The Automation Revolution Make2Pack Report to the WBF

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The Automation Revolution Make2Pack Report to
the WBF
THE FORUM FOR AUTOMATION AND MANUFACTURING
PROFESSIONALS

• David A. Chappell
• Make2Pack Chair Procter Gamble

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Dave Emerson Lynn Craig
Thought for the Day! There are several global
standards initiatives converging that will lead
to an automation revolution in manufacturing.
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Activity
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Activity
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Agenda

• Dont have time to Tell you!

Objective

• Share with you the results of the Make2Pack
  effort.
• Enlist your support for the final phase

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Charter
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Make2Pack Objectives
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Deliverables
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Time Line
WBF Make2Pack PackML
March 2006
18 Face2Face Meetings 18 Conference Calls
January 2004
May 2004
12/05
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Some Conclusions

• Automation requirements are similar across
  manufacturing
• Separation of procedure control and basic control
  provides significant benefits
• Parts of S88 are confusing and there is room for
  improvement in understanding
• Packaging machines can benefit from S88 modular
  concepts
• S88 can benefit from PackML concepts
• There is a strong desire in the end user
  community for improvement
• There is some resistance in the OEM community to
  change
• We still have more to do
• The end goal is incredibly valuable to all!

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Lots of Interest and Support
Grupo MPR Imass Alejandro GTI Schreck Achim GTI
Stegerwald Frank Hersheys Ramsey Jim Hersheys
Rhoads Herman Hixson-inc Vanover Mitch HLQ
Hawkins Bill Honeywell Albano Mark Honeywell
Bohan Jamie Honeywell Mars Pam Invensys/Wonderware
Brennan Sean ISA Ferson Lois Janssen
Pharmaceutica N.V. Buys Kris Kraft Foods Laffan
Liam Lund Institute of Technology Johnsson
Charlotta Manufacturing Automation Assoc. Craig
Lynn Marchi Peter Putnam Fred Verstraeten
Eddy Masterfoods Rivero Jorge Masterfoods USA
Rieger Ron Mettler Toledo Jeffery
Rodger Millennium Chemicals Wilkins
Maurice Morinaga Engineering Sugiura Tony
(Akitoshi) National Instruments Bailey
Mike National Instruments Chandhoke
Sundeep Nestle Anthony Abbott Nestle Besson
Jean-Paul Nestle Desbaillets Jean-Marc Sponsors
and Members of the WBF-OMAC-SP88 Make2Pack
Effort 154 People representing 83
Companies Company Name Last Name First
Name Nestle Frochaux Jean-Daniel NNE (Novo
Nordisk Engineering) Kristensen Morten NNE (Novo
Nordisk Engineering) Petersen Lars NNE (Novo
Nordisk Engineering) Stenbakken Mikael NovaTech
Charpentier Leo Oklahoma State University
Rhinehart R. Russel Omron Andersen Dave OSIsoft,
Inc. Zglenski Jennifer
Schneider Electric Keiter Uwe Schneider Electric
Owens Brian Schneider Electric Riedel
Martin Schneider Electric Tyehimba N'kosi Siemens
Backx Ivo Siemens Broucke Mario Siemens Henderson
Bill Siemens Moors Bart Siemens
Mueller-Heinzerling Thomas Siemens Pareijn
Guido Siemens Pieper Mike Siemens Schumacher
Heike Siempelkamp Emmerton Mike Sponsors and
Members of the WBF-OMAC-SP88 Make2Pack Effort 154
People representing 83 Companies Company Name
Last Name First Name SLControls Loughlin
Shane SLControls McFeeley Garvan SLControls
Mcmorrow Darragh SLControls Moran
Keith SLControls Morrissey Joe Stone Technologies
Unger Keith Systematix Carmount Mark Systematix
Neidert Richard Thermo Electron Corporation
Broski Gerry Tokyo Institute of Technology Batres
Rafael TV-Munchen Voigt Dr. Tobias TWP Training
Consultancy Scholten Bianca Uhlmann Pac-Systeme
Armbruster Markus Unilever Mcdonald Andrew VDMA
Koldau Alexander Wago DeCramer Mark WBF Staff
Monahan Tom YASKAWA Downie John YASKAWA Gegg
Jim YASKAWA Urda Andrew Yokogawa Emerson
David Zarpac Rumi Eric Zarpac Zepf Paul
Packaging Digest Mans Jack Packaging World
Reynolds Pat Pfizer Sharma Vik Pfizer Lynch
Ed Pfizer Martell Bob Pfizer Pillai Lou
(Velumani) Pfizer Swodzinski Paul PFM Peracchi
Sergio PMMI Egan Tom Polar Ferrero Francisco Pro
Mach Leuschke Scott Pro Mach Suchy Mark Procter
Gamble Aleksa Rob Procter Gamble Berg
Eric Procter Gamble Chappell Dave Procter
Gamble Fischer Achim Procter Gamble Fry
David Procter Gamble George Paul Procter
Gamble Joyner Jay Procter Gamble Koch
Chris Procter Gamble Lamping Mike Procter
Gamble Van Dyke Rick ProLeiT Lutz Martin Rexroth
Bosch Group Wenzler John Rexroth Bosch Group
Kessler Klaus Rockwell Automation D'Mura
Paul Rockwell Automation Hood Gavan Rockwell
Automation Maki Adam Rockwell Automation Morse
Rick Rockwell Automation Ray Kakali Rockwell
Automation Tennant Marcus Rockwell Automation
Trobisch Ruediger Rockwell Automation Vasan
Venkat Rockwell Automation Wagner Mike Rockwell
Automation Weatherhead Andy Rockwell Automation
Wodzisz Shoshana Rockwell Automation Seger
Dan SAB Miller Basson Garth SAB Miller Lotz
Willie SAB Miller Siddique Azim SAB Miller Trunek
Larry SAB Miller van Schoor Thinus Schering
Plough Nash Thomas Schering Plough Lees
Matthew Schneider Electric Hayler Steve
Effort 154 People representing 83
Companies Company Name Last Name First
Name 3s-Software Werner Manfred Aagard Smith
Brenton ABB Quirke John ARC Blanchard John ARC
Humphrey David Arla Foods Klemmensen Poul Arla
Foods Svendsen Arne Avid Solutions Rankin
John BR Industrial Automation Eder Franz BR
Industrial Automation Lang Siegfried BR
Industrial Automation Massey Nathan BR
Industrial Automation Sandhoefner Markus Beckhoff
Hoppe Gerd BR and L Consulting Brandl
