Opgradering og udskiftning af produktions it og automation

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1 Opgradering og udskiftning af produktions it og automation Seminar nr. 101 Lemvigh-Müller A/S Nordager Kolding 6 December 2012 Opgradering og udskiftning af produktions it og automation Lars Vilandt Arla Foods Arla IT - Head of Manufacturing Consulting Main Phone: Mobil / Phone: lavi@arlafoods.com 2 1

2 Dagsorden Oplæg Case Opsummering 3 Strategisk ambition

3 Tættere på Naturen i alt hvad vi gør 5 Omsætning

4 Omsætning fordelt på markeder 7 Omsætning fordelt på produktkategorier 8 4

5 Andelshavere og indvejet mælk Facts ca. 1/3 af denne mælk skal sælges på det frie marked. 9 Mælkeprisen 3. december 2012 Arlanoteringen er 286,9 øre/kilo konventionel mælk og 341,9 øre/kilo økologisk mælk. 10 5

6 NEW Production IT Strategy Production IT Strategy for Arla Supply Chain Strategic direction 2017 Owner: Supply Chain Board Version Production IT Strategy 2017 Strategic ambition Ensure optimal utilisation of Production IT in Supply Chain 1 CAPEX project 2 24x7 Solution 3 Improvement Services Care Services Master Plans CAPEX project support Production IT project managers pool IT-Surveys Proactive Solution maintenance 24x7 Application Support Shared Services OPEX/LEAN support SPC/APC LRM Energy Management 4 ONE Production Solution ONE Delivery model 6 5 ONE Automation Solution ONE Funding Model Our Character (LEAD, SENSE, CREATE)

7 Site A Site B Site N Best Practice Replication Best Practice Replication ONE Production IT platform Centralized IT systems E.g. SAP Site specific IT Systems E.g. MES, SCADA and PLC SAP Application Production Production Solutions Production Application Production Application Application Production IT.. SCADA Koncern netværk Automation PLC PLC Automation Solutions Automation Application Automation Application Application MES ERP Fabriks netværk Fortrådning Fieldbus / sensor bus Remote I/O Proces netværk Field netværk Best Practice Replication and Standardization 13 - ONE Production Solution Production Reporting Line Management System Recept Management System Efficiency Management System Manufacturing Integration and Intelligence (SAP MII) Energy Data Collection Statistical Process Control / Advanced Proces Control Warehouse Control System Automatic Guided Vehicles Control System Manufacturing Execution System Human Machine Interface System Database Invensys Wonderware Archestra platform PLC Proces Interface Machine Interface (PackML) Printer Interface Scanner Interface Weight Interface Instrument Interface x x Arla standard software application. Application owner and responsible for consulting and implemention. Standard software platform. Product owner and responsible for consulting and implemention. x Non standards. Only Product Owner In future development according to a product roadmap.. x Arla standardisation in progress. Only Product Owner In future development according to a product roadmap

8 Scoping Production IT Supply Chain Processes: Forecasting, Planning & Scheduling Farmers Milk Allocation & Collection Production Management Innovation Management Quality Management Energy Manage ment Plant Maintenance Performance Manage ment Warehousing Distribution Production Solutions TACO solution Production IT Process Orders SPC/ APC Production Data Cockpit Data coll. & Labelling Data collection Data coll. & Labelling OEE solution Ware house Execution Automation Solutions Utility systems (energy, air, water, cleaning) TACO computer Auto mation Instrument Instrument ON/Atline All systems.. Automation Automation Robots & AGVs

9 Oplæg Hør om udskiftning af styresystemet på et helt mejeri. Der er tale om udskiftning af et DCS system til et traditionel SCADA/PLC system. Hør om de tekniske udfordringer, og hvad det kræver organisatorisk at gennemførere en så gennemgribende udskiftning af styresystemet. Få et billede af hvorledes udskiftningen af automationsløsningen bliver koordineret og styret i forhold til den fysiske proces. Der vil komme eksempler på hvorledes automations designet og processen designet i det opgraderede system bliver opbygget for at sikre oppetid. En opbygning der sikre at automations systemet fremadrettet kan stepvis opgraderes uden at have væsentlig indflydelse på produktionen. 17 Case Vimmerby Arla Foods Vimmby history The Vimmerby plant was scheduled to produce approximately 44,000 tons milk powder annually from the 380 million kg milk corresponds to 20% of Arla Foods total milk volume in Sweden. The Vimmerby plant started proper production on December 23 december 2004 when the new plant started to process 800,000 kg milk per day. The plant was, however, not expected to work at full capacity before April Arla Foods has invested approximately DKK 800 million in the new plant which will eventually employ a workforce of December

