A t
ti
f
Automation of
Packaging
Packaging
Machines
Machines
Packaging Line Concepts
1300 blisters/m in Fast changes of the batches/ param etersThe machinery market is in transition
y
New trends are being born
Consumer behavior is becoming increasingly individual
Changing forms and designs
Changing forms and designs
Lower production costs
Implementing new regulations – e.g. FDA
ÎNew challenges for packaging machinery construction
Mechatronics Individual drives Hi h fl ibilit Individual drives, intelligent motion control Higher flexibility Short re-equipping times,
Modularization
Simulation Shorter ,online recipe change
Shorter
What is meant by Motion Control?
Motion Control is
the complete motion management
for a single or a multiple number of axes
The answer: Mechatronic solutions
M echanical M echanical solution M echatronic solution solution intelligent m otion control
,
Motion Control Functions
Positioning Gear
Positioning Gear
Cams Cam switches
Print-mark
synchronization
Coupling-in/ coupling-out
Motion Control in Packaging
Labeller Blister Pick & Place Fillers
Cartooner
Basic Automation Structure for a Machine – A Motion Control
S
ot o Co t o
System!!!!
T t ll I t
t d
Totally Integrated
Automation
The automation environment
The automation environment
Yesterday
Yesterday
Yesterday
PCs
PLCs
Automation
D i
PCs
Central
Process
Distributed
Production
Drives
Safety Technology
Safety Technology
Approaching a solution
in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interface
Comm u Data m a C onfiguring / Controllers u nications a nagement /programm Distributed I/O
Drives / field devices
The end of technology breaks: The end of technology breaks: Totally Integrated Automation
TODAY
TODAY
totalintegration
integration
automation environment
of the entire of ani
ti
integration
of anorganization
Approaching a solution
in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
Human machine interface
Comm u Controllers u nications Distributed I/O
Profinet – The Communication Backbone
PROFINET - The Industrial Ethernet Standard for Automation
D ata
I/O
M otion
Safety
Process
For all applications
For the entire work flow
PROFINET -- The open Industrial Ethernet Standard
O pen
Industrial
O pen
Industrial
! " # $Ethernet
" %02.&Standard
' ( " %02.& )*/"* *- ' ( " / "+Approaching a solution
in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
Human machine interface
Comm u Simatic Controllers u nications Portfolio Distributed I/O
Vertical integration
ERP, e.g. SAP
Management level (MES)
Operation level (SCADA / DCS) PCS 7 WinCC Control level Field level
Reduce interfaces & costs of engineering
Increase the intelligence of the automation
Horizontal integration
ERP e.g. SAP, Navision, etc
Management Level
Operations Level
MES
SCADA Process control systemPCS 7
MES
SIMATIC IT
Enterprise Asset Management
Plant Maintenance Management
Plant Information Management
Supplier Inbound logistics Outbound logistics Discrete Customer Process Control Level Field Level
Integrated engineering, diagnostics, communication and products
Field Level
Æ Transparent information from the automation system
Approaching a solution
in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interface
Comm u Simatic C onfiguring / Controllers u nications Portfolio /programm Distributed I/O
Drives / field devices
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 requirements is to integrate and achieve consistent approaches throughout all automation applications
The response – Totally Integrated Automation Portal
One framework – The total integration of necessary tools and g y
technologies, such as PLC, HMI and drive technology programming into one single platform
TIA Portal – an engineering framework that will make a differenceg g
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
Approaching a solution
in automation engineering
Uniform system architecture is the basis for integration
Process control system
Uniform system architecture is the basis for integration
C
Human machine interface
Comm u Simatic C onfiguring / Controllers u nications Portfolio /programm Distributed I/O
Drives / field devices
T
k & T
i
Track & Trace in
Packaging Lines
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 safetyIncrease 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 q g 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
Tracking & Tracing of products along the supply chain – from
Tracking & Tracing (T&T) is the action taken to track and trace products:
g &
g
p
g
pp y
production to the consumer
internally - within the production site and/or
externally - along the complete supply chain
Finished Filli / Raw Consumer Retail Distribu-tion Finished Product Ware house Filling/ Packa-ging Produc-tion Raw Material Intake/ warehouse Supplier External Internal External T&T T&T 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.
The internal T&T starts with the material intake and continues in the
&
production process
= Affected shipment, raw material, pallet
Internal T&T
-Raw Mat. Intake/Production
Identification of bad quality in a
Identify all affected shipment units
Starting Point Identification Track forward Block shipment
Identify all affected batches via Block shipment units still in quality in a delivered raw material or inter-mediate product shipment units (e.g. via pallet
identification) batches via genealogy (e.g. intermediate products, blending, packaging) 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)
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.
The product hierarchy is provided through
p
y
p
g
the entire internal T&T
* RFID or other AutoID technologies (such as bar code, data matrix code etc.)
