 1st (Steam)
The 2nd (Ford T)
The 3rd (www, PC)
The 4th Industrial Revolution
Internet of Things (IoT)
”DIGITAL”
New Business Models
INDUSTRIAL Internet of Things (IIoT)
Digital / Smart Manufacturing
INDUSTRY 4.0
The good old www: Internet
(of People)

11. Industry 4.0 - high level
Technologies – and Connectedness
• (New) Technologies
• Connecting Anything
• => New Business Models
• Sharing economy
• “Everything” as a service
Connectedness & New Business Models

12. BILLIONS AND BILLIONS OF DEVICES
• Already there are sites under
construction with 500,000 devices
May 25, 2016 12
Reference: Dennis Brandl

13. INTEGRATION NIGHTMARES
• Today the average worker in an modern plant
interacts with over 30 smart devices per day
• in the near future this will be over 300 to 3,000
smart devices per worker
• Integration is already the hardest part of any
new system
• Over 70% of the effort on a typical project
• Just for dozens of systems and hundreds of devices
May 25, 2016 13
Reference: Dennis Brandl

14. UNINTENDED JOB SECURITY
• Be Smart
• Or integration will become a generational project
• A 100,000 device refinery takes 5-10 years to get up &
running, a 1,000,000 device will take 50-100 years
• Train your kids/grandkids in automation & control
May 25, 2016 14
Reference: Dennis Brandl

15. BUT STANDARDS WILL SAVE US, RIGHT?
XKCD.COM
May 25, 2016 15
Reference: Dennis Brandl

16. Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. I4.0 overview
3. Mapping to Arla Foods’ Business needs
4. I4.0/Plug & Play - real world example of PackML
5. How I4.0 will become success - for all of us
6. Conclusions
7. Q&A

17. Mapping to Arla Business needs
TODAY: Connected, yet still hard work.
Distribution
Center
Distribution
Center
Dairy
Dairy
Dairy
SAP - Business IT system

18. Mapping to Arla Business needs
TODAY: Connected, yet still hard work.
Technologies:
- Automation
- RFID, scanners
- Printers
- Wireless LAN
- AGVs
- Robots
- Inline measure
- Analytical dev.
Dairy
Functions:
- Prod.Orders
- BOM/Recipes
- Collect ”all” data
- Traceability
- Quality
- Reporting
- Analytics
DATA
MES
- AGVs
- Robots
- Inline measure
- Analytical dev.
Technologies & Devices
- Automation
- RFID, scanners
- Printers
- Wireless LAN
SAP - Business IT system

19. Mapping to Arla Business needs
In I4.0 terms, the solution is:
Functions:
- Core Realtime (remain on site)
- Core Non-Realtime -> Cloud
- Non-Core function -> ext. Service
FACTORY
Technologies/Sensors/Devices
Arla Internal
BIG Data
Arla Strategic
Innovation Center
Energy
Optim.
Equipment
Optim.
IT-systems
Support
NON-core
Service
Offerings
ERP
<-Faster Connect

20. Mapping to Arla Business needs
What to consider, implementing I4.0
PARTIAL CONCLUSION:
• Decision: Which NON-core functions - to be bought as a service
• Cloud solutions: Costs move from CAPEX to OPEX
• INFORMATION strategy
• IT Security

21. Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. I4.0 overview
3. Mapping to Arla Foods’ Business needs
4. I4.0/Plug & Play - real world example of PackML
5. How I4.0 will become success - for all of us
6. Conclusions
7. Q&A

22. PackML - A real-world example (1:8)
Build faster Packaging lines
ONE Business Solution
ERP
ONE Production Solution
MES/Manufacturing Operations Mgmt.
ONE Automation Solution
Process
Automation
Production
Automation
Packaging
Automation
• Adopted ISA95 in 2002 for SAP/MES integrations
• Corporate MES-solution, implemented on 50+ sites
• ISA88 Library in place for Process Automation
• Since 2013, focused on faster integration of
production and packaging lines.