Dennis Brewery Martens Bloemen Paul CAMC/ATC Ryan
Dr. Kenneth Capmatic Mosseau Michel Cognex Keup
Mark Cognex Bierbaum Kris Consultant - Jean-Marc
Vielle Jean-Marc Control Engineering Hoske
Mark Coors Brewing Company Gray Doug Douglas
Machine Faust Joe DOW Salomons Henry DuPont
Falkenau Larry DuPont Gianakiz Harry DuPont Julie
F Smith ELAU Jensen Tom Juergensen Leif Kowal
John Eli Lilly Hawkins Aubrey Eli-Lilly Sorrak
Ken Enterprise Ireland Mullen Joan Enterprise
Ireland O'Malley Brian Genentech Wheeler
Mark General Electric Leppiaho John Georgia-Pacifi
c Salminen Jarmo
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Part 5 of the ISA-88 series of standards adds
measurable business value by integrating
manufacturing, packaging and enterprise
information systems through international
standards instead of custom programming
Next 5 Meetings 2 3 4 5
Press Find out More
Join Now! Its Free
Letter of Support Benefits
Report/ PDF PPT
Members list
Models
Charter
WWW.Make2Pack.ORG
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Make2Pack Where S88 and PackML create synergy
and understanding
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A Little Background
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Manual Process
How-To-Do-It
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Remote Activation and Monitoring is NOT
Automation
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Background History
Do-it Engineering/Programming
A Helper! The Augment
Basic Process Control Automation
Process Control Engineers
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Background History
An Augment Helper to Do-It
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Life is good until an augment goes bad?
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Who Can Make an Augment Behave?
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5.2.3 Structuring of equipment entities
All control related sections of the standard
assume that the process cell in question (both
physical equipment and related control
activities) has been subdivided into well defined
equipment entities such as units, equipment
modules, and control modules. Effective
subdivision of the process cell into well defined
equipment entities is a complex activity, highly
dependent on the individual requirements of the
specific environment in which the batch process
exists. Inconsistent or inappropriate equipment
subdivisions can compromise the effectiveness of
the modular approach to recipes suggested by this
standard. Subdivision of the process cell
requires a clear understanding of the purpose of
the process cell's equipment. Such understanding
allows the identification of equipment entities
that must work together to serve an identifiable
processing purpose.
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Differences Between Batch and Machine
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Automated Manual Operation
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S88 PackML Models
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Bringing Together Control and Equipment
How-To-Do-It Programming/ Engineering
Do-it Engineering/Programming
What-To-Do Business Decision
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Coordination
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Types of Control and Residency
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Nested CM Basic Coordination and Sequencing
Control
Internal Agents
Control Module Persistent Control
External Agent
External Agent
Bypass
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Command Interface
Command
Status
System Functions
Component of Control Functions
WBF Digital Device
Extended Functions
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Monolithic CM Control
CM
Control Module Persistent Control
Physical Devices
Physical Devices
Physical Devices
Physical Devices
Physical Devices
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Types of Control and Residency
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Nested EMs Procedural Control all of CM Control
Equipment Modules Equipment Procedural Control
Persistent Control
Control Module Persistent Control
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Monolithic EMs
EM
Equipment Modules Equipment Procedural Control
Persistent Control
Control Module Persistent Control
CM
CM
CM
CM
CC
CC
CC
CC
Physical Devices
Physical Devices
Physical Devices
Physical Devices
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Unit
Equipment Modules Equipment Procedural Control
Persistent Control
Control Module Persistent Control
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What is a Recipe Procedure and how does it Fit?
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Make2Pack Where process and packing join forces
to create understanding!
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Not Clear what Equipment Operations are made up
of Equipment Phase Reference or Equipment
Phase
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Control Recipe
Equipment Recipe Procedure
Equipment Control
Procedure
Equipment
Recipe
references
Procedure
Procedure
is an
is an
ordered
ordered
set of
set of
Equipment
Recipe Unit
references
Unit
Procedure
Procedure
is an
is an
ordered
ordered
set of
set of
Equipment
Recipe
references
Operation
Operation
is an
is an
ordered
ordered
set of
set of
Recipe
Equipment
Equipment
references
references
Phase
Phase
Phase
Reference
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Current Thinking on Modular Components
Unit/machine Recipe Procedural control
Equipment Modules Equipment Procedural Control
Control Module Persistent Control
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Procedural
Physical
Process
Control
Model (Lower