Internal T&T -Filling/Packaging (inside) 1 AutoID Tag* package Packaging machine 4
Read pallet at the goods issue AutoID Tag on the package Shipping gate g g g goods issue and create ASN g
Combine packages to a case with an AutoID Tag on
2
with an AutoID Tag Combine cases to a pallet
3
the secondary package with an AutoID Tag on the pallet
The T&T solution does consider all product hierarchies from the single item to the pallet.
pallet.
The product-hierarchy functionality is not limited to the filling/packaging process but applicable within the entire T&T.
External T&T provides the traceability of products
External T&T Supply Chain
& p
y
p
within the supply chain
pp y External T&T Internal T&T External T&T Identification of bad quality in a delivere d raw material or inter-mediate product Identify all affect ed shipment units (e.g. via pallet identif icatio n)
Starting Point Identification Track forward Bloc shipment
Identify all affected filling batches via genealogy ( Block shipme nt units still in wareh ouse. Recall affecte d deliveri
Suppliers Wholesaler Retail
es
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
Track and Trace
Packing Line – OPL Architecture
Plant Line – Server Li HMI
Optional External
Line Overview INTERNET
Line HMI Access
Engineering Station Diagnosis-Maintenance Station Overview Station Mobile Overview Station Panel PC6x7B Touch, 15" WinCC SingleStation WinCC/ Web Navigator
Backup&Recovery ADDM
SIMATIC PG Engineering Software High Performance Wireless PC
WinCC Web Client
SCALANCE Security Switch SCALANCE S CC S g eS a o Engineering Software SCALANCE X414-3 Line Switch WinCC Web Client
SCALANCE W788
Labeler Filler TopConveyor Palletizer Wrapper Beverage Proc Local HMI Panel Machine PLC Panel PC6x7B WinCCflexible Panel PC6x7B WinCCflexible WinCCflexibleTP177B Microbox PC420+ CPU315-2PN CPU319-2PN CPU319-2PN CPU315-2PN CPU319-2PN Panel PC6x7B WinCCflexible SCA-LANCE X204-2 Machine Switch
Sub Machine Motion Control
Microbox PC420+ FlatPanel, WinCCflexible SIMOTION D445 ET200S CPU RF180C PROFINET Connection block MV440 1D/2D-reader, IP65 e.g. RF620R RFID reader Read/write distance 2 m
Track & Trace solution
Track & Trace solution
Line controller package – already available
Track & Trace controller box
10,4 or 15” Touch Panel Track & Trace controller box Ethernet Network
Power I/O Controller 10,4 or 15 Touch Panel Power Supply for Controller and Devices Ethernet Network Site Level . . . . . . . . Supply e.g. PROFIBUS Optionally: Additionally signals Packer I/O Label Applicator Output Label Applicator RFID or C DMC reader or Barcode Connected via Bluetooth / USB to CMC Controller Packer I/O e.g. PROFINET These devices can also be t d t F h l l b dl t f th T&T li t l b d! Handheld Reader (optionally) Applicator and Printer Input Label Printer / Applicator Applicator and Printer Output Label Printer / Applicator DMC reader Input Reader or Barcode Scanner Output Reader connected to an existing PLC!
For each level, 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
Use Cases and Tasks
Use Cases and Tasks
Read DMC
on item level (single DMC)
on bundle/case level (single or bulk DMC)
on palette level (single DMC) 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
Trace production
The difference of reading and verifying is
on palette level (single DMC) not used by the pharma end customers.
Verify DMC
on item level (single DMC) 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.
Control DMC marking quality
Read DMC and/or human readable text
i l l Reading human readable text, is only
needed on item level. VS72x can be used for that and in the future MV440-OCR.
Trace plain text
E Pedigree Siemens solution for pharama industry
on item level Preferably OCR-B text shall be used.
The AutoID/RFID T&T solution provides interfaces to MES and to
SAP OER Functionalities & Benefits of the solution
Internal T&T
External T&T
/
&
p
S
ERP (i.e. SAP, etc.)
• 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 SAP ERP other ERP
SAP OER
SAP AII / XI
by SIMATIC IT
• Possible cross entity integration via SAP OER.
• Scalable, modular and flexible solution based on a
SAP AII / XI
o
n
standard platform
• Identification of objects basing on the EPCglobal standards (EPC, EPCIS, UID, etc.)
• Device- and data-management for SIMATIC IT and AII
AutoID/RFID Core Solutions
I t f t 3 d t t
D T&T Soluti
o
SIMATIC IT
and AII
• Interfaces with SIMATIC IT for Manufacturing operations
Interface to 3rd party systems
Device Management (Siemens & Non-Siemens)
Data management / Business logic
AutoID/RFI
• AutoID devices are managed by the AutoID/RFID Core Solutions.
AutoID Devices:
Benefits
Higher product safety to improve the protection of your brand
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 operationsy g g
Better governance of quality operation
R d ti f d k
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
d t f t
product manufacturer
Many years of experience in the realization and use of Tracking & Tracing solutions
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
Th
k
Thank you
N P d K R k
Name: Prasad K.Raverkar Department: I IA AS BD
Phone: +91 22 27645704
