Wine Producer

Uncorks Value Of Premium Wines With MES

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Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 1
Wine Bottling Transformation

Geoff Nunan
Principal Consultant Digital Transformation
Nukon
Digital Operations
Transformation

Industry 4.0 Digital Enterprise PwC - 2016 McKinsey Digital Compass

 Digital Operations Transformation Consumer Packaged Goods

Optimised Automated Data driven Predictive Transport

Robotics

Internet of Things
Digital Factory

End-to-End Visibility

Data Science
Scheduling Material demand Analytics Monitoring
Handling prediction
Digital Quality Automation of Smart Shelf
Improved safety Real-Time Knowledge
'Live' Inventory supply-chain Work Smart Packaging
Optimised optimisation
Machine Data Inventory Remote
drives business Remote, Monitoring &
process Integrated Control
Operations
Robotic Process
Automation
Digital Operations Transformation Maturity Model
Digital Automated Remote Predictive Optimised

Remove Automated End-to-end Data availability Business

paper Inventory visibility Processes run
Data Science without
Integrate Automated Remote Analysis team intervention
systems line replen Monitoring with Reliability
& Control experience Human
Enable Automated intervention
Mobility end-of-line Recommend only to manage
actions based exceptions
Co-ordinate Automated Experts on Data
activities Warehousing operate analysis Decision
across sites optimisation
A Model
Digital Factory
Digital Operations Transformation Factory Scheduling
Digital Production Line
Project Elixir

Expanding from 3 to 4 Replace custom system Strategy to move to vanilla, Squeezed

high-speed 10 years old modular solutions Busy company project
packaging lines no upgrade path schedule

01 EXPANSION
FOUR LINES 02 ADDRESS
LEGACY ISSUES 03 VANILLA
SOLUTION 04 TIGHT
TIMING
 Pilot Line Timeline
November January 2015 1st March 2016
2015 System Testing Go Live
Project Scoping &
Contract Negotiation

October 2015 December 2015 February 2016

Project Tender Design and Construction Water Trials, Training
and User Acceptance
Testing
 Remaining 3 Lines
March 2016 May 2016 July 2016
Planning System Testing Go Live

February 2016 April 2015 June 2016

Sign-off Pilot Line Design and Construction Go Live Preparation
Initiating the project - Requirements

Expanding from 3 to 4 Replace custom system Strategy to move to vanilla, Squeezed

high-speed 10 years old modular solutions Busy company project
packaging lines no upgrade path schedule

01 EXPANSION
FOUR LINES 02 ADDRESS
LEGACY ISSUES 03 VANILLA
SOLUTION 04 TIGHT
TIMING

Adding the next new Same as the old one, I need to be able to I dont have time to
line must be easy but upgradeable add new stuff easily change any of the
interfaces,

Fully configurable Same, but completely Must be modular and so it must act exactly
solution different extensible like the old one
Project Elixir

PaaS Hosted Solution

750Km away
from rural site

05 REMOTE
DATA CENTRE
The World Is Flat Assembling the team

FactoryTalk
4 ProductionCentre
1 Platform &
Development

CPGSuite Architect

Project Management 6
Solution Architecture
Configuration & Testing
Training & Support
So what happens on a wine bottling line?
Empty Finished
Bottle Winery Dry-Good Storage Product
Storage Store

Muselets Cartons Stretch Wrap

Bulk wine Corks Neck Tags Dividers Slip Sheets

Sparkling
Screw Caps Labels Stickers Stickers
Wine

Carton
Erector

Filler & Robot Case

Depalletiser Labeller Palletiser
Closures Packer
Legacy system

Custom Microsoft ASP.NET User Interface

Factory Talk Mertics

Factory Talk Transaction Manager

RS View SE

Line Control PLC 1 per line

 Orders

Order Updates
JDE Global Infor (CIS)
Order Status
Architecture
Orders Parts PPS Consumption Pallet Machine
List Comp Run Hrs

Consumption
Warehouse
Replenishment Reports
Request MARC Warehouse
Integration Database FactoryTalk VantagePoint+ Nukon Smarts
Pallet Deliveries Management
Pallet Completion

Pallet Pallet Production Performance Process

Production Module
PBOM Param Order Replenishment Consumption
Deliv. Comp Data Reports & Variables
Orders s Status Request
Dashboards

Orders
Performance
CPGSuite Management FactoryTalk
Suite Historian

Next Running Glass Glass

12 Next Order by Pallet Pallet Automated Automated
Order Material Material Machine Machine Machine Process
Orders Work Details for Validation
Consume Production State State Fault Variables
Centre Validation Result
Codes

Line Control PLC (One line Control PLC for each Line)

Next
12
Machine Process Label
Orders
State Variables Details

Wine Transfer Machine

Label Printing
PLC Control PLC
Interfaces
Order Management
Integrate Production
Schedule data with
Tank Level visibility

FactoryTalk View SE
embedded into MES
screen

Line Status Overview

 Focused local
workstations

Full visibility of recipe and

available inventory

Automated consumption
of pallets of glass via
control system interface

Consumptions
 Automated
production of pallets
via control system
interface

But with manual

over-ride

Palletiser performs
automated
production of pallets,
but allows for manual
consumption of slip-
sheets

Pallet Completions Finished Goods

Inventory Management
 Orders

Order Updates
JDE Global Infor (CIS)
Order Status
Architecture
Orders Parts PPS Consumption Pallet Machine
List Comp Run Hrs

Consumption
Warehouse
Replenishment Reports
Request MARC Warehouse FactoryTalk VantagePoint + Nukon Smarts
Integration Database
Pallet Deliveries Management
Pallet Completion

Pallet Pallet Production Performance Process

Orders PBOM Param Order Replenishment Consumption
Deliv. Comp Data Reports & Variables
s Status Request
Dashboards

Orders
Performance
FactoryTalk
CPGSuite Management
Suite Historian

Next Running Glass Glass

12 Next Order by Pallet Pallet Automated Automated
Order Material Material Machine Machine Machine Process
Orders Work Details for Validation
Consume Production State State Fault Variables
Centre Validation Result
Codes

Line Control PLC (One line Control PLC for each Line)

Next
12
Machine Process Label
Orders
State Variables Details

Wine Transfer Machine

Label Printing
PLC Control PLC
Custom view of downtime
events was created to
simplify user experience

Extension developed using

native API, so does not
impact upgrade path

Downtime Events (Performance Manager)

Extensive, 5-level reason
tree used to classify
downtime events

Custom reason entry form

developed to enhance
user experience

Native APIs used so

extension does not impact
upgrade path

Downtime Events (Performance Manager)

 Orders

Reporting Suite
Order Updates
JDE Global Infor (CIS)
Order Status

Orders Parts
List
PPS Consumption Pallet
Comp
Machine
Run Hrs Reporting Suite
Consumption
Warehouse
Replenishment Reports
Request MARC Warehouse FactoryTalk VantagePoint + Nukon Smarts
Integration Database
Pallet Deliveries Management
Pallet Completion

Pallet Pallet Production Performance Process

Orders PBOM Param Order Replenishment Consumption
Deliv. Comp Data Reports & Variables
s Status Request
Dashboards

Orders
Performance
CPGSuite Management FactoryTalk
Suite Historian

Next Running Glass Glass

12 Next Order by Pallet Pallet Automated Automated
Order Material Material Machine Machine Machine Process
Orders Work Details for Validation
Consume Production State State Fault Variables
Centre Validation Result
Codes

Line Control PLC (One line Control PLC for each Line)

Next
12
Machine Process Label
Orders
State Variables Details

Wine Transfer Machine

Label Printing
PLC Control PLC
Native ability to tie production
orders to historian time-frames
within the reporting suite

Event-framing, without the

need for event-frames

Filler Speed Trend

 Bring data together from
multiple sources to provide a
complete summary of shift
performance

