Recipe for Success: Smart Operations - South East Asia - Rockwell Automation
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July 2018 Issue 56
South East Asia
A Commitment Connected Data Drive Beyond Crafting
Inside to Taste Helps the Milk Flow Compliance with a Revolution
Electronic Batch Recordings
Recipe for Success:
Smart
Operations
EXECUTIVE MESSAGE
Contents
04 News & Events Pouring Technologies
Highlights on the journey toward
The Connected Enterprise
into the Industry
06 Cover Story –
Recipe for Success:
Smart Operations
Smart manufacturing can help companies
to enhance their business processes to a Digital transformation is a global industrial trend that uses networking and
level that could previously only be imagined. smart technologies to integrate all processes – from sourcing and
manufacturing to distribution.
10 Case Study
main text
A Commitment to Taste
We can see this today not just in the food and beverage industry, but also in
Connected Data Helps the Milk Flow
pharmaceutical and consumer packaged goods industries, which are complex
and rapidly evolving. Markets and tastes are changing yet nourishing growth in
12 Technology Watch
Drive Beyond Compliance with these industries. Consumers are more connected, informed and outspoken. And
Electronic Batch Records competition is everywhere — from store brands and online food providers to an
ever-growing number of specialty product makers.
14
Crafting a Revolution For companies in these vital sectors looking to remain competitive, understanding
how to maximize this golden chance to grow and develop their businesses and
16 Product & Solution organizations through better plants, people, processes and tools will be crucial. Food
Focus and drugs producers, both original equipment manufacturers (OEMs) and end users,
Introducing the latest and updated need operations and a workforce that can keep up.
technologies and solutions for
smarter operations Fortunately, smart manufacturing can help them do just that.
Smart manufacturing is connected, information-enabled manufacturing. It
July 2018, Issue 56
capitalizes on the latest technologies to re-define food and beverage operations.
This magazine is published 4 times a year by Rockwell Automation helps companies of all sizes build their Connected Enterprise
and improve their manufacturing processes by allowing data from multiple plants
and production lines to be gathered and analyzed, yielding better decisions based
on key performance indicators (KPIs).
This magazine is produced and printed by
When leveraging the cutting edge smart machines and solutions, they further
Regional Headquarter in Singapore
Rockwell Automation Southeast Asia Pte Ltd
No. 2 Corporation Road, connectivity and helping minimize exposure to information security risks.
#04-05/06, Corporation Place,
Singapore 618494
Main Telephone Line : (65) 6510 6688
Main Fax Line : (65) 6510 6699
If these industries can successfully realize the potential of intelligent connectivity
Website: http://www.rockwellautomation.com/en_SEA and automation technologies offered by The Connected Enterprise and smart
To subscribe or unsubscribe, substantial.
visit :
http://www.rockwellautomation.com/en_SEA/go/ATAP
I invite you to review this issue of Automation Today Asia Pacific to learn more
consider the strategy for starting a journey to smart manufacturing.
Your industry is marching forward. How well are you and your company preparing
Copyright© 2018 Rockwell Automation Inc. All rights reserved. The contents of this
publication may not be reproduced in whole or part without the consent of the
for the new incoming technologies?
copyright owner.
FactoryTalk Brew, FactoryTalk Network Manager, Integrated Architecture, IntelliCENTER,
LISTEN. THINK. SOLVE., PanelView, PartnerNetwork, Pavilion8, PharmaSuite, PlantPAx,
PowerFlex, Rockwell Automation, Studio 5000, VantagePoint are trademarks of Rockwell
Automation, Inc.
EtherNet/IP is a trademark of ODVA, Inc.
Microsoft Azure is a trademark of Microsoft.
Joseph Sousa, President
All other trademarks are the property of their respective owners.
2 ASIA PACIFIC
SOUTH EAST ASIA
Proven Expertise For Your Success
Leverage In-depth Experience to Achieve for Smart Manufacturing
Solution Partners, as part of our PartnerNetwork™, are comprised
of global system integrators with differentiated skills and industrial
experience in your domain.
Our growing community of system integrators in Asia Pacific
understands your challenges, combines new technologies and
simplifies system deployment with their application expertise.
This is how we bring your Connected Enterprise to Life.
Experience the power of our PartnerNetwork:
www.rockwellautomation.com/global/sales-partners
Copyright © 2018 Rockwell Automation, Inc. All Rights Reserved.
