Treasury Wine Estates Uncorks Value Of Premium Wines With MES Treasury Wine Estates produces close to 1 million bottles of wine a day at their Australian packaging facility. A legacy MES at the site limited insight and control of work order details. With a new bottling line, the company replaced the old system, integrating ControlLogix controllers with MES and manufacturing intelligence solutions from Rockwell Automation to boost inventory accuracy to nearly 100 percent and reduce downtime.

1. Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 1Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
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Wine Producer
Uncorks Value Of Premium Wines With MES

2. Wine Bottling Transformation
Geoff Nunan
Principal Consultant – Digital Transformation
Nukon

5. McKinsey Digital CompassIndustry 4.0 Digital Enterprise – PwC - 2016
Digital Operations
Transformation

6. Digital Operations Transformation – Consumer Packaged Goods
DigitalFactory
•Optimised
Scheduling
•Digital Quality
•'Live' Inventory
•Machine Data
drives business
process
Robotics
•Automated
Material
Handling
•Improved safety
•Optimised
Inventory
End-to-EndVisibility
•Data driven
demand
prediction
•Real-Time
supply-chain
optimisation
•Remote,
Integrated
Operations
DataScience
•Predictive
Analytics
•Automation of
Knowledge
Work
•Remote
Monitoring &
Control
•Robotic Process
Automation
InternetofThings
•Transport
Monitoring
•Smart Shelf
Smart Packaging

7. Digital Operations Transformation – Maturity Model
Digital Automated Remote Predictive Optimised
• Remove
paper
• Integrate
systems
• Enable
Mobility
• Co-ordinate
activities
• Automated
Inventory
• Automated
line replen
• Automated
end-of-line
• Automated
Warehousing
• End-to-end
visibility
• Remote
Monitoring
& Control
• Experts
operate
across sites
• Data availability
• Data Science
Analysis team
with Reliability
experience
• Recommend
actions based
on Data
analysis
• Business
Processes run
without
intervention
• Human
intervention
only to manage
exceptions
• Decision
optimisation

8. A Model
Digital Factory

9. Digital Operations Transformation – Factory Scheduling

10. Digital Production Line

11. Project Elixir
EXPANSION
FOUR LINES01 ADDRESS
LEGACY ISSUES02 VANILLA
SOLUTION03 TIGHT
TIMING04
Expanding from 3 to 4
high-speed
packaging lines
Replace custom system
10 years old
no upgrade path
Strategy to move to vanilla,
modular solutions
Squeezed
Busy company project
schedule

12. Pilot Line Timeline
October 2015
Project Tender
November
2015
Project Scoping &
Contract Negotiation
December 2015
Design and Construction
January 2015
System Testing
February 2016
Water Trials, Training
and User Acceptance
Testing
1st March 2016
Go Live

13. Remaining 3 Lines
February 2016
Sign-off Pilot Line
March 2016
Planning
April 2015
Design and Construction
May 2016
System Testing
June 2016
Go Live Preparation
July 2016
Go Live

14. Initiating the project - Requirements
EXPANSION
FOUR LINES01 ADDRESS
LEGACY ISSUES02 VANILLA
SOLUTION03 TIGHT
TIMING04
Expanding from 3 to 4
high-speed
packaging lines
Replace custom system
10 years old
no upgrade path
Strategy to move to vanilla,
modular solutions
Squeezed
Busy company project
schedule
‘Adding the next new
line must be easy’
Fully configurable
solution
‘Same as the old one,
but upgradeable’
Same, but completely
different
‘I need to be able to
add new stuff easily’
Must be modular and
extensible
I don’t have time to
change any of the
interfaces,
so it must act exactly
like the old one

15. Project Elixir
REMOTE
DATA CENTRE05
PaaS Hosted Solution
750Km away
from rural site

16. The World Is Flat – Assembling the team
1
6
4
CPGSuite® Architect
FactoryTalk®
ProductionCentre®
Platform &
Development
Project Management
Solution Architecture
Configuration & Testing
Training & Support

17. So what happens on a wine bottling line?
Depalletiser
Filler &
Closures
Labeller
Robot Case
Packer
Palletiser
Carton
Erector
Bulk wine
Sparkling
Wine
Screw Caps
Corks
Muselets
Labels
Neck Tags
Stickers
Dividers
Cartons
Stickers
Slip Sheets
Stretch Wrap
Finished
Product
Store
Empty
Bottle
Storage
Dry-Good StorageWinery

