More efficiency and transparency? You can get there. Optimized Packaging Line Answers for Industry.
When it comes to packaging lines, the name of the game is to connect machines from various manufacturers. The consequences frequently include high integration costs, longer production ramp-up times, and poorly defined responsibilities between the various OEMs. In addition, these types of diverse automation environments frequently result in higher maintenance costs and in turn, higher operating costs. We have not even touched on the lack of transparency and high service costs resulting from malfunctions and timeintensive troubleshooting. Siemens provides an intelligent response to tackle these challenges Optimized Packaging Line (OPL). 2
Optimized Packaging Line intelligently addressing complex challenges The vision: consequential standardization High production rates with maximum flexibility are expected from state-of-the-art packaging machines and lines. OPL was developed to address these requirements an innovative solution with a modular approach. It creates the basis to significantly reduce the total cost of ownership, increase the long-term security of investment and optimize productivity and quality. The concept: a modular system OPL is a comprehensive concept for the automation of packaging lines where significant cost savings can be achieved by using standards and software blocks. This permits seamless automation of packaging machines and lines, therefore fulfilling the prerequisites for straightforward, fast and cost-effective implementation of solutions with a high degree of innovation potential. Based on Totally Integrated Automation, our open system architecture for seamless automation, OPL integrates the complete packaging line by employing common automation and communication standards. Right from the start, minimizes the lifecycle costs and complexity of the complete plant or system. As a consequence, our well conceived concept creates the basis to fully leverage the optimization potential over the complete lifecycle of a packaging line regarding productivity, flexibility, reliability and energy efficiency. When all is said and done, OPL plays a decisive role in sustainably improving your competitiveness. Diverse machines with no data interfaces 3
Advantages down the line With OPL, you profit from a scalable line overview combined with a standard operating concept for diagnostics and maintenance. This means constant access to your system s status provided by a seamless flow of information. The resulting advantages are enormous: Machine data and diagnostics information are defined according to international standards and used in the line overview for evaluation purposes. Optimized Packaging Line: highlights at a glance Improved plant availability through more transparency Increased efficiency through reduced complexity Lower lifecycle costs through enhanced efficiency and transparency Shorter time to market through faster engineering 4
Scalable operator control and visualization based on standard machines along the complete line The strategy: seamless standardization OPL significantly speeds up machine to line integration through simpler interconnections and more clearly defined responsibilities between machine builder and integrator. Risks in the ramp-up phase of a packaging line are minimized while overall maintenance and expansion are simplified. Beyond this, customers are supported with a comprehensive range of training courses. Training courses are perfectly coordinated to address your requirements as machine builder or user. All of these factors not only significantly increase your level of effectiveness, but also decrease time to market as a result of shorter commissioning times. OPL consequentially uses and implements international standards including Weihenstephan and OMAC. In addition, preconfigured and tested standard functions are supplied. When applied, machines are integrated into lines more simply and quickly. Communication via PROFINET is also defined as standard plantwide interfaces for messages and alarms provide a seamless safety and operating concept. 5
Increased plant availability through improved transparency Weihenstephan standard and OMAC guidelines: linking elements between the production control and machine levels Through well-proven and communication capable components, OPL facilitates well-founded diagnostics of status messages and system faults. From the network via PC s and controls as well as connected sensors and actuators up to motion control, all enjoy the benefits of these standardized components. Simply better diagnostic functions When it comes to the line integration, OPL paves the way for fast, consistent and reliable display of the system faults and status messages, without high engineering costs. The consequential standardization of all systemrelated components permits a level of diagnostics which was previously unachievable. All components speak the same language. Interfaces and network connections are primarily designed for bidirectional communication, which means the complete topology of a machine can be read at the press of a button. Furthermore, line efficiency can be automatically monitored and provide detailed information at the module level, making it easier to identify bottlenecks regarding quality, performance and downtimes. This permits a fast response to minimize downtimes and optimize quality. 6
Central line overview and userdefined analysis of production data Simply less maintenance costs The diagnostic functions of OPL certainly pay off over the complete lifecycle of a plant or system in the form of significantly higher availability and reduced maintenance costs. If a fault occurs at a specific location in a plant, or if a fault message is output, the responsible parties are immediately notified either locally or via remote access with a mouse click as to which machine or component is involved, which material will soon be missing and which serial number and software version the spare part must have and more importantly, the precise location of the fault or disturbance. Faults can be quickly and efficiently tracked down and resolved with this enormous plantwide transparency. This also creates the prerequisites for proactive diagnostics, an efficient way of completely avoiding plant downtimes and the associated replacement of components. In