GE IND FOOD & BEVERA

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Ibhayi Brewery - world-class manufacturing from scratch in 18 months

Ibhayi Brewery's size, complexity and rapid implementation is not only testimony to the effectiveness of fast-track construction projects but also of present-day SCADA and MES software solutions coupled to sound system design and tight project management. Ibhayi is one of seven breweries in South Africa owned by the country's largest brewer who is also the 5th largest brewer worldwide with no less than 82 breweries outside the borders of the RSA. Ibhayi's ambitious time-to-first-brew from its day of approval of the project is one of those outstanding engineering achievements that we nowadays take so much for granted. The Ibhayi Project was given the nod of approval mid 1999 for the erection and commissioning of a green field brewery with the brief of replacing the old Port Elizabeth facility which had been in operation for a century. BUSINESS OBJECTIVES The Ibhayi brewery was to become a reality only if it could achieve the following: Produce its first brew by 21 August 2000 (less than 18 months after project approval) Maintain a continuous production capacity of 2,3 million Hectolitres by October 2000 (this meant a pack line of 50 000 bottles per hour). Handle five brands of beer Operate with only 120 members of staff (13 per shift). Support World Class Manufacturing standards (WCM) Support Best Operating Practices (BOP). Minimise inventory costs. OPERATIONAL REQUIREMENTS In order to maintain the required levels of efficiency to achieve its business objectives, it was decided to delegate full operational responsibility to multi-skilled operators who would be provided the information decision support they needed at all levels of the plant. Ibhayi's operational requirements included:

While there are many improvements to be implemented and lessons to be learnt, there's no disputing that we went live with one of the most complex projects of its type undertaken in Southern Africa and we did it in record time and under budget." Thinus van Schoor - Project Manager Manufacturing Systems, Ibhayi Brewery

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CP

YP Raw materials Brew House SG

YA

YS Storage Vessels SP

HD Filter Line KD KP KD KB

DW Bright Beer Tank SD SM

Fermentation Vessels YF

Packaging

BU

CU

Fig 1: Process overview

Low manning levels (13 operators per shift). Highly skilled operators - no "TV Brewers". This was one of the key requirements in that it involved shift personnel to remain in contact with production realities on a continuous and real-time basis rather than by watching monitors. Rapid problem solving and decision making. Providing operators with the necessary level of decision support would enable them to manage problems as they happened rather than the lengthy process of having to refer to anyone else for help. Autonomous production, maintenance and quality management at source. Distributed availability of real-time and management information. Maximum level of standardisation possible, specially with regard supervisory and alaem standards as well as PLC programming and automation standards. This was a fundamental requirement because of the number of overseas and local contractors that would be involved with the project. High support of manufacturing strategy. The use of proven technologies The monitoring of up to 76 000 tags.

SELECTING THE SOLUTION The scale and nature of the implementation of the brewery's MES and SCADA systems would require the combined efforts of OEMs (Original Equipment Manufacturers) based in Europe as well as a number of South African system integrators. In partnership with SAB, the Hatch Africa systems group were responsible for the overall role of Manufacturing Systems Integrator. Wonderware's FactorySuite range of industrial automation solutions was chosen because of : A weighted evaluation of the various components of FactorySuite (e.g. InBatch) had already been done and were already widely used in the brewer's other plants. Although Ibhayi's 76 000 tag requirement exceeds FactorySuite's maximum of 60 000, this was sufficient to provide the required level of supervision, automation and control while Wonderware addressed the issue of enhancing FactorySuite to meet Ibhayi's ultimate requirements. Wonderware's off-the-shelf functionality and integration capabilities The quality of existing interfaces for the Siemens S7 PLCs Compatibility with the brewery's adopted standards such as SQL 7.0

Fig 2: System overview

Fig 3: The Universal Workstation concept

Fig 4: System integration

The support available through Invensys as one of the main OEMs (Invensys plc owns Wonderware corporation as well as other companies who were in a position to make direct contributions to the project .e.g. APV who was given the responsibility for the beer brewing processes). The ability of OEMs based in Denmark, the UK and Germany to implement solutions based on FactorySuite and the availability of their continued support into the future. Altogether, twelve contractors were selected for the implementation of the Ibhayi project and this led to the rapid agreement on implementation standards and approaches since each contribution had to work seamlessly with every other. SOLUTION IMPLEMENTATION The improvement of quality while containing costs required not only the application of best operating practices but the empowerment of operators at all levels. That's why the concept of the Universal Workstation (UWS) was introduced. This lets production personnel access the information they need at logical locations throughout the plant. This plantwide, web-enabled approach has eliminated all the restrictions of function-specific machines. In addition, the Universal Workstations are also the control stations where operators can interact with the process as required. This means that they are not (and are not wanted to be) confined to the control room. The MES makes provision for product and quality tracking (PaQT) using Wonderware's InTrack while real-time statistical process control is achieved with the help of Wonderware's SPCPro solution. PaQT is also integrated with the brewery's LIMS (Laboratory Information Management System). Production scheduling by batch is done using the Electronic Planning Board which converts the divisional plan into the form required by the Wonderware InBatch batch execution system while displaying target schedules against actual results for each batch. A proper S88 batch design, led by process people proved crucial for a successful batch implementation. The MES is also integrated with the brewery's SAP R/3 Materials Management System and with the divisional centralised planning facility.

Other implementations included centralised alarming across plant areas, structuring workflows for the management of concessions, alarms and reports as well as the development of software tools to assist with the management of consistent data structures between applications which share data. The contractors involved at different stages of the process applied common and standardised SCADA standards (i.e. tag naming conventions, display management and types, etc.) using Wonderware's InTouch solution to produce the same look and feel in the supervisory system across the brewery. In amongst all this, Tight project management and the international integration of technologies and efforts would eventually win the day. REALISED BENEFITS Automation level: A sufficient level of standardisation was achieved. An acceptable level of S88 compliance was achieved. The same "look and feel" as well as process information content was achieved across different process areas (including the batch processing applications). The navigation principles used in the supervisory system were also applied to the brewing and packaging areas. The ambitious concept of a single brewing and utilities application was successfully achieved and enhancements currently under way for Suitelink and InTouch will allow the full roll-out to all Universal Workstations.

Fig 5: InTouch display showing the status of various filters in the plant

The Wonderware FactorySuite industrial automation solutions and Avantis enterprise asset management solutions are marketed and supported in Southern Africa by sole distributor, Futuristix Advanced Control Systems. Application engineering is primarily implemented by a network of accredited system integrators.

Futuristix Advanced Control System (Pty) Ltd PO Box 75591 Gardenview 2047 Tel: (011) 723 9900 Fax: (011) 453 1808 Email: info@futuristix.co.za Web: www.futuristix.co.za

Manufacturing Information System: The objective of providing the base platform for information analysis was achieved with good success. The implemented solution allows for the versatile manipulation of data to achieve different views and results. The site-wide tracking of quality, material and process data has been implemented and is currently being consolidated. One Year Later On 1st October 2001, Ibhayi celebrated its first year of operation and became the benchmark for breweries around the world. Delegations from the USA, Europe and Australia all attested to Ibhayi as being the world's best brewery and the standard by which others will be judged in terms of their manufacturing capability, manufacturing systems, organisational design and asset care.

The accreditation from the USA was particularly significant because in 1999, that's where the world's benchmark brewery was located but its owners now put Ibhayi 8 years ahead of them and the new global paradigm for breweries everywhere. These international accolades are eloquent testimony to the work that so many people (from within the company, its suppliers and local stakeholders) put into Ibhayi to get it up and running from a greenfield site to production in 18 months.

Fig 6: Topology diagram

" A l t h o u g h t h e re w a s n o l a c k o f re s o u rc e s a v a i l a b l e t o t h i s l a rg e p ro j e c t , p ro b a b l y t h e m o s t d i f f i c u l t t h i n g t o d o w a s t o c o o rd i n a t e t h e m a l l . W h i l e b u i l d i n g a n d p l a n t e re c t i o n a re w e l l - u n d e r s t o o d s c i e n c e s w i t h p re d i c t a b l e o u t c o m e s , brewing beer to incredibly close quality tolerances in such volumes and within such a short time isn't so easy. Especially when the entire country is your quality assurance department. Thankfully, we had a lot of dedicated help." John Coetzee - Manager Manufacturing Systems, Ibhayi Brewery