Shift Summary Report

 A filterable home-page for
order level reporting

Link to reports on inventory,

performance, Wine flows and
more

The home page for diagnosis

of issues

Work Order Overview

 The End-of-Order Report

A summary view of the order, quickly allowing the user to see if anything
has been missed

Work Order Detail Brief

 FactoryTalk Services Platform 2.74.00 (CPR 9 7.4) Multiple sessions generated from Line Side PCs
RSLinx Enterprise 5.74.00 (CPR 9 SR 7.4)

FactoryTalk Services Citrix Server

Platform Server
10.49.72.38

FactoryTalk Production Centre CPG Suite 10.1

Windows Server 2012 R2 Standard
FactoryTalk View Site Edition Server 8.10.00 CPR 9 SR 7.4
FactoryTalk View Site Edition Client 8.10.00 CPR 9 SR 7.4 CPG Suite Server
10.122.1.66
Network Architecture
FactoryView SE
Server
10.49.72.36 Performance Management 3.1.100915

Line Side PCs - CPG Clients (x 32) Performance

Management Server
10.122.1.67
Connect to CPG Suite
Server via Citrix

Microsoft SQL Server 2008 R2 SP3

WAN

PLCs SQL Server

Control Logix 10.122.1.68
MES Line Control PLC Line 1
10.49.72.140
Control Logix Historian 4.00.00.0104
MES Line Control PLC Line 2 Multiple Machine PLCs
10.49.73.147
Control Logix FactoryTalk
MES Line Control PLC Line 3 Historian Server
10.49.73.197 10.122.1.65
Control Logix
MES Line Control PLC Line 4 Microsoft SQL Server 2008 R2 Reporting Services
10.49.73.243 VantagePoint System Server 6.10.00
Dundas BI Deployment Centre 2.6.2.1000
TWE Vaadin App (Java based Downtime Application)

Vantage Point
Server
Operating System: Unless otherwise indicated, all Servers are virtualised and run Windows Server 2008 R2 Standard SP1 10.122.1.64
 Development Test Production
(Cloud)
Project Elixir Vantage Point Server Vantage Point Server
FT Vantage Point FT Vantage Point
Nukon Smarts Nukon Smarts
Vantage Point Server
FT Vantage Point
Nukon Smarts
FT Historian Historian Server Historian Server
SoftLogix
FT Historian FT Historian

CPG Suite Server

FT Production Centre
CPG Suite Server
FT Production Centre - CPG Suite
FT Production Centre
FT Production Centre - CPG Suite
CPG Suite Server
FT Production Centre
FT Production Centre - CPG Suite

Perf Man Server

FT Production Centre
Perf Man Server
FT Production Centre - PM Suite
FT Production Centre
FT Production Centre - PM Suite
Perf Man Server
FT Production Centre
FT Production Centre - PM Suite

SQL1 (Nukon Dev SQL1)

Vantage Point DB
SQL Server SQL Server
CPG Suite DB
Vantage Point DB Vantage Point DB
PM Suite DB
CPG Suite DB CPG Suite DB
TWE Interfaces DB
PM Suite DB PM Suite DB
TWE Interfaces DB TWE Interfaces DB
Next Steps ?
6 things to take home
We are 1 year into a 5 year Industrial Revolution (Industry 4.0)

45% of all activity can be automated now, but it starts with Digitisation

The World Is Flat And better because of it

Modular MES is a viable solution for legacy replacements

Agility requires Stability

The servers dont need to be at the factory but be careful

 Integrate Streamline Track Materials, Improve Performance
Business Data Supply Chain Inventory and Products

We exist to inspire teams and create transformational change by

delivering the technology solution to realise your vision.

nukon.com.au
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PUBLIC Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 39
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Rockwell Automation TechED 2017 @ROKTechED #ROKTechED Copyright 2017 Rockwell Automation, Inc. All Rights Reserved. 40