As we are getting ready for the Pack Expo in 2014 we’ve decided to take a
close look at the packaging automation market, and discuss ways in which Wonderware
software applications can be developed
for the packaging market. To discuss the Wonderware software offerings we will
be on exhibit at PACK EXPO 2014 in Chicago from November 2 to November 5 in Booth
E 7130. In addition, Niels Andersen will be on the innovation stage on Sunday,
November 2, 2014 2:00-2:30 PM ( PACKEXPO N-4570) providing “A
practical example of how to get the benefits of OMAC PackML without having to
replace the existing PLC”
When developing applications for the packaging automation
market, either as an OEM or as the application developer for a product
packaging line, it’s important to look at some of the trends of the packaging
market, and develop applications that not only meet your current requirements,
but have the flexibility to develop and change along with the industry. Here
are a few trends developing across the packaging industry:
Easily Customizable HMI
Templates –
Another trend that is applicable to both OEMs and application developers for
the packaging of a product line is the standardization of HMIs, and the
creation of template applications that can be easily customized. An HMI with a
standard look and feel greatly reduces the learning curve required for training
machine operators. Template HMIs designed to offer a consistent look and feel
make it incredibly easy to reduce both development time and training time for
the end user. When creating standardized HMIs and customizable HMI templates,
plan navigation and screen options for a wide variety of uses, so that screens
can be customized for different machines quickly and efficiently.
OMAC* PackML and Other Production
Improvement Resources
Another trend is the OMAC PackML, a controls language
standard which improves communication and interoperability between devices. Based on its Wonderware InTouch Machine Edition human
machine interface and Wonderware Historian software offerings, the Wonderware
OMAC PackML solution includes the PackML State Model, Control Modes and
PackTags, providing a well-defined pattern for describing machine conditions
and sharing the information with users and other systems. It simplifies
machine-to-machine communication, more tightly integrating packaging systems
with production line systems while reducing the communication burden on
real-time control systems. Additionally, a configurable user interface shows
machine operators exactly how much time they have spent in each machine state
and provides an overview of the most common reasons a system might stop. This
enables the operator to correct problems in real time, before stops can
negatively impact the business.
The solution integrates
natively with Wonderware System Platform, Wonderware MES Operations and Wonderware
MES Performance software. It can also be integrated with Wonderware Intelligence
software applications for access to a greater amount of production data. Such
integration contributes to business and line optimization, including new
ability to spot bottlenecks and manage work orders, as well as improves overall
equipment effectiveness, production execution and traceability.
Better Alarming Capabilities to Reduce Downtime – Packaging
solutions providers are increasingly requesting better diagnostic and alarming
capabilities that will assist in reducing machine downtime and product waste.
Many machine builders and packaging solution providers are including alarming
capabilities that will allow packaging machine operators to view and
acknowledge alarms from wherever they are, via smartphone or tablet. Because
one operator may oversee several machines, it’s important that they be able to
access individual machines without actually being present at the HMI panel.
Developing applications capable of sending alarms to a mobile HMI can
be one way to allow one operator to move down the product line as the product
does, and oversee the process from start to finish. Wonderware software can view alarms on a variety
of devices including smart phones.
A Focus on OEE Dashboards – Another trend in
packaging is a greater focus on OEE (overall equipment efficiency), especially
now that OEE data can be displayed directly on the HMI as an easy-to-read
dashboard, or shared through the Cloud to plant-floor managers who can make
decisions during packaging. With access to tablets and smartphones, it’s
possible to share OEE data from each machine on a line, and then read that data
in easily understood graphics that can enable quicker decisions. Wonderware Software
can offer ways to quickly and easily develop OEE capabilities for an HMI system.
Predictive and Preventive Maintenance – Properly built HMI Systems include
applications of predictive maintenance within the design, allowing equipment to
maintain higher levels of operational efficiency. Perform maintenance at
specified maintenance intervals instead of having equipment down-time during
production runs. Schneider Electric can help you design you application
to incorporate the latest science in predictive maintenance. Visit our booth (booth
E 7130) to learn more about Big Data management and reporting with Wonderware Online, combining
historian, mobile reporting and clients in an SaaS package.
Improved Integration – When packaging trends
change quickly, many machine builders and managers worry about obsolescence and
a lack of flexibility in packaging machines. Many machine builders and
packaging solutions providers are meeting the need for more flexible packaging
lines by choosing HMI/SCADA platforms that can be integrated easily with
disparate hardware and systems such as MES and ERP. Wonderware InTouch
Machine Edition serves as an excellent platform for these highly
integrated systems thanks to patented SQL database connectivity and over 240
native drivers for every major manufacturer of PLCs and controllers, along with
industry standard drivers and gateways to other HMIs and platforms.
Increased Safety Regulations, and Product Traceability –
Product traceability is a growing concern among manufacturers, particularly in
food, beverage, and pharmaceutical industries. This is especially true in
emerging markets, such as in Asia Pacific region and Latin America. Packaging
solution providers and machine builders can help customers meet this need by
developing applications that include automated reporting capabilities that
generate detailed reports for each packaging line. In addition, RFID and
barcode data can be stored automatically. Additional traceability measures such
as operator logins and password protection can improve accountability. Schneider
Electric is a leader in providing assistance in creating applications and
projects needed in creating Food and Pharma 21CFR Part 11 facilities.
*About
OMAC
The
Organization for Machine Automation and Control (OMAC) helps manufacturers and
suppliers work together to identify new and innovative ways to increase the
effectiveness of their production operations. OMAC brings together leading
End-User Manufacturers, OEM Machine Builders, System Integrators, Technology
Providers, and Non-Profit / Government Agency organizations to address issues
that confront global manufacturing today. OMAC’s two working groups, Packaging
and Manufacturing, lead the way in producing industry consensus guidelines that
help manufacturers reduce their delivery times, be more efficient with
available resources, and increase profitability. More information about
OMAC is available at www.omac.org.
For
more information about Wonderware InTouch Machine Edition, please visit www.wonderware.com/ITME,
blog.wonderware.com. You may also sign up for a weekly newsletter at wonderware.com/wwtimes
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