10 Case Old DCS System Back ground The Automation system at the Arla Foods Vimmerby plant was built on a Distributed Control System (DCS) delivered by Rockwell. Shortly after the plant had started production in year 2004 it was announce the DCS system only would have a limitied life cycle period due to a break with Honeywell Automation, on which the DCS system has been foundated. Present situation Overall it was stated from Rockwell, that they within a few years from now, no longer sees any possibilitys to support operation of DCS system. It was also stated, that specifice the system within the Wet area did not have capacity for future expansions. A replacement of the DCS system was therefore necessary. 11 December Case Projekt model og aktiviteter Phase Exploration Initiation Preanalysis Contract Analysis Selection Design Accept Implementation Handover Evaluation Closure Do the right thing - make it right Idea Analysis Planning Implement Termination Idea tools Idea assessment Goals and needs Stakeholders Uncertainty Resources Requirement. specification Project description Agreement with. project manager Project organisation Milestone schedule Costing estimate Budget Top 10 risk Management Idea tools Communication Make decisions Evaluation Change handling Quality assurance Top 10 risk Project history End documentation Follow-up plan Stop/Go/Hold/Recycle Gate rapport to steering group or Project committee 20 10

11 Case Projektets formål This project plan high light the overall goals needed for replacement of the existing Automation platform in Arla Foods Vimmerby to a future setup, that is align with standars, used within Arla Foods. Main deliverys for the project must focus on: A solution that ensures a flexible and easy production. A solution in which it must be fast and easy to implement changes or adjustments of tomorrows requirement, to the product that has to be manufacturd on the plant. A solution that contain reporting tools for online KPI, and benchmarking. A solution that contain OEE and Pavilion integrated tools, to ensure capacity utilization. A solution that contain full electronic material trackning/traceability and consumption reportning via MES to SAP R3. A solution that has a high uptime and can be maintained/supported locally by resources at the plant or within Arla Foods. A solution that are cost effective during the entire life cycle. 21 Case Definere opgaverne i projektet A steerable project: Meets a specific need Has a set of clear targets and success criteria Has a realistic plan - both in relation to time and resources Has built-in milestones and some clear status points Is aware of the status / attention points and has a plan B and C ready Clar communication and responsibility roads Has a plan for change management Has a good captain and crew on board! 22 11

12 Case Fastlæg roller og ansvar Sopnsor - Financing and supporting the project - Etc Steering Group - Representative from contractor and Arla Foods supporting the project manager with decisions on management, legael and financing issues. - Etc. Project Manager - Goals and needs - Stakeholders and communicationplan - Resources plan and organisation - Project description and top 10 risks - Budget and cost extimates -Time schedule, milestone plan and reporting - Etc. Reference Group -Representative from contractor and Arla Foods supporting the project manager and project teams with technical, legael and project execution issues. - Etc. Automation - CLX & HMI: (LevMatrix= 1,6,7,8,9,10,11,12) Hardware for control system - PLC & HMI applications - Process functionality - Etc December Manufacturing Execution Systems (LevMatrix= 1,2,3,4,5,6,7,9,11,12) - Order handling and execution - Recipe handling - Production data for KPI and quality - SAP data and interface - Production report - Etc. Infrastructure (LevMatrix=10,12,13) - Virituel serverplatform - Back up and restore - Network - IT security - Wireless - Etc Fastlæg hvad er inkl. og eks. leverance 24 12

13 Case Tidsplan, hold fast 4. Milestone 5. Milestone 6. Milestone 7. Milestone Factory test accepted Site implementation start Full production Hand over part 1 2 & 3. Milestone More activities within the detailed activity plan approved End of Evaluation Phase 1. Milestone Letter of intent - Automation End of Implementation Phase End of Design Phase Plan Do End of Analysis Phase Act Che ck 25 Case Forstå forretnings behov Supply Chain Processes: Milk allocation & collection Plant Maintenance Forecasting, Planning & Scheduling Production Management Quality Management Manufacturing Execution & Optimisation Warehousing Distribution Marketing & Innovation Customer Relations Management Sales Planning Forecast Suppliers Production Warehouse & Distribution Customer Consumer 26 13

14 Case Løsningen 27 Case Opsummering # 1 There are plenty of project managers who belive, that nine women can have a baby in one month. Lav planen og hold fast. Sørg for at få knyttet de rette kompetencer til projektet. Sørg for at få ledelsen involveret i projekt afviklingen

15 Case Opsummering # 2 Skab rum for at alle i projektet får mulighed for at lufte deres synspunkter

16 Tak for opmærksomheden Lars Vilandt Telefon: