Addressing the Challenges Associated with Integrating OEM Equipment into Production and Plant Operations

1. Complete series available
OnDemand
www.plantseminars.com
Welcome to today’s
presentation:
Visualizing
Hidden A Practitioner Approach To Driving Economic Profit in Continuous Improvement:
Information Packaging Line Productivity Food Plant Manufacturing Packaging
Featured Speaker: Featured Speaker: Featured Speaker:
Mathieu Loranger, Eng Mike Ruffner, Jim Whalen,
Featured Speaker: Food Distribution Company Rich Products
Eric Allen
Senior Technical
Manager at The JM
OnDemand OnDemand OnDemand
Smucker Company
Food safety and temperature Asset Reliability — Getting Real About Real-
Learn Secrets of Enterprise Get Behind The Scenes
integrity in food distribution Manufacturing Intelligence Time Cost Management
facilities At Frito Lay
Featured Speaker: Featured Speaker: Featured Speaker: Featured Speaker:
Mark Grimes Lars Johansen, Ed Michel, Rudy Westervelt (retired),
Chr. Hansen Frito-Lay Kroger
OnDemand OnDemand OnDemand OnDemand

2. Visualizing Hidden Information
Presented by
Eric Allen - Senior Technical Manager at The JM Smucker
Company
Hosted by
Tom Giunta – Invensys
Niels Andersen – Invensys
Slide 2

3. Niels Andersen,
Invensys Business
Value Solutions
Industry Pressures for
Manufacturers of
Branded Food Products
Slide 3

4. Asset Performance
Growth/Cost Strategy Asset strategy
Supply Chain Optimization
Slide 4

5. Value Chain
Supplier +
Make +
Logistics +
Retail
Cost Cost Cost Cost
The
Folger
Coffee
Source Make Deliver Sell
Company
Flexible Transportation
Lot size (EOQ) Lead Time
Consistency Product Variety
Raw Ingr. WIP FG Inventory FG Inventory FG Inventory
A B C D E F G H
AA BB CC DD EE FF GG HH
A B C D E F G H
Business Processes

6. Eric Allen
Senior Technical Manager
at JM Smucker Co.
Folger Coffee Plant
Case Study
Slide 6

7. Importance of Data-Driven Manufacturing
• As the level of automation increases and number of operators
decrease, need equipment to be easy to diagnose and track trends
• As information is made more obvious, the operation can make
better assessments of any situation
• When operators can solve basic problems, more advanced resources
can focus attention on more complex issues and improvements

8. What is an OEM?
• Original Equipment Manufacturer
• Many manufacturing plants buy production equipment from
machine builders
• Depending on the equipment, the vendor may make lots of
machines that are exactly the same, or may custom-build every
machine to the customer’s requirements

9. Issues with OEM equipment
• Adherence to corporate/plant standards
• OEM focus often on cost of purchase at expense of ease of
troubleshooting
• Different definitions of success
• Controls decisions often not considered up front by Purchasing.

10. An Example
• OEM Tray Erector purchased to enable new corrugate tray design
• Purchasing specified Allen-Bradley controls and Category 3 safety
interlocks
• No electrical design review until after machine was built

14. Operator Controls
• Start
• Stop
• Manual/Auto
• Glue On/Off
• Safety reset
• Lighted status indicators
• E-stop

15. Settings HMI
• 2 parameters per screen
• Function key navigation
• Mounted over 6 feet high

16. Start-up issues
Why won’t the machine start?

17. Immediate Changes at Install
Added ethernet module for communication
Built diagnostic screen on nearby Wonderware terminal

18. Factory Diagnostics
HMI Diagnostics

20. Production information
Issues
Stops
Production counts
Stop causes

21. Stop Causes
Define running/producing

22. Identify logic for each stop condition
Sometimes stops are combinations of logic

23. Safety Circuit Example
Category 3 redundancy
Nine guard doors, two E-Stops
Wired to safety relay
Wires to 3rd set of contacts cut off by OEM
Reset required for operation to re-enable
Redundant contactors in series for power

24. Very safe - but hard to troubleshoot
Reset Circuit
Input Circuit 1
Redundant Inputs
Relays and Contactors
One input to PLC to turn on Safety Status Light

25. Then one night…
Four hours down for safety fault
Electrical resource determined E-stop was problem, based on wiring
Actual problem was door switch
Could easily happen again