NEWS & EVENTS
A Collaborative Solution Combining Expertise Brings
for Today’s Brewer More Innovation Opportunities
Rockwell Automation and McRae Integration, a Rockwell Rockwell Automation joined
Automation Solution Partner and member of the the “Shapers,” a team of
Rockwell Automation PartnerNetwork™ program, are industrial automation
leveraging their combined strengths to help serve the growing specialists and solution providers
automation market for brewers. including ABB, Cisco and National
Instruments, to create a
The solution combines McRae’s carefully developed scalable communication solution for real-time and sensor-to-cloud
and repeatable software solutions with the PlantPAx® distributed applications in industrial operations. The solution will be based on
control system from Rockwell Automation. Together, the solution the OPC UA protocol, which allows easy and secure sharing of
helps breweries enhance quality and consistency, scale up information across different vendor technologies and the time-
production, reduce production complexities and better manage sensitive networking (TSN) suite of standards, which helps
recipes. In addition, product and solution support, service and improve latency and robustness in converged industrial networks.
training capabilities are available globally. Rockwell Automation has also joined Plug and Play’s corporate
partnership network, which provides access to qualified and
strategically aligned early-and-growth stage startups. Plug and
Advanced Automation Technology Play is a global platform that is creating startup ecosystems in
for World-class Mine many industries and bringing together the best startups and the
biggest corporations in the world. Through this collaboration,
NioCorp Developments Ltd awarded Rockwell Automation Rockwell Automation can identify,
the opportunity to engineer, design and procure process review and leverage new and
automation and instrumentation for NioCorp’s proposed d i s r u p t i ve I I oT te c h n o l o gi e s
critical minerals, mining and processing facility in Elk Creek, developed by world-class startups enhancing its industry-leading
Nebraska, U.S.
Rockwell Automation will be the main automation contractor related solutions and services.
for the project. The system integration will be provided through
MAVERICK Technologies, a Rockwell Automation company that
specializes in process automation solutions. Endress+Hauser, a Valuable Insights into
Brewing Process
Colorado State University (CSU) recently opened a new
hands-on brewing lab and industry showcase that will give
Strategic Partnership and Billion students practical experience for careers in the brewing
Investment Drive Digitalization and fermentation industries.
Malisko Engineering, a Solution Partner of Rockwell Automation,
led the automation specification and integration efforts of the
agreement for a strategic partnership that is expected to new brewery. CSU will be home to two future breweries, one
accelerate growth for both companies and enable them to modeled after a craft-style brewery and the other modeled after a
be the partner of choice for customers around the world who commercial brewery, albeit on a smaller scale. Both breweries will
want to transform their physical operations with digital run on the PlantPAx distributed control system (DCS) from Rockwell
technology. As part of the partnership, Rockwell Automation will Automation, and FactoryTalk® Batch software supports the reuse of
make a $1 billion equity investment in PTC, and Rockwell modular phase code, provides intuitive recipe authoring and has
Automation’s Chairman and CEO, Blake Moret , will join PTC’s built-in batch tracking and reporting.
“The on-campus breweries provide
closing of the equity transaction. industr y with a unique resource
The partnership leverages both companies’ resources, to engage in recipe development,
technologies, industry expertise, and market presence, and will lab testing, operational technology
include technical collaboration across the organizations as well as research and process data analytics,” said
joint global go-to-market initiatives. The alignment of their smart Dan Malyszko, director of operations
factory technologies and best-in-class information solutions will and lead engineer at Malisko Engineering of Denver. “With the
enable customers to achieve increased productivity, heightened PlantPAx system, students gain valuable insights into the brewing
plant efficiency, reduced operational risk, and better system process while getting practical exposure to a scalable, stable and
interoperability. operator-friendly automation platform.”
4 SOUTH EAST ASIA
NEWS & EVENTS
Showcasing Smart Manufacturing Ultimate Experience –
Advances and IIoT Opportunities
ASIA PACIFIC EVENTS
Learn and Share
GLOBAL EVENTS
Rockwell Automation recently presented at the Manufacturers and companies in the Asia Pacific
INTERPHEX event in New York, U.S., highlighting advanced region now have the chance to attend Rockwell
technologies and solutions to address challenges of life Automation TechED™ and the Process Solutions User
science companies on April 17-19 in New York, U.S. Group (PSUG) at the same time. Both events will be held in
JW Marriott Hotel Singapore South Beach, Singapore on
Attendees learned how they can use July 18-20.
digital and automation technologies to
help improve quality and compliance TechED is a multi- day,
and manage data integrity and security. hands- on event focusing
They also learned about single-use on the advanced technologies to help maximize assets
technologies that allow manufacturers and information across operations. The number of people
to improve flexibility and reduce footprint, helping to speed attending TechED is growing every year because it focuses
time-to-market. on the latest technologies to enable a Connected Enterprise
A few days later on April 23-27, Rockwell Automation and and demonstrates how companies can connect silos of
strategic alliance partners co-exhibited at Hannover Messe 2018 information to extract real business value.
in Hannover, Germany.