Model
Model
Portion)
Resulting
Procedural
Process
Equipment
Elements
provides process
Functionality
functionality
combined
to carry out a
with a
Process

Procedure(s)
Process
Cell(s)
provides process
functionality
combined
to carry out a
with a
Unit
Process
Unit(s)
Procedure(s)
Stage
provides process
functionality
combined
to carry out a
with a
Process
Operation(s)
Unit(s)
Operation
provides process
combined
functionality
with a
to carry out a
Phase(s)
combined
with an
Phase(s)
(See Figure 6)
Device
Action(s)
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Procedural
Physical
Process
Control
Model (Lower

Model
Model
Portion)
Resulting
Procedural
Process
Equipment
Elements
provides process
Functionality
functionality
combined
to carry out a
with a
Process

Procedure(s)
Process
Cell(s)
provides process
functionality
combined
to carry out a
with a
Unit
Process
Unit(s)
Procedure(s)
Stage
provides process
functionality
combined
to carry out a
with a
Process
Operation(s)
Unit(s)
Operation
provides process
combined
functionality
with an
to carry out a
Equipment
Process
Phase(s)
Module(s)
Action
(See Figure 6)
provides process
functionality
to carry out a
Control
Device
Module(s)
Action(s)
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Operations other than PackML Auto
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Example State Model For Batch Unit
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Equipment procedure
Line coordination
Equipment procedure
Equipment unit Procedure VFFS
Equipment unit Procedure cartoner
State table for VFFS operational code
Equipment unit Procedure case packer
Machine States and associated Steps
Equipment Phase Reference
Equipment Modules
Equipment Phase for weigh scale
Equipment Phase for bag feeder
Equipment Phase for Sealer and cutter
Equipment Phase for Date coder
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Unit Control Recipe
S88 Unit/Machine
Unit Recipe Procedural control
Unit/machine Procedural control
Operation Recipe
Unit/machine Persistent control
EM
Equipment Modules Equipment Procedural Control
Persistent Control
EM
Control Module Persistent Control
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Modes for Complex Systems Made Up of Many Modules
of Different Types

• Auto
• Semi-Auto
• Manual

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Semi-Auto
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Manual
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Auto Semi-Auto Manual
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Movement Within Procedures and Between
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Example Systems

• Batch
• Machine
• Continuous

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A Low Complexity Batch Cell
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A Low Complexity Packaging Machine
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Continuous Physical Model
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HMI - Wonderware
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Using S88 to Decompose a Packaging machine
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ISA S-88 Adaptation to Packing
S-88 Process Model
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Library of Reusable Automation
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The word today!
Define
Design
DigitalDevice
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WBFDigitalDevice Concept
Other Vendors
Other Vendors
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So What?
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Benefits
Effort and Cost to Meet Business needs
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Costs
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Significant Improvement in Process Reliability
MTBF Mean Time Between FAILURES mtbf mean time
between faults mttr mean time to resume MTTR Mean
Time To REPAIR
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Business Supply Chain
Manufacturing supply chain
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Dave Emerson Lynn Craig
Thought for the Day! There are several global
standards initiatives converging that will lead
to an automation revolution in manufacturing.
Questions?