Nestlé’s packaging automation strategies and OMAC Packaging Workgroup activities are intertwined and leading to new potentials for increasing packaging efficiencies worldwide.
Nestlé global automation manager and OMAC Packaging Workgroup (OPW) chair Dr. Bryan Griffen began his presentation at The Automation Conference, held in Chicago May22- 23, by describing the current status of his company’s multi-vendor OMAC packaging simulation line. But it soon became apparent that more initiatives were forthcoming, beginning with issues confronting Nestlé worldwide and leading to solutions that will be developed by OPW committees.
The new initiatives are human-machine interface (HMI) standardization, a standardized packaging user requirements specification, and on-screen machine diagnostics. These all represent topics that have defied standardization in the past, and which will all contribute to simplified and more efficient packaging operations.
HMI harmonization
Dr. Griffen showed 13 different HMI screens on a single packaging line, with absolutely no common look or feel, from inspection to check weighing to coding to packing and transport functions. He stated that more than 200,000 HMIs are currently in use in Nestlé factories, by over 70,000 people involved in packaging operations. Because the screens are all different, specific training is required for each type of equipment, costing both time and money.
To solve this problem, he showed a standard HMI solution that has been developed by the company’s Packaging and Automation groups. Machine-specific requirements are displayed in the center of each screen, but a common template has been produced for a top menu bar, command buttons, navigation, and active alarms and event messaging.
He stated that the template will be more user friendly, will allow operators to become more mobile across machines and lines, and make more diagnostic information accessible from the equipment. The initial HMI specifications have been completed, are currently under internal validation, and pilot applications are being executed.
URS standardization
With international standards come the opportunity to streamline and standardize user requirements specifications. Dr. Griffen revealed a series of eight modules covering Nestlé’s packaging requirements. The modules are: Procurement, Line integration, Equipment, Safety/health/environmental, Hygiene, General design, Quality and Electrical & Automation.
Electrical specifications, he recounted, formed the basis to begin standardization, covering Labeling, Grounding and shielding, Wiring, Buttons and alarms management, and documentation. This specification was delivered in September 2011 and is not only in use for all new machine specifications, but serves as a checklist during Factory Acceptance Testing (FAT).
On-screen machine diagnostics
A fundamental difference between process and packaging for Nestlé, Dr. Griffen explained, is that Nestlé develops its process technology internally and therefore intimately understands and owns the intellectual property of the control code. Packaging machinery, however, is developed by many different machine builders, so Nestlé does not want maintenance personnel accessing code that is not natively familiar.
To make this happen, he called for machine builders to make all diagnostic and corrective actions accessible on the HMI rather than going inside the controller. He recognized that this will require a new effort from most suppliers, but one which will add value by reducing downtime and improving efficiency.
This coincides with the views of some machine builders who express concern that too often changes made to their code by customers to solve a problem in reality only mask the root cause, which can lead to a more serious maintenance or warranty condition in the longer run.
In addition, Dr. Griffen gave updates on Nestlé’s safety specification and how the OMAC simulation line is proving that different brands of controller can communicate on the same network and protocol, using international standards and coordinating equipment without the nee for a separate line PLC.
He identified how the OPW committees support the Nestlé strategies described in his presentation in terms of both technology and marketing. And he shared a PackAdvantage timeline for identifying barriers to adoption, quantifying benefits, coordinating with the appropriate OPW committees and subcommittees to resolve barriers, and presenting a final report at PACK EXPO International 2012.
In his conclusion, Dr. Griffen stated that “We believe that standardization is imperative to improving our overall equipment effectiveness; PackML is our standard for packaging machine automation.
“We are fully committed to the PackML strategy, and we continue to support and develop this strategy through active participation in the OMAC Packaging Workgroup.
“We are developing complimentary tools and specification for application as part of our PackML strategy, these include HMI specifications, communications standards and safety system integration – all of which are focused on improving the operability and maintainability of our packaging systems.”
