MEL System by Zenon
An innovative modular end-of-line packaging system.
The MEL System® (Modular End-of-Line) is a real breakthrough in the design and implementation of integrated end-of-line systems.
The MEL System® incorporates two very important innovations: a modular approach (MEL-ready modules concept) and the Backbone, an IT-control super- module combining MES, PLC and SCADA technologies.
An added benefit of the system is that it can incorporate supply chain functionality (e.g. automated direct shipping and warehouse delivery tracking).
The MEL System® has been successfully implemented at a number of multinational manufacturing companies, delivering dramatic increase in productivity, OEE and optimal utilization of existing infrastructure.
Automation in Manufacturing (Unit-4) by Varun Pratap Singh.pdfVarun Pratap Singh
Unit 4: Production and assembly systems
Automated production lines- fundamentals, system configurations, work part transfer mechanisms, storage buffers, control of production line, applications. Automated assembly systems- fundamentals, system configurations, parts delivery at work stations, applications.
Automation in Manufacturing (Unit-4) by Varun Pratap Singh.pdfVarun Pratap Singh
Unit 4: Production and assembly systems
Automated production lines- fundamentals, system configurations, work part transfer mechanisms, storage buffers, control of production line, applications. Automated assembly systems- fundamentals, system configurations, parts delivery at work stations, applications.
Different layouts for various manufacturing systems
3 three basic types of layout:
Process layout
Product layout
Fixed-Position layout
3 hybrid layouts:
Cellular Manufacturing
Flexible Manufacturing Systems
Mixed-model Assembly Lines
Industry 4.0 - Enabling operational excellence of packaging linesStephane Potier
Industry 4.0 is a revolution in operational excellence for smart factories. Packaging industry experts weigh in on current trends and share their visions for the future.
Stefano Rizzo, SVP Strategy and Business Development di Polarion Software ed Edoardo Sivera, Senior Electronic System Engineer di CNHi, presenteranno gli attuali processi di sviluppo Veicolo e di sviluppo Elettronico in CNHi, le relative esigenze di integrazione della toolchain e di come la collaborazione sinergica di Polarion Software e di Siemens PLM potranno rispondere a tali esigenze.
5 Techniques to Achieve Functional Safety for Embedded SystemsAngela Hauber
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
5 Techniques to Achieve Functional Safety for Embedded SystemsMEN Micro
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
Drop by drop the ocean builds up. Similarly, small innovations build up to count in implementing Industrie 4.0 across the world.Presently there are more examples in German Factories but the other countries are fast catching up. All these small examples give a remarkable picture of how the world is changing. And also gives us a direction to how we should change our skill sets to meet the ever growing Knowledge Economy. For students, you get an idea where research work is headed. The examples of Applications of Industrie 4.0 will give an idea of how small drops of technology changes is building into an ocean of Innovative ideas across the Industrial Spectrum.
VigilantPlant is Yokogawa's automation concept for safe, reliable and profitable plant operations
Our concept is for a plant to be a place where people can be watchful and attentive, while the business responds quickly and efficiently to change. Non-stop production is assured as the plant’s personnel confidently expand their capabilities.
A contemporary redesign of the traditional XiL system, capable of seamlessly going from verification and validation with SiL, through MiL and HiL, ending up as the backbone of a full-featured Digital Twin of the vehicle or system.
Impacts of integrated safety on machine and plant conceptsNinad Deshpande
The world is now moving on to integrated safety which integrates safe and standard data on a common network. Even in a decentralized architecture, communication is possible over a single bus, thus harvesting the benefits of integrated safety.
In plants users have machines from different vendors communicating on different fieldbuses. These fieldbuses need different safety protocols. These safety standards are proprietary and not compatible with one another. openSAFETY is the only open source and fieldbus independent safety protocol.
The Internet of Things (IoT) is a revolutionary concept that connects everyday objects and devices to the internet, enabling them to communicate, collect, and exchange data. Imagine a world where your refrigerator notifies you when you’re running low on groceries, or streetlights adjust their brightness based on traffic patterns – that’s the power of IoT. In essence, IoT transforms ordinary objects into smart, interconnected devices, creating a network of endless possibilities.
Here is a blog on the role of electrical and electronics engineers in IOT. Let's dig in!!!!
For more such content visit: https://nttftrg.com/
Different layouts for various manufacturing systems
3 three basic types of layout:
Process layout
Product layout
Fixed-Position layout
3 hybrid layouts:
Cellular Manufacturing
Flexible Manufacturing Systems
Mixed-model Assembly Lines
Industry 4.0 - Enabling operational excellence of packaging linesStephane Potier
Industry 4.0 is a revolution in operational excellence for smart factories. Packaging industry experts weigh in on current trends and share their visions for the future.