18. Legacy system
Line Control PLC – 1 per line
RS View SE
Factory Talk Transaction Manager
Factory Talk Mertics
Custom Microsoft ASP.NET User Interface

19. Architecture
Production Module
CPGSuite®
Performance
Management
Suite
JDE Global
Integration Database
MARC Warehouse
Management
Orders Parts
List
PPS Consumption Pallet
Comp
Consumption
Orders
PBOM Param
s
Consumption
Replenishment
Request
Infor (CIS)
Line Control PLC (One line Control PLC for each Line)
Machine
Control PLC
Label Printing
Pallet Deliveries
Pallet
Comp
Pallet Completion
Replenishment
Request
Orders
Order Updates
Order Status
Order
Status
Next
12
Orders
Next
Order
Running
Order by
Work
Centre
Glass
Pallet
Details for
Validation
Glass
Pallet
Validation
Result
Automated
Material
Consume
Automated
Material
Production
Machine
State
Machine
State
Machine
Fault
Codes
Orders
Process
Variables
FactoryTalk®
Historian
FactoryTalk® VantagePoint®+ Nukon Smarts
Process
Variables
Performance
Reports &
Dashboards
Production
Data
Warehouse
Reports
Wine Transfer
PLC
Next
12
Orders
Machine
State
Process
Variables
Label
Details
Machine
Run Hrs
Pallet
Deliv.

20. Interfaces

21. Order Management

22. Line Status Overview
Integrate Production
Schedule data with
Tank Level visibility
FactoryTalk® View SE
embedded into MES
screen

23. Consumptions
Focused local
workstations
Full visibility of recipe and
available inventory
Automated consumption
of pallets of glass via
control system interface

24. Pallet Completions – Finished Goods
Automated
production of pallets
via control system
interface
But with manual
over-ride
Palletiser performs
automated
production of pallets,
but allows for manual
consumption of slip-
sheets

25. Inventory Management

26. Architecture
CPGSuite®
Performance
Management
Suite
JDE Global
Integration Database
MARC Warehouse
Management
Orders Parts
List
PPS Consumption Pallet
Comp
Consumption
Orders PBOM Param
s
Consumption
Replenishment
Request
Infor (CIS)
Line Control PLC (One line Control PLC for each Line)
Machine
Control PLC
Label Printing
Pallet Deliveries
Pallet
Comp
Pallet Completion
Replenishment
Request
Orders
Order Updates
Order Status
Order
Status
Next
12
Orders
Next
Order
Running
Order by
Work
Centre
Glass
Pallet
Details for
Validation
Glass
Pallet
Validation
Result
Automated
Material
Consume
Automated
Material
Production
Machine
State
Machine
State
Machine
Fault
Codes
Orders
Process
Variables
FactoryTalk®
Historian
FactoryTalk® VantagePoint® + Nukon Smarts
Process
Variables
Performance
Reports &
Dashboards
Production
Data
Warehouse
Reports
Wine Transfer
PLC
Next
12
Orders
Machine
State
Process
Variables
Label
Details
Machine
Run Hrs
Pallet
Deliv.

27. Downtime Events (Performance Manager)
Custom view of downtime
events was created to
simplify user experience
Extension developed using
native API, so does not
impact upgrade path

28. Downtime Events (Performance Manager)
Extensive, 5-level reason
tree used to classify
downtime events
Custom reason entry form
developed to enhance
user experience
Native APIs used so
extension does not impact
upgrade path

29. ReportingSuite
Reporting Suite
CPGSuite®
Performance
Management
Suite
JDE Global
Integration Database
MARC Warehouse
Management
Orders Parts
List
PPS Consumption Pallet
Comp
Consumption
Orders PBOM Param
s
Consumption
Replenishment
Request
Infor (CIS)
Line Control PLC (One line Control PLC for each Line)
Machine
Control PLC
Label Printing
Pallet Deliveries
Pallet
Comp
Pallet Completion
Replenishment
Request
Orders
Order Updates
Order Status
Order
Status
Next
12
Orders
Next
Order
Running
Order by
Work
Centre
Glass
Pallet
Details for
Validation
Glass
Pallet
Validation
Result
Automated
Material
Consume
Automated
Material
Production
Machine
State
Machine
State
Machine
Fault
Codes
Orders
Process
Variables
FactoryTalk®
Historian
FactoryTalk® VantagePoint® + Nukon Smarts
Process
Variables
Performance
Reports &
Dashboards
Production
Data
Warehouse
Reports
Wine Transfer
PLC
Next
12
Orders
Machine
State
Process
Variables
Label
Details
Machine
Run Hrs
Pallet
Deliv.

