Cost Effective pproach Approach for Automation

(1)

Cost Effective Approach

for Automation

(2)

Packaging Variety is increasing!!!!

(3)

Drive Technology dominates packaging machine construction

Output cams gear

coupler

Main drive cam disk

Mechanical solution

Drive Technology dominates packaging machine construction

Motion Control

Logic Control

Technology

Mechatronical solution

virtual

leading axis motion control functions

Motion Control

servo drives

Logic Control Technology

(4)

The answer: Mechatronic solutions

M echanical M echanical solution M echatronic solution solution

intelligent m otion control

,

(5)

(6)

Example of a mechatronic solution

p

"Line shaft"

ÅÆ

"Shaftless technology"

Mechanics Shaftless technologygy

Disadvantages

Machines are not flexible

Advantages

High productivity

Machines are not flexible

Lower quality

Restricted productivity

High productivity

High flexibility

High product quality

Machines can be easily

Machines can be easily expanded

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Mechatronics through Motion Control

Motion Control is

the complete motion management

for a single or a multiple number of axes

(8)

Motion Control System

Motion + PLC +

Motion Control System

Technology Control

&

Line Module Motor Module Line Module Servo control UP

&

Motor Module Servo control UP DN DN Drive Control Motion Controller

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Motion Control Functions

Positioning Gear

Positioning Gear

Cams Cam switches

Print-mark

synchronization

Coupling-in/ coupling-out

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Motion Control in Packaging

Labeller Blister Pick & Place Fillers

Labeller

Cartoner Stretch Wrapper

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Basic Automation Structure for a Machine –

A Motion Control System !!!!

M otion Controller

D isplay n n

Com m unicatio Isochronous Com m unication (6 m s

y

Rem ote I/O Com m unicatio

n Bus

Isochronous Com m unication (6 m s)

D rive System M otor Servo y m D P/AS-I AS Interface !..12

...

Servo M otor Servo M otor SW G R

Induction M otor

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Tubular bag machine

Æ

Example of tubular bag machine

M ti C t l A i i T b l

Tubular bag machine Motion Control Axis in a Tubular

Bagging Machine

-The puller / foil feed and the sealer ( X and Y axis ) are driven by servo motors

- The seal has to take place at a specific position on the web and hence print mark correction is required.

- The cross sealer moves to synchronize with the web before it starts the sealing operation.

-While sealing it is important to coordinate with the dosing system ton ensure material falls in the pouch just after sealing starts

-In a nutshell, the sealer , the puller axis are h i d ith t i t l i i th b synchronised with a master virtual axis i.e the bag length

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The 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

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T t ll I t

t d

Totally Integrated

Automation

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The automation environment

Yesterday

PCs

PLCs

Automation

D i

PCs

Central

Process

Distributed

Production

Drives

Safety Technology

(16)

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

(17)

The end of technology breaks: The end of technology breaks: Totally Integrated Automation

TODAY

total

integration

automation environment

of the entire of an

i

ti

integration

of an

organization

(18)

in automation engineering

Uniform system architecture is the basis for integration

Comm u Controllers u nications Distributed I/O

(19)

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

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PROFINET -- The open Industrial Ethernet Standard

O pen

Industrial

O pen

Industrial

# " $ %

Ethernet

$ &02.'

Standard

* + $ &02.' 34/$4 4- * + $ / $5

(21)

Approaching a solution

Uniform system architecture is the basis for integration

Comm u Simatic Controllers u nications Portfolio Distributed I/O

(22)

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

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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

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Approaching a solution

Uniform system architecture is the basis for integration

C

Comm u Simatic C onfiguring / Controllers u nications Portfolio /programm Distributed I/O

(25)

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

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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

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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

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in automation engineering

Uniform system architecture is the basis for integration

C

Comm u Simatic C onfiguring / Controllers u nications Portfolio /programm Distributed I/O

(29)

I

t

bilit

Improve traceability

Using reliable identification techniques

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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

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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

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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.

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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.

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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.

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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

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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 _{WinCCflexible}TP177B 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

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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

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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

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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:

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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

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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

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Th

k

Thank you

N Vi k R

Name: Vivek Roy Department: I IA SC IC

Phone: +91 22 27645765