Understanding current constraints to optimize line efficiency requires holistic visibility into what is happening now, while predicting future actions. For this to work, plant operations will need to be properly connected and automated across people, processes, and technology. Join integration experts, Chris Heim and Gage Gibson from AbeTech, who will share real examples of how connecting machines, systems, processes and people has helped to significantly increase capacity and reduce compliance risks. In this session you will also learn key steps to start building end-to-end plant floor visibility to enable quality and operations management - as well as executives - to better track line efficiencies and proactively identify potential issues. Key questions manufacturers will get answered include: How do I reduce line errors and make production less labor-intensive? What machine data should be regularly extracted and analyzed? Where should we add process automation to line operations? How can I reduce lost productivity during start-up, shutdown, or changeovers?

1. Beyond Compliance
Webinar & Podcast Series for Process Manufacturers
Boost Output with Current Resources:
How Connectivity Drives Line Efficiency & Business Outcomes
Chris Heim
President
Gage Gibson
Product Development Manager

2. // Meet Your Host
✔Improve Yield
✔Maximize Productivity
✔Ensure Compliance
Plant Management Platform
hello!

3. ✔Only panelists microphones are active
✔Ask questions! (Q&A at end)
✔Recording link will be shared
✔Audio issues: use call-in number
Before We Get Started
BEYOND COMPLIANCE
Just so you know…

4. BEYOND COMPLIANCE
Boost Output with Current Resources: Meet the Speakers
Chris Heim
President
Gage Gibson
Product Development Manager

5. Poll Question
What is holding you back from collecting the type of data that you need?
A) I don’t know where to start
B) I need more resources
C) I need more buy-in
D) I don’t have the expertise

6. BEYOND COMPLIANCE
Objectives:
● How do we justify collecting line efficiency data?
● Where do we start?
● Real World Examples
Session Overview

7. Poll Question
Who would you consider the best player in MLB?
A) Aaron Judge (Yankees Outfielder)
B) Shohei Ohtani (Angels Pitcher/DH)
C) Nolan Arenado (Cardinals 3rd Baseman)
D) Sandy Alcantara (Marlins Pitcher)

8. BEYOND COMPLIANCE
Why does data matter?
BEYOND COMPLIANCE

9. BEYOND COMPLIANCE
Why collecting data matters?
● Can operate with a reduced workforce
● Real time data increases reliability of results
● Remove human error or fraud

10. Sensor data tracks in-counts of raw
product coming into the line, and out-
counts of finished product leaving the
line.
STEP 1

11. Sensor data is fed into OEE to
track performance and quality.
STEP 2

12. Temperature, metal detection,
and weight data is monitored in
real time.
STEP 3

13. (Typical Food Plant Layout)
Example: Meatball plant
Temperature
Gateway
Machine Interface
Touchscreen Input
Scoreboards
Handheld input
Scenario #1 Scenario #2
Scenario #3
Scenario #4
Fully-Cooked
Meat Plant

14. Floor Scale
Ambient
Temp Gateway
To SC
Touch Computer
Scenario #1: Production Area

15. Machine
Interface
Interface Box can Monitor a PLC
and/or a camera/photo-eye:
❑ Machine status
(Running/Idle)
❑ Machine speed (CPM)
❑ Presence of product
exiting the machine
Gateway
Scenario #1: Production Area

16. Scenario #2: Packaging Area
Machine
Interface
Data from Bagger
❑ Run status
❑ Drops per minute
❑ Total wt. produced
❑ Avg. package wt.
(Bagger)

17. Machine Interface
Data from Checkweigher:
❑ Record of every weighment
(every bag of meatballs)
Data from Metal Detector:
❑ Count of metal detections
❑ Time stamp of detection events
❑ Confirmation of product
rejection
(Checkweigher and Metal Detector)
Scenario #2: Packaging Area

18. Scenario #2: Packaging Area
(Box Counts and Downtime Tracking)
Machine Interface
& Input Device
Photo-eye
Used for:
❑ Monitoring box counts
❑ User input during
downtime events

19. Scenario #2: Packaging Area
(Box Counts and Downtime Tracking)

20. ❑ Temp Probe is used to check
the temperature of incoming
product before it is accepted.
❑ Wall-mounted sensor send
the temperature of the room
where they’re installed on a
pre-set, timed interval.
❑ Each unit can be set to send
at a separate time interval,
(i.e. once and hour may be
okay for some rooms, others
may need once/5 minutes).
To Plant Management Platform
Temp
Probe
Ambient
Temp
Gateway
Scenario #3: Temperature Monitoring

21. In the Manager’s office… Or on the go.
Scenario #3: Temperature Monitoring

22. For FC products, internal cooked
temperature is a food-safety
critical control point (HACCP).
To Plant
Management
Platform
❑ Internal temperature must reach 165F
to ensure consumer safety.
❑ If sold by the pound, overcooking
results in loss of profits out the
smokestack.
❑ Liability protection pushes toward
overcook, profit concerns push toward
undercook.
Scenario #4: Fully Cooked Temperatures

23. Using statistical methods
based on real-time
sampling, we are 99.7%
certain that all of our
internal temperatures
are above the food-safe
level.
Alarms can be raised
based
on data trends, allowing
for a setpoint adjustment
BEFORE un-safe product
is made and frozen.
Scenario #4: Fully Cooked Temperatures

24. BEYOND COMPLIANCE
How can we make the most of your data?
Plant
Scoreboards
Automate
Collection
Plant Management
Platform

25. Poll Question
What area of your plant has the most potential value for data collection?
A) Receiving
B) Line Start
C) Product Temperatures
D) Ambient Temperatures
E) Packaging/Detection

26. Questions?
BEYOND COMPLIANCE
Chris Heim
President
AbeTech
Gage Gibson
Product Development Manager
AbeTech

27. More Resources at www.safetychain.com
White Papers & Surveys
Webinars & Videos
Product & Partner Info
Solution Consultation
BEYOND COMPLIANCE
Learning More:
SafetyChain Content Library
www.safetychain.com/content-downloads
AbeTech Resources:
www.abetech.com/knowledge-center