Stefano Rizzo, SVP Strategy and Business Development di Polarion Software ed Edoardo Sivera, Senior Electronic System Engineer di CNHi, presenteranno gli attuali processi di sviluppo Veicolo e di sviluppo Elettronico in CNHi, le relative esigenze di integrazione della toolchain e di come la collaborazione sinergica di Polarion Software e di Siemens PLM potranno rispondere a tali esigenze.
5 Techniques to Achieve Functional Safety for Embedded SystemsAngela Hauber
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
5 Techniques to Achieve Functional Safety for Embedded SystemsMEN Micro
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
Failures of safety-critical electronic systems can result in loss of life, substantial financial damage or severe harm to the environment.
Safe computer systems are typically used in avionics or railway applications requiring particularly high reliability. This also goes for the medical market, while industrial automation environments demand more and more functional safety as technology becomes readily available.
Drop by drop the ocean builds up. Similarly, small innovations build up to count in implementing Industrie 4.0 across the world.Presently there are more examples in German Factories but the other countries are fast catching up. All these small examples give a remarkable picture of how the world is changing. And also gives us a direction to how we should change our skill sets to meet the ever growing Knowledge Economy. For students, you get an idea where research work is headed. The examples of Applications of Industrie 4.0 will give an idea of how small drops of technology changes is building into an ocean of Innovative ideas across the Industrial Spectrum.
VigilantPlant is Yokogawa's automation concept for safe, reliable and profitable plant operations
Our concept is for a plant to be a place where people can be watchful and attentive, while the business responds quickly and efficiently to change. Non-stop production is assured as the plant’s personnel confidently expand their capabilities.
A contemporary redesign of the traditional XiL system, capable of seamlessly going from verification and validation with SiL, through MiL and HiL, ending up as the backbone of a full-featured Digital Twin of the vehicle or system.
Impacts of integrated safety on machine and plant conceptsNinad Deshpande
The world is now moving on to integrated safety which integrates safe and standard data on a common network. Even in a decentralized architecture, communication is possible over a single bus, thus harvesting the benefits of integrated safety.
In plants users have machines from different vendors communicating on different fieldbuses. These fieldbuses need different safety protocols. These safety standards are proprietary and not compatible with one another. openSAFETY is the only open source and fieldbus independent safety protocol.
The Internet of Things (IoT) is a revolutionary concept that connects everyday objects and devices to the internet, enabling them to communicate, collect, and exchange data. Imagine a world where your refrigerator notifies you when you’re running low on groceries, or streetlights adjust their brightness based on traffic patterns – that’s the power of IoT. In essence, IoT transforms ordinary objects into smart, interconnected devices, creating a network of endless possibilities.
Here is a blog on the role of electrical and electronics engineers in IOT. Let's dig in!!!!
For more such content visit: https://nttftrg.com/
Sachpazis:Terzaghi Bearing Capacity Estimation in simple terms with Calculati...Dr.Costas Sachpazis
Terzaghi's soil bearing capacity theory, developed by Karl Terzaghi, is a fundamental principle in geotechnical engineering used to determine the bearing capacity of shallow foundations. This theory provides a method to calculate the ultimate bearing capacity of soil, which is the maximum load per unit area that the soil can support without undergoing shear failure. The Calculation HTML Code included.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
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Our project explains about the student management. This project mainly explains the various actions related to student details. This project shows some ease in adding, editing and deleting the student details. It also provides a less time consuming process for viewing, adding, editing and deleting the marks of the students.
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This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
Cosmetic shop management system project report.pdfKamal Acharya
Buying new cosmetic products is difficult. It can even be scary for those who have sensitive skin and are prone to skin trouble. The information needed to alleviate this problem is on the back of each product, but it's thought to interpret those ingredient lists unless you have a background in chemistry.
Instead of buying and hoping for the best, we can use data science to help us predict which products may be good fits for us. It includes various function programs to do the above mentioned tasks.
Data file handling has been effectively used in the program.
The automated cosmetic shop management system should deal with the automation of general workflow and administration process of the shop. The main processes of the system focus on customer's request where the system is able to search the most appropriate products and deliver it to the customers. It should help the employees to quickly identify the list of cosmetic product that have reached the minimum quantity and also keep a track of expired date for each cosmetic product. It should help the employees to find the rack number in which the product is placed.It is also Faster and more efficient way.
