Packaging Line Concepts blisters/min Fast changes of the batches/ param eters

Transcription

1 Automation ti of Packaging Machines

2 Packaging Line Concepts 1300 blisters/min Fast changes of the batches/ param eters

3 Complexity of Interelationships

4 The machinery market is in transition New trends are being born Consumer behavior is becoming increasingly individual Changing forms and designs Lower production costs Implementing new regulations e.g. FDA New challenges for packaging machinery construction Mechatronics Individual drives, intelligent motion control Higher flexibility Short re-equipping times, online recipe change Modularization Simulation Shorter time-to-market

5 Packaging Variety is increasing!!!!

6 What is meant by Motion Control? Motion Control is the complete motion management for a single or a multiple number of axes within a plant or a machine.

7 The answer: Mechatronic solutions Mechanical solution Mechatronic solution intelligent m otion control,

8 From Mechanics to Mechatronics (film)

9 Motion Control Functions Positioning Gear Cams Cam switches Print-mark synchronization Coupling-in/ coupling-out

10 Motion Control in Packaging Labeller Blister Pick & Place Fillers Strech Wrapper Cartooner Shrink Packing Palletizer

11 Basic Automation Structure for a Machine A Motion Control S ot o Co t o System!!!!

12 T t ll I t t d Totally Integrated Automation

13 The automation environment Yesterday Yesterday PLCs PCs Distributed Safety Technology Central Automation Production Process Di Drives

14 Approaching a solution in automation engineering Uniform system architecture is the basis for integration Process control system Human machine interface Controllers Distributed I/O Data ma anagement Configuring/ /programm ing Commu unications Drives / field devices

15 The end of technology breaks: Totally Integrated Automation TODAY of the entire total integration automation environment of an organization

16 Approaching a solution in automation engineering Uniform system architecture is the basis for integration Process control system Human machine interface Controllers Distributed I/O Commu unications Drives / field devices

17 Profinet The Communication Backbone PROFINET - The Industrial Ethernet Standard for Automation Data I/O Motion Safety Process For all applications For the entire work flow For all branches

18 PROFINET -- The open Industrial Ethernet Standard Open Industrial Ethernet 02. / - Standard /

19 Approaching a solution in automation engineering Uniform system architecture is the basis for integration Process control system Human machine interface Controllers Distributed I/O Simatic Portfolio Commu unications Drives / field devices

20 Vertical integration ERP, e.g. SAP Management level (MES) Operation level (SCADA / DCS) WinCC PCS 7 Control level Field level Reduce interfaces & costs of engineering Increase the intelligence of the automation Optimize and speed up the production transparency

21 Horizontal integration e.g. SAP, Navision, etc ERP SIMATIC IT MES Enterprise Asset Management Plant Maintenance Management Plant Information Management Management Level Process control system PCS 7 SCADA Operations Level Inbound logistics Process Supplier Customer Discrete Outbound logistics Control Level Field Level Integrated engineering, diagnostics, communication and products Transparent information from the automation system Cost reduction for spare parts and resources

22 Approaching a solution in automation engineering Uniform system architecture is the basis for integration Process control system Human machine interface Controllers Distributed I/O Simatic Portfolio Configuring/ /programm ing Commu unications Drives / field devices

23 Customer requirements for engineering Market situations and customer requirements go hand in hand Tasks are growing increasingly complex The only way to meet these market demands and customer requirements is to integrate and achieve consistent approaches throughout all automation applications

24 The response Totally Integrated Automation Portal One framework The total integration of necessary tools and technologies, such as PLC, HMI and drive technology programming into one single platform TIA Portal an engineering g framework that will make a difference The 3 main objectives for TIA Portal were: Intuitive, efficient, proven

25 Benefits of Totally Integrated Automation Portal all integrated software products share uniform services provided by the engineering framework Data consistency through out all editors significantly reduces errors and saves time a single and consistent look and feel of all software products makes them easier to learn and more intuitively to use