At that event, Rockwell Automation demonstrated how it PSUG is an interactive industr y-leading event to
can help companies accelerate digital transformation and use gain greater insight into the latest process automation
Industrial Internet of Things (IIoT ) technologies to be more technologies. It provides a unique perspective on how to
competitive and to bring new value to their operations. optimize process applications as well as the opportunity to
interact with the Rockwell Automation global process team.
Rockwell Automation on the Move Rockwell Automation invites industry professionals to join
these events and realize the importance of investing in smart
manufacturing and production, as well as the costly risks of
Rockwell Automation On The Move™ (RAOTM) 2018 missed opportunities.
Conferences were recently held in Seoul, Korea. Over a
thousand attendees came to the events on May 10 and Additionally, Industry of Things World Asia and the Pharma
discovered the latest technologies, applications and services Manufacturing Execution System (MES) Singapore will also be
from The Connected Enterprise portfolio, as well as smart held that week. As a global platinum partner for Industry of
manufacturing solutions. Things World and Pharma MES events, Rockwell Automation
The company’s strategic partners from the PartnerNetwork
program presented their collaborative offerings at the events. Sands in Singapore on July 16 – 17.
There were also various technical sessions and hands-on labs.
AP Customer Events Calendar
Upcoming in Jun - Aug 2018
FactoryTalk Analytics platform, intelligent motor control solutions
and premier integration capabilities. Event City/Country Date
6th Asia Drink Conference Bangkok, Thailand 15, June
Industry of Things World Asia
Marina Bay Sands,
16 – 17 July
Singapore
Pharma MES Asia
JW Marriott South Beach,
18 – 20 July
Singapore
RAOTM 2018 Ho Chi Minh City, Vietnam 24, July
Rockwell Automation On The Move 2018 at Conrad Seoul, Korea
TechED & PSUG China Beijing, China 24 – 25 July
After the success in Korea, the next RAOTM was held in
RAOTM 2018 Hanoi, Vietnam 2, August
Nanjing, China on May 23-24. Through these events, Rockwell
TechED Australia Sydney, Australia 28 – 30 August
Automation provided industry professionals and manufacturers
in Asia Pacific with information on smart manufacturing * Each event is subject to change
technologies, which will enable them to implement The For more details, visit :
Connected Enterprise. www.rockwellautomation.com/global/events/events.page
SOUTH EAST ASIA 5
COVER STORY
Evolving industry challenges are confronting smart manufacturing enables a single view of
global food and beverage manufacturers. The operations within an organization and seamless
three major drivers behind these challenges communication across people, data and assets.
are demands from retailers and consumers, With enhancements to real-time collaboration
requirements from regulators for the quality of food and continuously improved processes, smart
that is produced, and needs from brand or business manufacturing keeps operations moving.
owners who want to make superior products while
The Right Tools.
Bringing together disparate networks, improving
All of this requires companies and manufacturers production visibility and attaining better control of
to embrace new Industrial Internet of Things (IIoT) processes can help make operational improvements
and digital technologies to continually address
process improvements and production expansion activities such as changeovers. Additionally, wider
opportunities. availability of information can help manufacturers be
more responsive to supply-chain developments and
Smart manufacturing can help food and beverage improve on-demand production.
businesses take a fresh and more sophisticated In particular, food and beverage producers can use
approach to the way they run their operations. smart manufacturing technologies to transform and
Connecting previously disconnected processes, improve manufacturing operation, including:
6 SOUTH EAST ASIA
Recipe for Success:
Smart Operations
Smart manufacturing can help companies to enhance their
business processes to a level that could previously
only be imagined.
• Better intelligence: Manufacturing information is • Enhanced control: A modern distributed control
the basis for deeper analysis to improve operations. system (DCS) integrates all automation processes
The ability to access real-time information on into one plant-wide system. DCS features, such as
parameters, such as temperature, pressure, cook model predictive control (MPC), alarm management
time and clean-in-place, can help to create a more and batch management, can help improve
proactive approach to food safety and quality. plant efficiencies and operational performance.
Automated data collection, logging and reporting Virtualized servers and workstations can help
also help to reduce the regulatory compliance reduce IT investments, improve uptime and extend
burden. life cycles.
• Enterprise manufacturing intelligence (EMI): • Smar ter machines: Smar t machines and
EMI software organizes, correlates and presents equipment can provide unprecedented access
production information to help operators spot to data. Real-time data can be logged and
issues and adjust in real time. Data-rich dashboards analyzed to help workers make better decisions
display how a machine or line is performing and and support optimization of not only their
notifies workers if production parameters exceed machines, but their entire manufacturing
pre-set limits. process.