Hierarchical Digital Twin of a Naval Power SystemKerry Sado
A hierarchical digital twin of a Naval DC power system has been developed and experimentally verified. Similar to other state-of-the-art digital twins, this technology creates a digital replica of the physical system executed in real-time or faster, which can modify hardware controls. However, its advantage stems from distributing computational efforts by utilizing a hierarchical structure composed of lower-level digital twin blocks and a higher-level system digital twin. Each digital twin block is associated with a physical subsystem of the hardware and communicates with a singular system digital twin, which creates a system-level response. By extracting information from each level of the hierarchy, power system controls of the hardware were reconfigured autonomously. This hierarchical digital twin development offers several advantages over other digital twins, particularly in the field of naval power systems. The hierarchical structure allows for greater computational efficiency and scalability while the ability to autonomously reconfigure hardware controls offers increased flexibility and responsiveness. The hierarchical decomposition and models utilized were well aligned with the physical twin, as indicated by the maximum deviations between the developed digital twin hierarchy and the hardware.
2. Contents
o Company profile & Strongpoints
o End-of-line: Definition & Challenges
o MEL System
• Definition & Block diagram
• The Modular approach
• The Backbone
• Areas of application
• Benefits
• Implementation
o Installations and case studies
o Contact information
3. Company profile
A Greek packaging automation company with a successful record in the international
market since its establishment 27 years ago.
Design, construction, integration, commissioning and support of automated
end-of-line packaging systems and complete lines.
www.zenon-robotics.com
4. Company Strongpoints
> 150 installations > 120 robots installed
Preferred supplier of many Multinational companies
Installations and technical support all over Europe & the Middle East
Specialization areas: Food, Beverage, Pharma & Cosmetics, Chemicals, Paper
Strategic partnerships with the top suppliers of packaging equipment
25 Specialized engineers
Member of the THEODOROU Group of companies (www.theodorougroup.com)
5. End-of-line: definition
The end-of-line is the part of the packaging operations in a manufacturing plant
which starts after the individual product packaging machines and continues
until the shipping units (carton, multipacks, pallets etc.) are delivered for direct
shipping or to the warehouse.
End-of-Line
Individual packages Supply chain
6. End-of-line challenges
The end-of-line is considered as a separate entity in the packaging operation.
The challenges it faces are:
It must be designed to add minimum extra costs to the packaging
operations.
The supply chain starts at the end-of-line. Hence the end-of-line must
ensure a proper start and smooth transition to the supply chain.
8. The MEL System®
The MEL System® is a complete end-of-line automated system developed by Zenon.
It features:
• Packaging machinery, industrial controls and IT combined in one unique
integrated system
• Innovative design with modular approach
MEL System®Individual packages Supply chain
9. Block Diagram
THE MEL System®
The MEL System® has 4 distinct equipment phases and 1 IT / Control backbone:
Other factory
systems (MRP,
WMS, Scada, etc.)
OperatorsERP
Individual
Product
Packaging
Machines
Phase PPO
Primary
Packaging
Operations
Phase TPO
Tertiary
Packaging
Operations
Phase DS/WDO
Direct shipping/
Delivery to
warehouse
operations
Phase SPO
Secondary
Packaging
Operations
BACKBONE
Supply
chain
10. The Innovation
Modular approach at the equipment, devices and machinery level
Contrary to the individual packaging of products which has a wide
variety of different equipment and processes, the end-of-line is much
more uniform. This allows the adoption of a modular approach at the
equipment, devices and machinery level.
Integrated approach at the control and IT level
A unique control and IT system lies at the backbone of the MEL
System®, enabling:
- The integration and synchronization of the individual modules
delivering efficiency and flexibility
- The positioning of the MEL System® as the starting point of the supply
chain
11. The modular approach
o The end-of-line operations are separated in 4 distinct phases.
o Each phase includes a number of individual modules, each serving a specific
operation.
o The modules can operate both as autonomous units and as integral parts of the
whole MEL System®.
o Each module consists of devices and components, either built and integrated by
Zenon or sourced by external suppliers, Zenon’s ‘integration partners’.
o The MEL System® modules cover the requirements of the end-of-line
operations. However it is highly unlikely that in a particular implementation, all
modules of the MEL System® will be used.
12. The “MEL-ready” concept
All the modules of the MEL System® are “MEL-ready”, i.e. they can operate
autonomously but also as a part of the complete system.