26 Approaching a solution in automation engineering Uniform system architecture is the basis for integration Process control system Human machine interface Controllers Distributed I/O Simatic Portfolio Configuring/ /programm ing Commu unications Drives / field devices

27 T k & T i Track & Trace in Packaging Lines

28 Challenges and requirements in the market Comply with legal and consumer protection requirements (e.g. EC 178/2002) Recall of specific and differentiated range of products Ensure not to have wrong deliveries Increase protection of public health and safety Identify the origin of an individual product/ingredient and to whom a product has been supplied (one up/one down traceability) Enable unique identification and seamless monitoring of intermediate and end products Brand protection - especially for valuable products in order to avoid counterfeits Optimization of the production and logistics process Comply with customs and tax regulations Ensure trouble-free and traceable cooperation and collaboration between all parties involved, both in-house and with external partners Pressure of retailers (like Walmart and Metro)

29 Tracking g& Tracing of products along the supply ppychain from production to the consumer Tracking & Tracing (T&T) is the action taken to track and trace products: internally - within the production site and/or externally - along the complete supply chain Supplier Raw Material Intake/ warehouse Filling/ Packaging Production Distribution Finished Product Ware house Retail Consumer External T&T Internal T&T External T&T Forward/Downstream T&T (from raw material to product) Backward/Upstream T&T (from product to raw material) T&T is based on traceability-data that is generated during the production process. This data provides information about the genealogy of the product. Various AutoID technologies are used for the tracking & tracing solution such as RFID, Data Matrix Code and Bar Code.

30 The internal T&T starts with the material intake and continues in the production process Internal T&T - Raw Mat. Intake/Production = Affected shipment, raw material, pallet Starting Point Identification Track forward Block shipment Identification of bad quality in a delivered raw material or intermediate product Identify all affected shipment units (e.g. via pallet identification) Identify all affected batches via genealogy (e.g. intermediate products, blending, packaging) Block shipment units still in warehouse. Recall affected deliveries Affected shipments/raw materials are identified within the production process at the starting- /delivery-point. These raw materials are tracked though the primary and secondary production (e.g. mixing, blending). At the end of the process affected finished products can be blocked in order to avoid their delivery or tracked & traced through the external supply chain.

31 The product hierarchy is provided through the entire internal T&T Internal T&T - Filling/Packaging g g * RFID or other AutoID technologies (such as bar code, data matrix code etc.) 1 AutoID Tag* (inside) package Packaging machine 4 Shipping gate AutoID Tag Read pallet at the on the package goods issue and create ASN 2 Combine packages to a case with an AutoID Tag on the secondary package 3 Combine cases to a pallet with an AutoID Tag on the pallet The T&T solution does consider all product hierarchies from the single item to the pallet. The product-hierarchy functionality is not limited to the filling/packaging process but applicable within the entire T&T.

32 External T&T provides the traceability of products within the supply chain External T&T Supply Chain External T&T Internal T&T External T&T Starting Point Identification Track forward Bloc shipment Suppliers Identification of bad quality in a delivere d raw material or intermediate product Identify all affect ed shipment units (e.g. via pallet identif icatio n) Identify all affected filling batches via genealogy ( Block shipme nt units still in wareh ouse. Recall affecte d deliveri es Wholesaler Retail ID Points AutoID Identification points (e.g. at supplier, wholesaler, retail) provide data for the T&T along the supply chain. The data captured at the ID points can be provided to the manufacturers ERP system of the manufacturer in order to have a complete internal and external T&T.