SOUTH EAST ASIA 7
COVER STORY
Get More Out of Production managing the workforce. All companies and their plants
When it comes to improving yields, smart - regardless of size - are under the same pressures to
manufacturing provides opportunities to not improve productivity and protect workers.
only follow the flow of ingredients and track yield
throughout production, but also gives more in-depth As older, more experienced workers retire, younger,
insights into key production areas that can help show less experienced workers are taking their place. And
where operations can improve. new workforce needs new tools and workflows to
Manufacturing execution system (MES) software
is one of the fundamental building blocks in process to change, workers need information.
control within food and beverage production. It
automates data collection for deeper and more Worker-specific instructions and contextualized
immediate production visibility. This can help production information can help reduce complexity for
manufacturers make better decisions based new workers. Mobile devices can deliver information
on operations, the commodity market and raw to them in an interactive, familiar format. Digitizing
ingredients to help manage material variance and processes can also capture critical “tribal knowledge”
improve yield. from experienced workers before they retire and
improve efficiency in operations and work conditions
Traceability within the supply chain is becoming for a new workforce.
or help prevent and manage recalls. By applying For example, after Milk Specialties Global rolled out
MPC as an intelligent layer on top of the existing new manufacturing intelligence systems across their
automation system, operating parameters for three raw milk facilities, production control systems are
all processes can be captured. The MPC predicts no longer data isolated, and the reporting capabilities
conditions of the process areas and lines and then are no longer outdated and labor intensive. With the
makes ongoing adjustments to continuously increase FactoryTalk® VantagePoint® enterprise manufacturing
has the real-time visibility and workers can view data
For example, Miraka had their dairy processing quickly and within multiple contexts to understand
plants adopt an innovative solution to identify production data such as chemicals in products (CIP)
process improvements and maximize production. chemical usage and tracking.
The installation of Pavilion8® MPC software and smart
upgrades to the control system helped them achieve
There are tailored scoreboards in
a capacity increase of more than four percent during
key production stages for workers to
peak season, and raised the moisture targets by 0.04
view displaying plant-summary data
percent.
in different areas. Also, reporting capabilities
are smarter as automated reporting saves time
Even a small improvement in yield can translate to compared to manual reporting. Workers are
empowered to meet production targets.
example, maximizing material usage and reducing
scrap annually by as little as 1 percent can save
hundreds of thousands of dollars in wasted material. Moreover, safety systems that are integrated with
machinery control systems can help mitigate risks
and are not as prone to nuisance shutdowns as older
Miraka’s facilities in New Zealand hardwired systems. With data on safety incidents,
reduced product variability issues manufacturers can identify risks and adjust areas where
and increased the consistency of
safety-related shutdowns are occurring.
their dairy products. They have also improved
protein and fat control, providing the potential
to reduce fat plus protein giveaway by more
Measure the Meters
Improved productivity can be a corollary benefit
than 100 tonnes per year.
when companies use smart manufacturing to
address their management of resources, including
Frictionless Productivity water, air, gas, electricity and steam (WAGES).
The applications and advantages of smart
manufacturing are not just confined to machines - Since energy costs continue to rise, food and
they can also create real benefits when it comes to beverage producers are taking greater control
8 SOUTH EAST ASIA
over these expenses to gain a critical competitive
advantage. The key to reducing energy-related
costs is understanding where, when and how
much is being consumed. Armed with this
information, companies can proactively manage
load requirements, improve system performance and
reduce costs.
Smart technologies in energy management help need to protect not only their uptime and intellectual
manufacturers track energy consumption in some property but also the processes, equipment and
people responsible for keeping the products safe and
production lines. By monitoring consumption, these high quality.
companies can make operational changes to reduce
energy consumption and costs. For example, Arnott’s started their smart plant
operations by having their manufacturing plant in
Access to historical data also allows management Adelaide, Australia, move to a new control platform.
to address intermittent or persistent power-quality They leveraged the intelligence of the PowerFlex®
issues, such as voltage sags or harmonics. By doing variable speed drives on an EtherNet/IP™ network to
so, they can save thousands of dollars in damaged help operators access real-time information securely
equipment or poor-quality product, and avoid in the plant. Since the systems were centralized and
penalties associated with power-factor problems on the site’s flexibility and agility were improved, the
the energy grid. This type of data monitoring and company successfully reduced engineering time and
analysis is critical to making improvements; hence production loss during the plant upgrade.
companies are able to look ahead and make smarter
decisions when it comes to controlling energy usage.