30. Filler Speed Trend
Native ability to tie production
orders to historian time-frames
within the reporting suite
Event-framing, without the
need for event-frames

31. Shift Summary Report
Bring data together from
multiple sources to provide a
complete summary of shift
performance

32. Work Order Overview
A filterable home-page for
order level reporting
Link to reports on inventory,
performance, Wine flows and
more
The home page for diagnosis
of issues

33. Work Order Detail Brief
The ‘End-of-Order’ Report
A summary view of the order, quickly allowing the user to see if anything
has been missed

34. NetworkArchitecture
Operating System: Unless otherwise indicated, all Servers are virtualised and run Windows Server 2008 R2 Standard SP1
Line Side PCs - CPG Clients (x 32)
PLCs
WAN
Connect to CPG Suite
Server via Citrix
FactoryTalk Services
Platform Server
10.49.72.38
FactoryTalk Services Platform 2.74.00 (CPR 9 7.4)
RSLinx Enterprise 5.74.00 (CPR 9 SR 7.4)
FactoryView SE
Server
10.49.72.36
Windows Server 2012 R2 Standard
FactoryTalk View Site Edition Server 8.10.00 CPR 9 SR 7.4
FactoryTalk View Site Edition Client 8.10.00 CPR 9 SR 7.4
Citrix Server
Multiple sessions generated from Line Side PCs
CPG Suite Server
10.122.1.66
FactoryTalk Production Centre – CPG Suite 10.1
Performance
Management Server
10.122.1.67
Performance Management 3.1.100915
SQL Server
10.122.1.68
Microsoft SQL Server 2008 R2 SP3
FactoryTalk
Historian Server
10.122.1.65
Historian 4.00.00.0104
Vantage Point
Server
10.122.1.64
Microsoft SQL Server 2008 R2 Reporting Services
VantagePoint System Server 6.10.00
Dundas BI Deployment Centre 2.6.2.1000
TWE Vaadin App (Java based Downtime Application)
Control Logix
MES Line Control PLC Line 1
10.49.72.140
Control Logix
MES Line Control PLC Line 2
10.49.73.147
Control Logix
MES Line Control PLC Line 3
10.49.73.197
Control Logix
MES Line Control PLC Line 4
10.49.73.243
Multiple Machine PLCs

35. Project Elixir
Development
(Cloud)
Test
Vantage Point Server
CPG Suite Server
Perf Man Server
FT Vantage Point
Nukon Smarts
FT Historian
SQL1 (Nukon Dev SQL1)
FT Production Centre
SoftLogix
FT Production Centre - CPG Suite
FT Production Centre
FT Production Centre - PM Suite
Vantage Point DB
CPG Suite DB
PM Suite DB
TWE Interfaces DB
Historian Server
CPG Suite Server
Perf Man Server
FT Historian
SQL Server
FT Production Centre
FT Production Centre - CPG Suite
FT Production Centre
FT Production Centre - PM Suite
Vantage Point DB
CPG Suite DB
PM Suite DB
TWE Interfaces DB
Vantage Point Server
FT Vantage Point
Nukon Smarts
Production
Historian Server
CPG Suite Server
Perf Man Server
FT Historian
SQL Server
FT Production Centre
FT Production Centre - CPG Suite
FT Production Centre
FT Production Centre - PM Suite
Vantage Point DB
CPG Suite DB
PM Suite DB
TWE Interfaces DB
Vantage Point Server
FT Vantage Point
Nukon Smarts

36. Next Steps ?

37. 6 things to take home
• We are 1 year into a 5 year Industrial Revolution (Industry 4.0)
• 45% of all activity can be automated now, but it starts with Digitisation
• The World Is Flat – And better because of it
• Modular MES is a viable solution for legacy replacements
• Agility requires Stability
• The servers don’t need to be at the factory – but be careful

38. We exist to inspire teams and create transformational change by
delivering the technology solution to realise your vision.
nukon.com.au
Integrate
Business Data
Streamline
Supply Chain
Track Materials,
Inventory and Products
Improve Performance

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Copyright © 2017 Rockwell Automation, Inc. All Rights Reserved. 40Rockwell Automation TechED 2017 @ROKTechED #ROKTechED
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