2014 ARC Industry Forum: Applying programming standards to system integration

Certified integrators are important for the implementation of PackML, according to Jeff Shiepe, project engineer at Nestle. In his presentation at the 2014 ARC Industry Forum, he toplined some integration challenges and lessons learned in a recent Nestle factory expansion.

02/14/2014


It is important to use a certified integrator for a PackML implementation, said Jeff Shiepe, project engineer for electricity and automation at the Nestle professional LJ Minor Factory in Cleveland, Ohio, at his 2014 ARC Industry Forum presentation entitled “Lessons learned in the system integrator-end-user customer relationship.”

Nestle makes bases for bases, sauces, and concentrates. The factor is flexible, small batch, and custom. In 25 years, Shiepe’s factory expanded its 200,000 square-foot facility by 175,000 square. Increasingly the factory has transitioned to automation

Schiepe toplined some challenges associated with the expansion:

  • Maintain flexibility and quality
  • Process orders came through multiple systems.
  • Complete integration with MES and ERP systems, adding packaging side of the factory
  • Communication among equipment was needed to support the business model.

Nestle installed supervisory controls through the PackML standard, connecting equipment PLCs to supervisory control (PackML) up to MES/ERP, propagating appropriate data between layers based on the PackML unit states. The system provides triggers to MES for automated transactions.

Getting buy-in on PackML value was a challenge, so it was important to hire a certified integrator with PackML experience to correlate project parameters and how PackML would be implemented. Integrator explained concepts and benefits in layman’s terms to those in the plant.

Working with original equipment manufacturers (OEMs) was a challenge, and the integrator helped since PackML isn’t the standard for most OEMs. Integrator provided sample PLC code to all OEMs and worked as necessary with OEM engineers.

Lessons learned:

  • Must develop well-defined specs, and all stakeholders must agree. Once coding starts, changes are costly.
  • PackML needs more exposure to global OEMs and should be part of their offerings.
  • Until OEMs embrace PackML, there will be additional costs, but benefits outweigh them.
  • Have a contingency plan. If OEMs can’t or won’t do it, ensure integrators can.
  • Ensure that the integrator understands PackML (or any technologies used) and can train OEMs to use it.
  • As a last resort, the integrator has to be willing to write the code if the OEM can’t or won’t.
  • Develop checks and balances to herd off any problems.

- Mark T. Hoske and Jordan M. Schultz, content managers, CFE Media, Control Engineering, and Plant Engineering, mhoske@cfemedia.com, jschultz@cfemedia.com.



No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
The System Integrator Giants program lists the top 100 system integrators among companies listed in CFE Media's Global System Integrator Database.
The Engineering Leaders Under 40 program identifies and gives recognition to young engineers who...
This eGuide illustrates solutions, applications and benefits of machine vision systems.
Learn how to increase device reliability in harsh environments and decrease unplanned system downtime.
This eGuide contains a series of articles and videos that considers theoretical and practical; immediate needs and a look into the future.
Additive manufacturing advancements; Machine vision enhances robotics; Fieldbus evolution; Process safety; Advice from System Integrators of the Year; Road to IANA
Salary and career survey: Benchmarks and advice; Designing controls; Remote data collection, historians; Control valve advances; Hannover Messe; Control Engineering International
System integration: Best practices and technologies to help; Virtualization virtues; Cyber security advice; Motor system efficiency, savings; Product exclusives; Road to Hannover
This article collection contains several articles on the Industrial Internet of Things (IIoT) and how it is transforming manufacturing.
PLCs, robots, and the quest for a single controller; how OEE is key to automation solutions.

Find and connect with the most suitable service provider for your unique application. Start searching the Global System Integrator Database Now!

The digital oilfield: Utilizing Big Data can yield big savings; Virtualization a real solution; Tracking SIS performance
Getting to the bottom of subsea repairs: Older pipelines need more attention, and operators need a repair strategy; OTC preview; Offshore production difficult - and crucial
Digital oilfields: Integrated HMI/SCADA systems enable smarter data acquisition; Real-world impact of simulation; Electric actuator technology prospers in production fields
click me