26. Need safety circuit to run
Which part of the circuit is not working?

27. Just as safe - but more data
13 safety inputs to PLC, still redundant circuits

28. Check door 2 - then what’s next?

29. Safety circuit is ready

30. Glue Pattern
No way to visualize
12 timer settings
Just “numbers”

32. Lessons Learned
• Operator Effectiveness is Dramatically Impacted by Choice of
Interface
• Focus HMI on Issues that Impact Losses
• OEM- Specify Hardware Very Clearly
• OEM- Pick your battles, you may not get value from OEM doing
certain design vs. doing at plant
• Look at every issue as an opportunity to be prevented in the future.

33. Operators liked the information
so much - they requested a
separate Wonderware station
just for the tray erector so they
didn’t have to walk back and
forth.

34. What’s next

35. Niels Andersen,
Invensys Business
Value Solutions
Summary
Slide 35

36. Value Analysis Solution focus
Demand (Forecast) Supply Chain
Cash (Working Capital) Inventory Decision Support
Supply (Operations) Plan
Adherence
Real Time
Costing
Asset
Utilization
Workflow
Dashboard
Intelligence
Alert
Maintenance
Compliance
Productivity
Availability
Cycle Time
Execution
Controls
Schedule
Tracking
Quality
Safety
Energy
Yield
Tools and
Technology
© Invensys
00/00/00
Sli
de
36

37. Wonderware capabilities
Asset Performance
Real-Time Equipment Quality Collaboration
Platform Effectiveness Management Workflow
• Integration & • OEE Calculations • Understanding Process, People,
Information • Downtime Variance Systems
Framework Tracking • Spec’s SOP’s
• Process • Root Cause • Data Collection
Historian Escalations,
Analysis • SPC Approvals
• HMI • Reporting and • Sample Plans
Visualization performance Event/KPI
• HACCP Support Triggering
• Portal tracking
Slide 37

38. Invensys Business Value Solutions (BVS)
Understand ..
• your true business potential of your current assets
• how to measure, empower and improve your performance
BVS offers …
• consulting services
• guidance on where to invest in solutions to get the optimum performance
• unique methodologies for calculating financial performance in real-time
Slide 38

39. Q&A
Slide 39

40. A special thank you to our presenter
Eric Allen
The JM Smucker Company, Folger
Coffee division, Kansas City, MO
Tel. 816-346-1700
Cell. 913-558-0004
Eric@DataDrivenManufacturing.com
www.linkedin.com/in/ericallenkc
@EricAllenKC

41. Where do you go from here?
Complete series available
OnDemand
www.plantseminars.com
your local Wonderware distributor:
www.wonderware.com -> About Us > Contact Sales
Tom Giunta
+1 (856) 986-1289 | tom.giunta@invensys.com
Niels Andersen, Invensys Business Value Solutions
+1 (949) 636 4991 | niels.andersen@invensys.com

42. Speaker Bio – Eric Allen
Current Position: Senior Technical Manager at JM Smucker Company’s Folger Coffee
facility in Kansas City, MO
Over 20 years experience in a variety of engineering and operational management positions
with Folger Coffee, including a number of new equipment start-ups, data collection and
controls integration efforts, leadership of performance improvement efforts, and managing
day to day operations of production departments.
Summary of Experience/Knowledge:
Eric has managed capital projects of up to $10 million as well as annual operating budgets of
$10 million. He has led organizational change, implementing self-directed teams in a union
factory, leading a number of plant pillars in Total Productive Maintenance, as well as
delivering results through the systemic use of automated data-driven metrics.
In-depth technical knowledge in packaging machinery design and troubleshooting, making
numerous technical contributions, utilizing expertise in Control Loop Tuning, Web Control
Theory, programming of Programmable Logic Controllers, Human Machine Interfaces, and
set-up of virtual computers.
Specialties
Experienced pillar owner for Autonomous Maintenance, Focused Improvement, Education
and Training, Leadership, Initiative Management
Statistical Process Control, Control Loop Health, Web Handling, Front End Engineering,
Total Quality Management, Reliability Engineering;
Allen-Bradley and Siemens PLC, Wonderware, GE Proficy Plant Applications and Historian,
Computer Networking, Computer Virtualization;
Interests: Family (wife and two children), playing golf and basketball, gardening