Thanks to the upgrade, Arnott’s plant
For example, Faribault Foods’ bean plant replaced
its existing production infrastructure with a process and setup process and reduced human error.
solution to boost efficiency on managing WAGES
consumption information. With a new set of Allen-
Bradley® smart drives and controllers and by A Key to Stay Ahead
deploying more intelligent motor control throughout There is no one-size approach for all. Also, smart
the plant, they reduced more than 38 percent of manufacturing is not a product that can be bought
natural gas usage and more than 100 million gallons or a machine that can be installed. It is a journey
overall water usage each year. and it is a case of helping manufacturers understand
where they can start.
Faribault Foods understands the
Some companies have made it. Their success
importance of greening the entire
food supply chain. Through smart proves that smart manufacturing has the potential
manufacturing, the company increased product to transform food and beverage manufacturing
quality and regulatory compliance. Also, they operations.
successfully improved production reliability and
The ability to access relevant, real-time and role-
based information can help enable more informed
decision-making at every level and create nearly
Protect the Data and Recipe endless opportunities to improve processes.
Advances in equipment, control systems and
food and beverage manufacturing. By combining the
Internet of Things, wireless and mobile technologies, and more responsive operations.
data analytics and network infrastructure, companies
can access and act on the data from their operations.
For all the benefits that smart manufacturing can beyond operational improvements. A secure network
infrastructure, greater connectivity and access to
to security. actionable information create opportunities to
enhance quality, food safety and worker safety – all
In the food and beverage industry, manufacturers while helping ease regulatory compliance.
SOUTH EAST ASIA 9
CASE STUDY
A Commitment to Taste
A brewing solution with a single system helped a leading global brewer ensure
the consistency of their beer’s quality
China has become the largest beer
market in the world, serving up
more than double the pints
compared with the United States last year.
This fact plays an important part in the
global strategy of a leading company in the
beer industry – they brew one in three cans
of beers sold worldwide. In order to expand
its presence in the market, the company
built three new breweries in China and
strived to maintain strict taste quality
control. control. They also used the PlantPAx panel new breweries was put into operation. With
To ensure the "consistency of taste of library at the computer layer to provide a the open network, the PlantPAx system
every bottle of beer at every brewery," the standardized interface for dynamic display, provides a high level of compatibility with a
company needed a mature, reliable and alerts, event and trend management. wide range of automation technologies.
multifunctional automation platform that The standardized presentation of By leveraging EtherNet/IP™ networking
could enable the precise, systematical logic and graphic objects ensured the technology, the network at control layer
control over each piece of equipment consistency of information received
and each step of the process and allow by operators and their operations and of I/O for a very convenient configuration.
for simple, consistent operation and Boasting excellent scalability, the PlantPAx
maintenance. Support for standardization standardized operation of equipment and system could easily meet the demands of
was an essential factor. personnel. capacity expansion in the future.
In addition to the PlantPAx capability in The recipe management functionality
Additionally, the new breweries had to standardization of upper and lower devices, and record tracking further optimized the
stay consistent with the company’s other the standardized implementation of the process management, and the modular
breweries around the world in the taste engineering team of Rockwell Automation function extension simplified the design
and quality of beer produced to expand satisfied the strict requirements of the of spare parts and training, reducing the
their capacity with the increasing market company. breweries' maintenance and operations
demands. This required the application The Historian in PlantPAx provided costs while significantly contributing to
systems to have steady scalability for at a single platform for data analysis and increased efficiency and consistent high
storage, and an integrated SQL server into quality.
remained advanced for 10-20 years. the SCADA software package as one data
source. With the brew solution from Rockwell
Standardization Additionally, the equipment-level Automation, the company set a new
Across the Brewery standardized integration solution provided record in feeding rate by completing the
After comparing multiple systems, the a variety of network topologies, including whole brewing process from feeding,
company selected a brew solution from
Rockwell Automation based on their methods - with a Stratix 8000™ switch six hours and 24 minutes, nearly one hour
PlantPAx® distributed control system as used as the backbone of information and shorter than the previous record.
the basic control system for the three new control networks and Stratix 6000 and 2000 Such high-efficiency operation of the
breweries in China. series switches used for equipment and three breweries have paved the way for
The breweries installed the PlantPAx add- production lines. the company's further entry into East and
on interface (AOI) library at the controller Southwest China and even countries like
layer, which included analog, digital input, Cheers to Success Burma, thus significantly expanding the
output of pumps and valves, and loop After one year of construction, one of the company's market share in China.
10 SOUTH EAST ASIACASE STUDY
Connected Data Helps the Milk Flow
Three dairy manufacturers have successfully unlocked their possibilities to
ongoing optimization and improvement
In the dairy industry, the production operations, the EMI software collects,
is dynamic and commodity-driven. correlates and displays real-time process, making continuous improvements.