The MEL-ready concept is important as it allows:
the gradual integration of the modules in a packaging line: individual modules
of the MEL System® can be purchased separately and can operate
autonomously. These modules can be integrated and be incorporated in a
whole MEL-system at a later stage.
the use of existing end-of-line systems in the MEL System®: Zenon’s engineers
can certify if the customers’ existing/legacy systems are “MEL-ready” and can be
incorporated as modules of the MEL System®. The MEL System® has been
designed so that existing end-of-line machinery can be easily incorporated with
a few minor modifications into the MEL System®.
16. Phase DS/DW
Direct shipping/Delivery to warehouse
At this phase the MEL System® delivers the shipping units either for direct shipping
to the loading bays or to the warehouse.
The delivery can be automatic (through sorting systems) or using forklifts, or a
combination of the above.
17. The Backbone
The Backbone of the MEL System® has been developed by Zenon’s experienced
software and control engineers.
It is a unique combination of PC, PLC and Scada based software, designed to
deliver:
1. Integration of the MEL System® modules in one efficient system
2. Synchronization of the modules: In all packaging plants, although the individual
operations might be efficient, when they operate as a system the overall
efficiency is much reduced. The Backbone of the MEL System® provides a
solution to this problem.
3. Connectivity to the various other plant IT/control systems: The MEL System®
lies in the heart of the packaging operations. The seamless connectivity to the
other IT systems (ERP, MRP, MES, WMS, other Scada etc) can secure a smooth
end-of-line operation and the secure start of the supply chain.
18. The Backbone (cont’d)
4. Information intelligence: The Backbone incorporates a number of
Manufacturing Execution System (MES) functions like:
• Raw materials usage
• Production and work flow monitoring
• Traceability data
• Quality control data
• Various actual production metrics, KPIs and statistics, OEE
• Maintenance data (predictive, preventive and emergency)
• Fault & Stoppages data recording (brake downs, changeovers etc)
All the above information is presented in a meaningful and interactive way to the
system operators and management.
19. Areas of application
The MEL System® can be used by any manufacturing plant involved in the
packaging of food, beverages, pharma, cosmetics, metal parts, paper etc.
The primary packaging of the products can be in the form of bottles, boxes,
cans, jars, spray cans, sacks, bags, buckets etc.
The secondary packaging can be in the form of cartons, trays, multipacks, other
shrink film packs or a combination of the above.
The shipping units can either be tertiary packages (pallets), secondary packages
or a combination of them.
20. Benefits
To the production
• Increased productivity
• Overall safety improvement
• Cost reduction (good ROI reported from customers)
• Ease of use with minimum needs for operator interventions and maintenance
• Flexibility
• Quick product changeovers
• Error minimization
• Meaningful production data presentation
• Ease of implementation
• Optimal resources utilization (space, manpower, existing equipment and IT)
• Expandability
21. Benefits (cont’d)
To the supply chain
• A sure start of the supply chain, both at the physical (shipping units) and the
data flow levels
• Can cope with both direct warehousing and direct shipping or any combination
of those
• Can quickly adapt to unexpected changes in demand/incoming orders
• Excellent ROI
22. Implementation
Our customers consider us not only simple system integrators but also
trusted business and manufacturing consultants and partners.
We strive to deliver to our customers real value by combining
technology innovations into realistic implementations.
In every project, we strictly follow the below steps :
In depth analysis of customer requirements
Existing infrastructure (mechanical, electrical, IT) analysis
Detailed proposal
Implementation and commissioning
After-sales support contracts
However our role continues after the implementation of each project and we remain
close to our customers to cover their evolving needs.
24. Case studies
ATHENIAN BREWERY (HEINEKEN)
• Depalletizing of full crates
•Palletizing of empty crates
• Decrating of full crates
• 1st level packaging of bottles into shrinked multipacks
• Coding of multipacks (expiry date, Lot number)
• 2nd level packaging of multipacks into shrinked bundles
• Labeling of bundles (expiry date, description, barcode)
• Palletizing of bundles
• Stretch wrapping of bundle pallets
• Supervision and control system
Click here to see: Video Case Study
25. Case studies
SYNGENTA SA
• 2 pick & place systems for bottle caps
• 3 cartesian bottle casers
• Robotic palletizer for cases
• Pallet transfer
• Stretch wrapping
• Lines & tanks SCADA system
Click here to see: Video Case Study
26. Case studies
PEPSICO
•Fully automated conveyance and sorting for cases (20 SKUs)
• 5 robotic palletizers for cases
• Pallet transfer
• Stretch wrapping