DAu konference - september 2013 Sådan sikres ensartet kvalitet i MES applikationer implementeret på 70 Arla mejerier Allan Møller Schmidt, Solution Consultant Arla Foods GBS-IT, MSA 23-09-2013
Tema - Rejse 23-09-2013 2
Agenda Introduktion Rejsen mod ensartet Arla standard MES løsning Hertil Fremad Arla produktions IT strategi 2017 Erfaringer / konklussion 23-09-2013 3
KORT OM ARLA 23-09-2013 4
Arla i korte træk Ejere: 12.256 Mælkeindvejning: 10.410 mio. kg.* Produktion i 12 lande Produkter sælges i mere end 100 lande Omsætning: 63 mia. DKK Medarbejdere: 18.112 23-09-2013 5 *Heraf 2.881 mio. kg. der ikke er ejermælk
Arlas udvikling siden 1970 1970 2000 2011 2012 Arlas tre globale brands: 23-09-2013 Kilde: Arla Foods, februar 2013 6
De tre fokusområder i Strategi 2017 Udvikle kerneforretningen og de tre globale varemærker Vækst på markeder uden for EU Mere effektiv i hele værdikæden 23-09-2013 Kilde: Arla Foods 2013 7
REJSEN TIL NU 23-09-2013 8
MOTIVATIONEN for at standardisere Proprietary Solutions Open Standards SAP R/3 MM PP-PI QM PI-PCS SAP R/3 MM PP-PI QM PI-PCS SAP Business Connector / XML ISA-95/WBF standard (B2MML XML) MES System X Plant A,B,C.. MES System Y Plant M,N,.. MES System.. Plant.. MES/ PCS MES/PCS Plant X MES/PCS Plant Y MES/PCS Plant.. PLC PLC PLC PLC PCS 23-09-2013 9
System landskab i Arla Process optimisation applications Online SAP near-infrared instruments & applications Weighing systems, Cleaning optimise, Permance & downtime software ETC.. ISA S95 OEE Downtime Maint. measure Energy & Environ. Manufacturing Applications (The MES area) ArchestrA ArchestrA ArchestrA ArchestrA ArchestrA ArchestrA Foxboro Other.. Operator SW/HMI IGSS FIX SattGraph WW IGSS P-net /? Foxboro Process control Siemens Siemens SattCon Siemens SattCon Siemens P-net/Siem. Foxb/Siem SITE1 SITE 2.. SITE 99 23-09-2013 10
Arla Produktions Server Arla Foods term for software og hardware komponenter nødvendige for at kunne levere MES og SCADA funktionalitet på en ensartet måde til enhvert mejeri. 23-09-2013 11
Historian ERP SAP MII Integration (B2MML) MII Web service RMS (MII Client) Reporting Brugerflade (ordrehåndtering, rapportering) LMS (MII Client) EMS (MII Client) Recept Recipe DB Site DB MES Web service MES 4.0 MES DB Job Queue OEE Prod DB Sporbarhed Job afvikling Efficiency DB IAS PEM (Object) OCO (Object) IAS_Queue (Object - per entity) Historian DB (runtime) EMO (Object) Dispatcher (Object) PLC_Queue_Sequencer (Object) IAS_Queue_Sequencer (Object) SCADA objects PLC PEM_Queue Arla developed component Integration PLC_Queue 23-09-2013 12 (PackML) Standard component SCADA IAS/PLC control modules System/Program
Production Data Warehouse KPI benchmarking Ad hoc Analysis Reporting Data mining KPI definition Production Aggregering Data Warehouse Standard information model Site DB Efficiency DB Recipe DB Historian DB (runtime) Prod DB MES DB Arla Production Server 23-09-2013 13
1 portal til rapporter & analyser 23-09-2013 14
REJSEN - HERFRA 23-09-2013 15
Timing 2004-2011 Production-IT, meget teknologi orienteret Nov. 2011 Supply Chain Board kræver ny klar strategi Det er tid til standardisering på på tværs af Arla Foods Strategi proces Jan. 2012 > Okt 2012: Version 1 godkendes ONE Production Solution Automation afsnit tilføjes Jun. 2013: Version 2 godkendes ONE Automation Solution 23-09-2013 16
Scope for Produktions-IT i Arla Foods: 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 IT Production Solutions 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) Auto mation Instrument Instrument ON/Atline All systems.. Automation Automation Robots & AGVs. 23-09-2013 17
Site A Site B Site N Best Practice Replication Best Practice Replication Best Practice replikering - ONE Production Solution Production Reporting & DWH 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 23-09-2013 18
Site A Site B Site N Best Practice Replication Best Practice Replication Best Practice Replikering - ONE Automation Solution PLC Proces interface Machine Interface (PackML) Printer interface Scanner interface Weight interface Instrument interface Process Area Packaging, Filling & Warehouse Area HMI SCADA PLC Process interface PLC PLC PLC WW Intouch Siemens, Rockwell HMI SCADA Line Master PLC Machine interface (PackML) WW Intouch Siemens, Rockwell I/O I/O I/O PLC Standard Machine PLC Standard Machine PLC Standard Machine 23-09-2013 19
Produktions IT Strategi 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 23-09-2013 ONE Production Solution ONE Delivery model ONE Automation Solution ONE Funding Model 5 Our Character (LEAD, SENSE, CREATE) 20 6 7
SolutionQA - Mål Kvalitetssikring Sikre best practices Ensartede standard løsninger Minimere risiko Let at supportere Feedback Til One Production solution (Arkitekter) Til Supplier Relations Up-to-date standard 23-09-2013 21
SolutionQA Hvornår? Design review FDS review Komplekse/strategiske projekter: Arkitekt på hele vejen Tager eksisterende app med i vurderingen HOTO review Ensartet HOTO proces for projektoverdragelse til drift/support Sikre at den modtagende organisation er klar til at overtage projektet Site og support 23-09-2013 22
Udfordringen: Kommunikation! Internt 7 Business Groups på BG-ledelses, mejeri-ledelses og teknisk niveau ( Ca. 70 x 10 personer) Arla-IT kolleger( 250 personer) Andre centrale funktioner: OPEX, Indkøb, HR, QEHS,.. Leverandører ( ca. 200 relationer ) 4 Platform leverandører( SAP, Wonderware, Siemens, Rockwell) 8 foretrukne MES/PLC Integratorer 10? Turn-key leverandører(tetra Pak, GEA, SPX, Krones,..) 150+ Udstyrs leverandører/maskinbyggere (PackML) 23-09-2013 23
ERFARINGER - KONKLUSION 23-09-2013 24
Erfaringer Multi leverandør setup kræver opmærksomhed Det kræver standard løsning for at kunne optimere implementering, drift og support Kvalitet dækker både organisation, implementering (projekt) og løsning (funktion) Kommunikation tager tid Forandring er svært 23-09-2013 25
allan.schmidt@arlafoods.com Spørgsmål? 23-09-2013 26
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