To h e l p m e e t h i g h d e m a n d , business and laborator y data. It has
companies require a shift in thinking about established a “system of record” that The integrated control and information
what processes and technologies are used, produces a consistent set of facts upon solution provide the facility operators with
as well as what new skills are needed. which decisions can be made. This has the data they needed to make informed
helped justify operational changes and decisions about their operations. With a
The challenges and opportunities are as investments that are crucial to helping the modern system, the facility can now get rid
varied as the companies themselves. Some company keep up with market demands. of the 2,500 hours of manual data collection
may discover bottlenecks in a process that Following the positive changes, the system each year.
can be solved through enhanced machine
control, while others may find that the 7 percent increase in throughput. Process Improvement
ability to predict maintenance and reduce When Miraka decided to embark on
downtime delivers the most benefit. The Besides, the new analytics from the process optimization, they teamed up with
possibilities are endless, but they all need to manufacturing intelligence system helped Rockwell Automation to deploy a system
begin with the basic step – get connected. the facilities manage their water usage. to optimize their milk powder production
Workers were able to monitor drain flows plant in New Zealand. The company had
Advanced solutions and smart and water spikes, keep tabs on water usage its plant adopted the Pavilion8® model
machines enabled by The Connected and address issues such as leaks to meet predictive control (MPC) software platform,
Enterprise empower manufacturers to gain the required reduction. which includes modules to control, analyze,
connectivity in equipment and gain insights monitor, visualize and integrate information
into operations, resulting in automation Continuous Improvements a n d p ro c e s s e s, to i d e n t i f y p ro c e s s
with real-time controls. When Agropur Cooperative discovered improvements and maximize production.
that its Don Mills facility in Canada could no The innovative solution helped the
Operational Improvements longer produce seamless data necessary company increased more than 4 percent
Milk Specialties Global needed help to to continuously improve operations, they in capacity during the peak season, raised
keep up with high demand, therefore they implemented an advanced solution from moisture targets by 0.04 percent and
invested in manufacturing intelligence to Rockwell Automation to modernize the improved protein and fat control to reduce
achieve real-time analytics and insights into facility. The solution included a set of fat plus protein giveaway by more than 100
its operations to drive improvements in Allen-Bradley® ControlLogix® controllers, tonnes per year. In addition, optimization
production processes. PowerFlex® drives and PanelView™ human of the machines resulted in an estimated
The company rolled out the FactoryTalk® machine interface (HMI) hardware. Each energy savings of greater than one percent
VantagePoint® enterprise manufacturing HMI ran FactoryTalk® View Site Edition per ton of milk powder during peak
intelligence (EMI) software from Rockwell software on a virtualized server, establishing production.
Automation across its three primar y the standard for all additional software.
raw milk facilities in the U.S. Within their This created the foundation for converting By installing advanced technology and
reams of data into actionable information. equipping machinery to collect more
The company also installed FactoryTalk data at the edge, businesses can gain
AssetCentre software to manage insights into how to get the most out of
automation assets and versions control, their smart machines and predict failures
and keep up-to-date documentation. The before they happen. The optimized and
FactoryTalk VantagePoint EMI then provided connected processes in smart factories
a new level of access to all data from will deliver high-quality products, improve
disparate systems across the entire facility agility and increase revenue, giving smart
as the software exposed what occurred on manufacturers a competitive edge.
SOUTH EAST ASIA 11TECHNOLOGY WATCH
Drive Beyond Compliance with
Electronic Batch Recordings
digitizing paper records while conforming to regulations.
Technology and regulations often A GPS of Operations time-to-market by using a modern and
change the food and drug market. By replacing paper-based with dynamic EBR.
Although smart manufacturing is computer-based workflows, chances of
pushing a rapid development of smart getting human error are lowered and The quality assurance (QA) teams can
machines and equipment and offering compliance processes speed up. However, use its review-by-exception functionality to
many new possibilities, the Food and Drug EBR technology can do far more than spot deviations much faster than scanning
Administration (FDA) is also stepping up its
enforcement of regulations. Some industry professionals describe only can it speed up documentation review
Manufacturers are experiencing tough EBR as a GPS of manufacturing operations times and reduce the time required for
scrutiny across the globe and the spectrum because it can guide users to the desired releasing a product from the warehouse,
of their industries, especially in quality destination, find the shortest trip, provide but it also can improve batch accuracy and
control activities, safety reporting and alerts to dangers, and give real-time consistency.