23. PackML - A real-world example (2:8)
Cheese Production Line – example
ON THIS ONE CHEESE PACKAGING LINE:
9 units, from 7 suppliers, from 4 countries

24. PackML - A real-world example (3:8)
The PackML ”USB” connector
• Arla has no large technology center. We build packaging lines, mainly by
integrating standard units from our industry
• Challenge is to integrate units into a working line
• Faster, faster, faster
LINE Control
PackML
LINE Control
PackML PackML

25. PackML - A real-world example (4:8)
Cheese Production Line – example
PackML as interface to Units
PackMLPackML

26. PackML - A real-world example (5:8)
Making it easy for the operators !

27. Packaging Line Implementation – IMPROVED ..
03 July 201628
Timeline
Analysis
Phase
Implementation phase
Timeline
Contract
Signed
Ana
lysis
Implementation
phase
Site
Installation
FAT
test(s)
Site
Installation
SAT test (s)
Improved Production Time
Time to Market

28. PackML - A real-world example (6:8)
Business Value
Success items:
 Specification (forward to contract) much faster
 Works across all automation (PLC) platforms
 Test suitcase for remote FAT testing
 Data => Business information from day-1
 Harmonised Operator interfaces!
OEE
SEE also ARC article:

29. PackML - A real-world example (7:8)
Business Value
Machine Project Time Cost Prod.Time
Specification -> Sign Contract ++ +
Integration tests (FAT & SAT) ++
Training (Operators & Maint.personnel) ++
Commisioning (”burn in”) +
Operations (5-8 years ?) Time Cost Prod.Time
Maintenance (time to repair) +
OEE / Optimisation +
Training (Operators & Maint.personnel) + +
Line changes/New units /New products + ++ ++

30. PackML - A real-world example (8:8)
Gathering momentum for PackML
• P&G and Arla Foods offer their company
standards documents on OMAC website
for unrestricted use (based on OMAC
membership)
• Company and platform-independent
OMAC Best Practice Guide is in progress.
For end-users and Machine builders to
get started. Nestlé is actively supporting
this as well.

31. Agenda
1. Arla Foods - Global Dairy Foods Manufacturer
2. I4.0 overview
3. Mapping to Arla Foods’ Business needs
4. I4.0/Plug & Play - real world example of PackML
5. How I4.0 will become success - for all of us
6. Conclusions
7. Q&A

32. For Industry 4.0 to get success
Connectedness need Protocols
Send Mail
Write English
Prequisite:
Agree language
Receive Mail
Read English
”The Internet takes care of the rest ...”

33. For Industry 4.0 to get success
What the Internet does for you...
An IP adress
Physical
Infrastructure
WAN/LAN/
Wireless
IP Protocol
Mail protocol
Language
An IP adress
Physical
Infrastructure
WAN/LAN/
Wireless
IP Protocol
Mail protocol
LanguageThe
Internet

34. For Industry 4.0 to get success
PackML – showing the way !
PackML is a good example of a high level ”DOMAIN” Protocol of I4.0
• An agreed common language, and lower levels taken care of
Packaging
Line Control
An IP adress
Machine unit
An IP adress
Physical Infrastructure
WAN/LAN/Wireless
OMAC PackML
Physical Infrastructure
WAN/LAN/Wireless
OPC UA OPC UA
OMAC PackML
IIoT
OPEN Standard Protocols
PackML in this case

35. Copyright © 2016 OMAC. All rights reserved.
OMAC - OPC Foundation Collaboration
Bryan Griffen, OMAC Chair
The Need for Standards in Packaging
Automation
Wednesday, May 25, 2016

36. 37Copyright © 2016 OMAC. All rights reserved.
Complexity and standards: case study #1
Lack of standard brings complexity
to an inherently simple system!

37. 38Copyright © 2016 OMAC. All rights reserved.
Our automation systems are diverse, but
must liaise to facilitate integration
• Inside the box certainly needs to be proprietary. Outside the box we need
an open standard used by everyone. This will allow:
– Data exchange
– Machine interface/coordination
– Safety monitoring
• OEMs can simplify integration by eliminating proprietary architectures at
the system level, and instead using open standards.

38. 39Copyright © 2016 OMAC. All rights reserved.
PackML is our standard for packaging
equipment automation
PackML
States
Execute, Held,
Suspended…
PackTags
Which state?
How long in state?
Alarm Events?
Modes
Producing,
Maintenance,
Manual
• Packaging Machine Language
• Industry standard (ISA TR88.00.02)

39. 40Copyright © 2016 OMAC. All rights reserved.
Collaboration with OPC Foundation to define
an open communication protocol
• OPC UA provides a vendor agnostic solution to communicate
PackML states, modes and PackTags to any machine

40. 41Copyright © 2016 OMAC. All rights reserved.
Strong, global leadership from member
companies drives automation standards
across industry
Visit the OMAC website here.

41. 42Copyright © 2016 OMAC. All rights reserved.
Next gen packaging lines will be natively
capable of full integration via PackML &
OPC UA
PackML
PackML
PackML
PackML
PackML
PackTagsOPC UA
network
Tag Database,
Historian, etc.
MES Apps
PackML

42. Mapping to Arla Business needs
OPC-UA – Basic I4.0 Protocol
Manufacturing Execution Processes/Functions ...
Milk
Intake
Area
Main
Production
Areas
Filling /
Packaging
Areas
Semi/Finish
Goods
Warehouse
Areas
OPC UA Basic I 4.0 Protocol
OPC UA
PackML PackMLPackML
I4.0 I4.0 I4.0
Process
Optimisation
OEEDetail
Scheduling
Track &
Tracing
Process
Optimisation
OEE
Process
Optimisation
OEE
OPC UA
SAP Business System
Data
Warehouse

43. For Industry 4.0 to get success
End users requirements to I4.0
1. Standardisation bodies (and there are many) must cooperate
closely to define generic, OPEN Standards.
2. The end user requirements are:
”any application” to “any device” communication

44. Wrap-up
Conclusions
• Industry 4.0 is less about (new) technologies and more about
Connecting & New Business Models
– and doing it fast, maintainable, upgradable
• PackML is a clear case of Standardisation Benefits
Cost reduction, faster projects, harmonised interface, operator
efficiency, higher uptime. Its ready – use it!
• I wanted to give you a background for understanding the ”Protocol
challenges” of I4.0.
(We, the end users, do NOT want to get caught - having to choose
between proprietary platform communities in the Manufacturing
space)

45. Q&A
Your are always welcome to contact me at:
Arne.Svendsen@ArlaFoods.com
https://dk.linkedin.com/in/arnesvendsen
Further
studies 

46. 47
Arla PackML interface
OMAC - Organization for Machine Automation and Control

47. 48
Arla PackML interface
TR88.00.02
Machine builders
Unit control program
TR88 Model
Machine builders
Unit control program
TR88 Model
”Upper IT-system”
TR88/PackML
ISA88/Part-5
(Make2Pack)

48. 49
Arla PackML interface
PackML Statemodel

49. 3 July 201650
Arla PackML interface
PackML is a part of the Arla standard purchase contract
50

50. Time
Overall Interface demand
PackML
Specification
Interface details defined
PackML SDS
PackML
test suitcase
Arla PackML interface
PackML implementation as of 1st of January 2015
Valid data from day 1

51.  SETUP
 UNIT
 TEST SUITCASE
• 22 mandatory tests
• 3 optional tests
TEST SUITCASE UNIT
52
Arla PackML interface
Test suitcase

52. 7/3/2016
Arla PackML interface
Machine builder training

53. • Arla PackML OEM implementation
03 July 201654
Agenda

54. 03 July 201655
Arla PackML OEM implementation
PackML State Manager

55. 56
”Upper” IT system
Solution 3
PackML
”Upper” IT system
Solution 2
PackML
Gateway PLC
PackTagsSocket TCP/IP
Socket TCP/IP
”Upper” IT system
Solution 3
Gateway
PackML
Socket TCP/IP
Arla PackML OEM implementation
Interface solutions
”Upper” IT system
Solution 1
”Upper” IT system
Solution 1
”Upper” IT system
Solution 2
PackML
PackTags

56. Arla PackML OEM implementation
Interface requirements and Specification for Units - PackML
57
Selected
Mark type
Unit
type
Connection type Specification in section
Type
#1
PackML State model
simulator
7 Configuration of PackML State
model simulator
Type
#2
PackML State model
simulator
7 Configuration of PackML State
model simulator
Type
#3
TCP/IP Socket
communication
8 Configuration of PackML unit

57. Arla PackML OEM implementation
PackML “Lite” – type 1 & 2
58

58. Arla PackML OEM implementation
PackML “Lite” – type 3
59

59. Arla PackML OEM implementation
60
TR88.00.02 specification of minimum set of PackTags

60. Arla PackML
Line Controller