addition to pure calendar-based maintenance, planning tools such as PM-MAINT used in the production environment provide real performance and event-driven maintenance. Simply integrated solutions Based on standardized data interfaces, OPL provides a modular system of special, independent products to achieve a high degree of process transparency. These components help to achieve maximum production performance and quality and effectively monitor quality data as well as operating information. For instance, the LMS (Line Monitoring System) provides dedicated functionality and a graphic user interface to analyze the efficiency of the production system and perform cause analyses. For example, data acquisition and compression in OEE KPIs, including availability, performance, quality, OEE as well as additional customer-defined KPIs. Simply easier coordination The Line Control Unit (LCU) coordinates the various machine states and speeds. By avoiding unnecessary start/ stop operations, LCU helps to establish an optimized product flow. A controller specifically developed for the purpose ensures that the LCU is also in a position to integrate transport systems and conveyors, which are not assigned to specific machines. The functions of LCU at a glance: Starting/stopping lines Setpoint speed of the line Buffer management 7
Increased efficiency through reduced complexity As a result of component standardization, OPL reduces the complexity of the complete line. The resulting advantages are enormous in each phase of the plant or system lifecycle. These advantages extend from increased efficiency through perfect interaction to lower costs and expenditure through higher level of standardization. Reduced complexity lower costs With OPL you profit from a lower range of different components. This simplifies maintenance, minimizes spare parts and stocking and shortens maintenancerelated downtime. OPL can significantly reduce your training, maintenance and engineering costs, which in turn sustainably reduces your overall costs. We are happy to calculate your cost saving when using OPL: Through our benefit calculation tool you obtain clear, concise results within the context of analysis precisely harmonized to your plant or system. More standardization lower costs Standard blocks according to definitions of OMAC packtags and Weihenstephan standards for the SIMOTION motion control system and the SIMATIC automation system offer standard interfaces for all packaging machines. This is the way how communication from machine to machine and from the machine to the MES (Manufacturing Execution System) is realized. And quickening construction, commissioning and line integration for machines while simplifying operation, maintenance and diagnostics standardized and data links to supervisory computers and the IT system. The use of open, standardized software structures minimizes engineering, maintenance and integration costs. Preconfigured software libraries and blocks for basic automation tasks (e.g. for handling modules), which are simple to adapt, reduce the amount of application software required. This increases the reliability of machines. 8
Higher operating reliability higher productivity A practical user interface design has been a decisive quality feature of state-of-the-art machines for a long time. This is the reason we worked closely with machine OEMs and end users to standardize the navigation and operating areas. User-friendly HMI templates and a library of icons were the result of this collaboration. This led to minimized training costs, downtimes and waste due to incorrect operator actions. Furthermore, this secures a significantly more consistent production rate in multi-shift operation with operators of varying qualification levels at the machine. More reliability more safety Maintaining control over production has topmost priority in the automation environment. The network and security concept of OPL supports you when implementing a reliable network. Star as well as ring-type structures and ringtype redundancy are available. Services and appropriate industry products, such as managed SCALANCE X switches, ensure that only authenticated users can access secure operations. This also applies to remote access via crsp. More up to date better overview With OPL, complex version checks and updates are a thing of the past, making it easier to comply with legal stipulations (audit trail, user management etc.). Our innovative and extremely reliable solutions for tracking and tracing provide clear product identification and traceability in compliance with international regulations. 9
Higher energy efficiency higher productivity For industry, energy efficiency represents a challenge and an opportunity: Systematically leveraging all of the energy saving potential available is an effective strategy to increase competitiveness over the long term. We can support you in achieving this objective with our extensive portfolio for operational energy management. Identify, evaluate and realize We address this topic comprehensively and systematically. We consider energy management as a process, which we subdivide into three phases: In phase 1, all energy flow in the system is documented and displayed, based on usage and associated costs. In this way, you obtain an extremely high degree of transparency of all of your energy flows. In the next step, results from phase 1 are systematically analyzed to evaluate suitable optimization measures. During phase 3 all measures are implemented. Within the context of our portfolio, we provide detailed concepts including leading-edge systems and products, which play a decisive role in reducing energy usage. Special emphasis is given to the drive technology, as this represents approximately two thirds of the electrical energy consumed by industry as a whole. Lower consumption, feedback energy For processes involving lots of moving parts and components, OPL facilitates the highest degree of efficiency with significantly lower lifecycle costs. This is achieved through energy-saving motors with matching drive technology capable of energy recovery, such as SINAMICS S120 drives. As a consequence, braking energy and reactive power can be utilized within the DC link and fed back into the line supply without any harmonics. This is realized using our Active Line Module (ALM). 10