manufacturing operations. Organizations feedback. Pre-validated recipe building blocks
have therefore star ted paying more available in advanced EBR systems can be
attention to reduce risks through the W h e n i n te gr a te d i n to a s c a l a b l e re-used to achieve shorter deployment
implementation of strong management manufacturing execution system (MES) times. Instead of time-consuming custom
controls. such as Rockwell Software PharmaSuite® programming and validation, recipe authors
MES, EBRs become more dynamic and can use a library of instructions to create
Electronic batch records (EBR) were once can support operations in new ways.
mainly used for helping pharmaceutical Especially when operations are moving to
companies automate away the mountains a Connected Enterprise, EBR can begin to Likewise, real-time information access
of paperwork required for maintaining access enterprise-wide information, deliver creates opportunities to speed up processes
production batch records. When part of the role-based instructions to workers and throughout the production cycle. For
FDA specification known as 21 CFR part provide exception-based reporting. example, gauge data can be automatically
11 was issued, production facilities were collected versus requiring a worker to
permitted to use EBRs to document each Faster Routes physically walk to each gauge and record
step in the production, packaging and Time-to-market is critical for their readings. The ability to collect and
handling of every batch of their products. pharmaceutical manufacturers who want review process information helps make the
Since then, industries started to realize how to meet customer demands and maximize identification and removal of unnecessary
automating batch records can also help tasks such as redundant material checks
dates. There are multiple ways to accelerate
12 SOUTH EAST ASIAMoreover, the time savings only become
greater in a Connected Enterprise. The
ability to connect an EBR system to mobile
devices, for example, can give workers faster
and more convenient access to information
OMPLIANCE
Lengthy compliance activities drive up
the cost of production operations while
the product sits waiting to be shipped.
Additionally, human errors made during the
production or documentation processes
can result in wasted product or, worse,
contamination and potential recalls.
N ow m a n u f a c t u re r s c a n u s e E B R
technology to find new ways to optimize or transmitted. By integrating EBRs into an applications that must comply with 21 CFR
total cost of production. MES, manufacturers can automate manual Part 11.
Adopting an EBR system for compliance documentation processes to reduce the
purposes immediately removes the time likelihood of errors, such as miscalculations This latest version of machine-level
and costs associated with storing physical and false records. HMI has a new onboard audit feature
documents. Dynamic EBRs can expand that records and stores operator’s actions
on those savings — for example, by using The ability to integrate recipe and order locally. It also audits all tag writes and
automated QA functions to reduce the cost information in a Connected Enterprise can system actions, such as a user logging
of researching process deviations. help get the right information to workers in to acknowledge an alarm. The system
as efficiently as possible. For example, the can export the audit history, alarm history,
Also, reducing the risk of human error system enables delivery of individualized, and diagnostic log to a comma-separated
combined with EBR features, such as values (CSV) file. This information can be
enforceable workflows, can help prevent operators, and enforcing processes and used to generate an EBR.
production or recording errors and reduce
wasted product. Furthermore, preventing CFR part 11. And most importantly, in this A New Direction
these errors can also help minimize the era of Internet of Things (IoT), it can ensure Governments around the world
chance of expensive, brand-ravaging all electronic records to be trustworthy and are designing and implementing anti-
product recalls. reliable. counterfeiting regulations. While the
In addition, EBR’s security features, regulations each have their unique flavor,
such as role -based access, can help they share similar approaches in requiring
restrict production activities to authorized manufacturers, not only in pharmaceutical
personnel. but also other consumer packaged goods
(CPG) sectors, to use serialization systems
Enhanced to Comply for product traceability and authentication.
Original equipment manufacturers Complying with these regulations will be
(OEM) need to ensure that they and their critical for global manufacturers operating
customers are ready to meet the challenges in multiple countries.
of compliance as requirements change.
Therefore, scalable human machine With the growing need to reduce errors
EBR enables review by exception to speed
product release and increase warehouse
interface (HMI) software becomes critical as well as overhead, along with effective
turnaround times. to stay competitive while overcoming process control and quality management,
compliance obstacles and taking full EBR technologies are developing rapidly
Driving Compliance advantage of the cost savings of electronic and are set to continue seeing steady
A paperless EBR system harnesses documentation. demand over the coming years.
the power of automation and greater Advances in EBR systems represent a
connectivity to help ease and even improve FactoryTalk® View Machine Edition (ME) new future filled with opportunities for
demonstrated compliance. version 10.00 from Rockwell Automation is manufacturers that are still reliant on paper-
The FDA 21 CFR part 11 applies to developed to address various demands of based reporting systems – opportunities to
records in electronic form that are created, food and drug manufacturers flexibly and be compliant, more productive and more
modified, maintained, archived, retrieved is added with functionality designed for
SOUTH EAST ASIA 13APPLICATION PROFILE
Crafting a Revolution
Brewery automation technology is helping breweries create more and better beer and
maintain a consistently high quality
Beers made from the same raw With all of these priorities, having During the milling process, it becomes
materials may look similar, but they access to real-time data can play a central easier to control recipe amounts, roller
are dramatically vary in both taste role in better managing and monitoring gaps, auto start-up and shutdown, and
the brewing process. To accommodate sieve analysis. Mash mixing and wort
brewing techniques. This is the unique the growing need of a modern brewing
charm of beer. system, Rockwell Automation developed management are made more transparent.
