Automation platform selection

Anders Fridh - Tetra Pak

Public
AsF/2015-05-20
Introduction
Anders Fridh

Background
Started 1989 as automation engineer at SattControl in Malmö, Sweden.
Positions over the years
► Automation Engineer
► Automation Responsible
► Project manager
► Technical coordinator
► Platform owner
► Manager - Platform development

Public
AsF/2015-05-20
Tetra Pak introduction: Focused on our customers
We specialise in providing customers with complete solutions
for the processing, packaging and distribution of food products

/2015-04-08
 Present in more than 170 countries and operations in all
continents

82 sales offices around the world 6 R&D units

32 market companies 13 Technical Training Centres /2015-04-08
Total world deliveries 2014

Carton packaging material, millions of

packs
179,888
Distribution machines
1,425

Processing units
Packaging machines
1,847
484

/2015-04-08
Tetra Pak Group, January 2015
Machines in operation

69,900 8,875 19,167

processing packaging distribution
units machines machines

/2015-04-08
Tetra Pak in summary, January 2015

► Employees: 23,460
► Net sales mio €: 10,900
► Countries where Tetra Pak
packages are available: >170
► Packaging material and closure plants: 37
► Filling machine assembly plants: 5
► R&D units: 6
► Technical training centres: 13

/2015-04-08
Automation Solutions from Tetra Pak
Automation system top priorities/drivers
Equipment Automation Plant Automation
► Majority of Tetra Pak equipments ► Plant Automation Platform
have automation embedded delivered customized as
(PLC+local HMI)
Tetra PlantMaster™
► Common look & feel between
different types of equipment ► +600 plant solutions in operation
► +3700 equipments delivered ► Horizontal and vertical integration
annually in the areas of PLC, User
Interface & MIS/MES with
Internal Plant Automation interface to ERP
► Packaging material plants fully
automated

Public
AsF/2015-05-20
What is an automation platform for Tetra Pak?

All reusable HW & SW components needed to deliver

automation solutions with high efficiency and quality
in the area of PLC, SCADA/HMI and MIS/MES

The platform is a combination of standard components

from automation suppliers and specific components
for a certain domain.

Public
AsF/2015-05-20
 Border lines for Tetra Pak plant automation platform

Enterprise resource planning (ERP)

Customer order Production report

Tetra PlantMaster

Manufacturing execution system (MES)

Processing line Packaging line

Materials handling

Raw materials Warehouse management system (WMS) Finished goods

Public
AsF/2015-05-20
How to select/create components for an automation
platform?
It is a challenging environment !

► Equipment, line, plant and enterprise levels

► PLC, SCADA/HMI, MIS/MES
► Connections towards external systems (ERP, WMS, LIMS…)
► Change/upgrade pace differs
► Industry standards with different maturity
► Brand recognition
► System integrators and end user requirements
► Capabilities
► Customer preferences
Public
AsF/2015-05-20
Some reflections around the challenges
Needs for the different levels: equipment, line, plant and enterprise

Level Automation suppliers Tetra Pak add-on

• Low HW & SW cost • Standardized interfaces for efficient integration
Equipment • High performance - Upstream/downstream equipment
• Reliability - HMI
• Openness & Connectivity - MES
• Diagnostics / User friendly maintenance • Usability / Common look & feel
• IP protection • Built in know-how
• Configuration capabilities
• Low HW & SW cost • Unified system independent SW model
Line / Plant • More program memory • Usability / Common look & feel
• Flexibility • Simplicity  Easy to change/customize
• Openness & Connectivity & supplier • Efficient engineering
independence
• Diagnostics / User friendly maintenance
• Simplicity in debugging / change
• Standardization • Standardization on formats (B2MML etc)
Enterprise • Connectivity (ERP and multi sites) • Define important multi site data
• Data transfer / consolidation • ERPMES connectivity (Orders, performance
data…)
• Translation of enterprise information to specific
equipment and manage real time data/historian data

Public
AsF/2015-05-20
Some reflections around the challenges
PLC systems, HMI/SCADA and MIS/MES

System High level selection criteria for Tetra Pak

• Low HW & SW cost
PLC • Engineering efficiency
• Traditional and PC-based PLC systems
• Global availability and support
• Low HW & SW cost
HMI • Customization possibilities on template basis
• PLC independent connectivity
• Configuration possibilities
• SW license cost
SCADA • Engineering efficiency
• Performance (Screen update time)
• Customization possibilities on template and project basis
• PLC independent connectivity
• Integrated system / Single point of configuration
MIS/MES • Flexibility and customization possibilities (data exchange, reporting, dashboards…)
• Engineering efficiency

Public
AsF/2015-05-20
Some reflections around the challenges
Change update pace differs

Our customers exchange and update the different systems with different
paces!
This means different requirements on the automation platform to lower
costs and risks when it happens.

► Modularity
► Flexibility
► Connectivity (Technical and functional)
► Unified system independent SW model

Public
AsF/2015-05-20
Some reflections around the challenges
Industry standards with different maturity

Standard helps both end users and system integrators!

… but maturity differs a lot.

Standards are
► Supplier independent (Ethernet, OPC…)
► Supplier dependent (Profibus, Devicenet…)
► Widely open for interpretations (S88, PackML…)

Manufacturing industry will benefit with more supplier independent

standardization!

Public
AsF/2015-05-20
Some reflections around the challenges
Brand recognition

Brands are more or less dependent due to system type.

Experiences from our customers. Where is a specific brand most

important:
1. PLC
2. SCADA
3. MIS/MES
4. Local HMI

Public
AsF/2015-05-20
Some reflections around the challenges
System integrators and end user perspective on needs

End customer / User System Integrator

► Low investment / operational cost ► Engineering efficiency
− Single point of configuration
► Reliable
− Minimize number of engineering tools
► User friendly
− Easy to operate ► Testable / validation support
− Easy to maintain / upgrade / change ► Customization
− Common look & feel − Functional integration
− Act as one system
► Diagnostic tools
► Easy to optimize
► Flexible
− Production changeover
− New SKUs

Public
AsF/2015-05-20
Some reflections around the challenges
Capabilities

Both end users and system integrators have limited capabilities.

We all invest in know-how for our people.
Three main areas of knowledge:

Automation
& IT System
integration
technology

Customer
operations

Changing the automation platform means

reinvestment in people!

Public
AsF/2015-05-20
Some reflections around the challenges
Customer preferences

What ever you have selected as automation platform, the customer or

supplier has their own preferences of what is important. 

Corporate standardization on all levels:

► HW / SW / Networks…
► Brands
► International standards
► Maintenance and support ambitions
► Domain functionality
► …

Public
AsF/2015-05-20
Our ambition with Tetra Pak plant automation platform

► The world class automation platform shall enable business growth

and engineering efficiency
► Automation solutions delivered with the platform shall secure
success for our customers during total life cycle

How?
1. Use commercial available systems and standards as far as possible
2. Build a system independent software model (S88 based)
3. Build & validate SW components, libraries and templates based on
the software model

Public
AsF/2015-05-20
 Plant Automation Platform used for
Tetra PlantMaster solutions

Production Production Quality Production Production Production Maintenance

dispatch scheduling assurance reporting analysis tracking viewer
Tetra PlantMaster

Production Data
execution acquisition

Information solutions – MIS/MES software

Production control – PLC and User Interface

Commercially available hardware and software products

Internal
AsF/2014-08-12
Thanks for your attention

Public
AsF/2015-05-20