33 Track and Trace Packing Line OPL Architecture Plant Line Server Line HMI WinCC/ Web Navigator Backup&Recovery ADDM Overview Station Mobile Overview Station High Performance Wireless PC WinCC Web Client Line Overview Line Switch SCALANCE X414-3 Security Switch INTERNET SCALANCE S Optional External Access Diagnosis-Maintenance Station Engineering Station Panel PC6x7B Touch, 15" SIMATIC PG WinCC SingleStation Engineering Software SCALANCE W788 Beverage Proc Local HMI Panel Machine PLC Machine Switch Labeler Filler TopConveyor Palletizer Wrapper Panel PC6x7B WinCCflexible CPU319-2PN ET200S CPU Panel PC6x7B WinCCflexible CPU319-2PN SIMOTION D445 SCA- LANCE X204-2 TP177B WinCCflexible CPU315-2PN Panel PC6x7B WinCCflexible CPU319-2PN CPU315-2PN Microbox PC420+ FlatPanel, WinCCflexible Sub Machine Motion Control MV440 1D/2D-reader, IP65 PROFINET RF180C Connection block e.g. RF620R RFID reader Read/write distance 2 m

34 Track & Trace solution Line controller package already available 10,4 or 15 Touch Panel Track & Trace controller box Ethernet Network Site Level Label Applicator and Printer RFID or DMC reader Input Label Input Reader Printer / Applicator e.g. PROFINET Controller Power Supply I/O Output Label Applicator and Printer Output Label Printer / Applicator e.g. PROFIBUS DMC reader or Barcode Scanner Output Reader Connected via Bluetooth / USB to CMC Controller Handheld Reader (optionally) Power Supply for Controller and Devices Optionally: Additionally signals Packer I/O These devices can also be connected to an existing PLC! For each level, l e.g. bundle to case, one of these T&T line controler can be used! It is also possible to connect all reader of a complete line to one controller with one HMI

35 Use Cases and Tasks Trace production Reading a DMC is done on each level. Highest speed the packaging machines have on item level with a maximum speed of 400 items / min. OEMs have machines, that are much faster, but this high speed is not used by the pharma end customers. Read DMC on item level (single DMC) on bundle/case level (single or bulk DMC) on palette level (single DMC) Control DMC marking quality The difference of reading and verifying is, that the quality of the DMC is controlled. Several parameters of the code are checked, described later in this document. Verify DMC on item level (single DMC) E Pedigree Siemens solution for pharama industry Trace plain text Reading human readable text, is only needed on item level. VS72x can be used for that and in the future MV440-OCR. Preferably OCR-B text shall be used. Read DMC and/or human readable text on item levell

36 The AutoID/RFID T&T solution provides interfaces to MES and to ERP (i.e. SAP, etc.) External T&T SAP OER SAP ERP SAP AII / XI Internal T&T SAP AII / XI other ERP Functionalities & Benefits of the solution Integration to SAP ERP dependent on business workflows: if external T&T may interface directly SAP AII if internal T&T, contextualization to MES data is made by SIMATIC IT Possible cross entity integration via SAP OER. D T&T Solutio on AutoID/RFI SIMATIC IT AutoID/RFID Core Solutions Interface I t f to 3rd party systems Device Management (Siemens & Non-Siemens) Data management / Business logic AutoID Devices: RFID Tags/Readers, Data Matrix Code, Bar Code Scalable, modular and flexible solution based on a standard platform Identification of objects basing on the EPCglobal standards (EPC, EPCIS, UID, etc.) Device- and data-management for SIMATIC IT and AII Interfaces with SIMATIC IT for Manufacturing operations AutoID devices are managed by the AutoID/RFID Core Solutions.

37 Benefits Higher product safety to improve the protection of your brand, your customers and the consumer of your products Faster recall capability Reduction of administrative cost Flexible response to rising market requirements Increase efficiency of tracking and tracing operations Better governance of quality operation Reduction of scrap and rework

38 Benefits unique selling proposition Siemens offers the only all-in-one Tracking & Tracing solution available across the world Siemens is one of the world largest Tracking & Tracing product manufacturer Many years of experience in the realization and use of Tracking & Tracing solutions Complete solution from hardware through MES System, systems integration and operation to process consulting Ready to use solutions for all steps the product life cycle Fast roll-out and high quality

39 Thank you Name: Prasad K.Raverkar Department: I IA AS BD Phone: Mail: prasad.raverkar@siemens.com