Safety first Based on Safety Integrated, safety functions can be realized with the highest degree of flexibility but minimum engineering and wiring costs. To do this, OPL offers concepts and support when creating safe machines and production lines based on fail-safe products. The safety functions of SINAMICS drives prevent potentially hazardous motion from the very start. For more advanced safety functions, the drive position control remains fully active: This is not only decisive for quickly restoring operation but also in the setting-up and test modes with the protective door open. The advantage for you: shorter downtimes and less waste and therefore higher productivity. 11
Shorter time to market through accelerated engineering Today more than ever before, time to market plays a key role for the success of a company. As a result, engineering is becoming increasingly more significant: You have a clear advantage over your competitors if you can minimize production time without sacrificing quality. Here, we can provide our technical expertise and know-how with our easyproject project generator. Quickly and simply implement projects By using libraries and functions, the project generator allows completely new projects to be generated. It also allows individual libraries to be integrated into existing projects. For instance, it uses the OMAC library and generates machine projects including horizontal and vertical communication as well as the mode & state manager. In addition to the basic data interfaces for communication, the project generator includes many additional features so that individual machines can be simply integrated into the OPL line overview. The result: standardization of all machines on a high-performance automation system and operating concept. Web servers with OMAC pages in the controls simplify diagnostics, permit preliminary tests and slash engineering costs when integrating machines into a line. A loadable and runnable project is created with just a few clicks by simply selecting SIMOTION components with the required standard and user-specific modules Open for expansion You have the opportunity to integrate your own blocks and mechatronic modules while adapting existing ones Modular machine functions Simple and standard machine structures by modularizing machine functions based on functional units in compliance with the international ISA-88 standard Project Generator Axis Function Block Message Handling Interpreter Communication LCom OMAC OMAC Edit 12
OPL project generator Experience more about the OPL project generator on our mobile website Build on experience and competence Our many years of experience in the widest range of sectors combined with our comprehensive application know-how for packaging solutions are firmly embedded in OPL. Comprehensive software libraries, sample applications and best practice examples for plants and machines have been harmonized to create a seamless and standard- ized overall system. This includes high-performance hardware and software components for packaging-related automation tasks. The result: Highest degree of seamless integration over the complete packaging line, which, through the modular structure, can be adapted to current re-quirements at any time. kwh DRIVERS www WS Machine Energy Acquisition OMAC PackTags data interface L Drivers SIMOTION IT web pages WS Edit Foil feed DPV1 START UP Line Integration Tool LDPV1 OEE Format-Handling Intelligent Infeed Startup Check MOMA LCU OMAC LMoma Line Control LCU Dosing Intelligent Belt Cartoner OMAC mode & state manager 13
Lower lifecycle costs through comprehensive support The purchase of machines and equipment represents only 20% of the complete lifecycle costs of a plant or system. This is why costs for integration, power and spare parts must be considered when evaluating packaging machine and line costs. This is the reason that it would not be correct to evaluate packaging machines and lines exclusively as a result of their capital investment costs. Rather, costs for integration, power and spare parts must also be evaluated. The complete range of services from a single source Project manual that defines the scope of the standardization: specification, component list, machine architectures, software libraries, standard user interfaces, documentation and program management Comprehensive support based on our global network of application centers: conversion service for machine OEMs, local support, training, back-office support center, compatibility tests and project coordination Close collaboration between project coordinators, machine OEMs and companies operating the machines: plant and system planning and gap analyses, project coordination, online knowledge platform, commissioning support for operating companies, operator training and OPL partner database 14 A high percentage of your capital must be employed to run the plant or system on a day-to-day basis
Competent partnership from A to Z We provide our experience and competence for your project, with one objective: To help you handle increasing complexity and improve the efficiency of your engineering process. You also reduce your global support costs through our infrastructure. Competent support worldwide We support you in the complete process of OPL-compliant automation. A project team made up of specialists in packaging automation and personnel from application centers locally support your project. This starts in the planning phase and extends over the complete runtime. This secures the highest degree of consistency, irrespective of the machine manufacturer. You can count on our support when integrating machines into your lines, regardless of your location 15
Get to know more: siemens.com/opl Optimized Packaging Line. Decisive advantages through continuous standardization Significant reduction of the total cost of ownership Increased long-term security of investment Harmonization of interfaces More about OPL: Visit our mobile website. Subject to change without prior notice Order No.: E20001-A1480-P620-V1-7600 DISPO 06372 WÜ/48590 B1VE.52.3.04 WS 09132.0 Printed in Germany Siemens AG 2013 The information provided in this brochure contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract. All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners. Follow us on: twitter.com/siemensindustry youtube.com/siemens Siemens AG Industry Sector Motion Control Systems P.O. Box 31 80 91050 ERLANGEN GERMANY