FactoryTalk® Craft Brew solution for process
The core elements of a great brew have and batch applications, giving craft brewers, Fo r e x a m p l e , o p e r a t o r s c a n g e t
not changed for generations, with varying system integrators and brew house original information pertinent to batch production
combinations of malt, hops, water and equipment manufacturers (OEMs) a single, captured and correlated at critical quality
yeast coming together to the beverage standardized control system. points from the FactoryTalk View Machine
drinkers know and love. What has changed, Edition (ME) or Site Edition (SE) human
however, are the means of monitoring and With custom librar y built on the machine interface (HMI), set with pre-
managing the brewing process to ensure PlantPAx® distributed control system configured systems for tanks and different
the quality and consistency or repeatability (DCS) core library and scalable controllers modes for level of operator interaction.
of the end product. providing a modern architecture, brewers
can improve sequencing of batches to Moreover, the system’s fermentation
For the Needs of Craft Brewer temperature control and recipe
Regardless of the size of the brewery ease recipe adjustments. Most importantly, management offer operators the options
and the method used, brewers will have they can gain insight into their operations to run in auto, semi-auto, or manual mode,
several priorities for producing their to monitor and track batch quality. and allow them to tailor the system with
customizable messages and recipe names.
of maximizing yield, maintaining quality, Accurate Brew House Control Not only can it reduce manual tending of
improving cleaning and minimizing losses. In the brew house, data from a scalable each process and optimize productivity, this
control system can support more efficient results in better decisions that help improve
inventory, blending and bills of materials.
product.
Technology and Crafting Beer
O n e o f t h e b e n e fi t s o f m o d e r n
technologies is that brewers can now
keep an eye on their fermentations on
their mobiles. They can access brewing
histor y and events, batch repor ting
and advanced diagnostic data via the
Grain Silo Milling Mashing Lautering Brewing
HMI from any location. Also, the system
offers comprehensive protection against
unauthorized modifications to code or
process values, protecting their investment.
Overall, the data that only automation
can provide is invaluable in terms of
Cooling Fermentation Conditioning Filtration Packaging establishing and maintaining the quality
Brewers need easy-to-use modern automated solutions to help monitor and control and consistency of any given brew. And
every step of the craft brewing process because the data is stored, brewers can
14 SOUTH EAST ASIAadopt more flexible recipe management,
modifying existing recipes and trying
information from the automation layer to
the MES layer. It integrates enterprise-level Flexible recipe
new types of beer. Whether procedures
are performed by the equipment or the
automation and information to enable
The Connected Enterprise and help inform management
operators, consistency of the brews remains
under control without losing the artistry.
business decisions, complementing large
regional and global breweries’ functional
enables brewers
Better Serve Rapid Demand
requirements outside of FactoryTalk Craft
Brew.
to be creative,
Consumer demand for craft beer and
the level of competition for innovation The solutions can help reduce complexity
modify existing
and efficiency is increasing for craft beer
producers.
during start-up and brewery operations, as
well as the dependence on specific skills
recipes,
The technologies for brewers to consider
sets in the workforce. By removing the need
for engineering intensive custom-coded
and try new styles
vary with the size of their operations. A applications, these scalable solutions enable of brews,
microbrewer might produce up to 15,000 brewers of all size to enhance production
barrels annually, with approximately 75 quality and time -to-market through all with
percent or more of the beer produced sold digitalization and improvements.
a few simple,
Competitive Edge:
digitally-driven
manual mode or applying simple control
techniques. Sustain and Gain
A regional craft brewery, on the other to grow at a compound annual growth procedures.
hand, with a majorit y of volume in rate (CAGR) of 8.8 percent during the
“traditional” or “innovative” beers, could forecast period 2016-2022. Yet, for many
be producing between 15,000 barrels experienced brewers, a transition to
and 6,000,000 barrels annually. Smaller automated systems is jarring, but necessary.
breweries might be operating in a semi-
automated mode, with larger breweries Small breweries want to grow larger,
fully automated. outstripping their ability to perform every
operation manually. When they need to
Whatever their size, these breweries will brew eight to 10 batches of beer wort per
want to compete in today’s dynamic market day, automation becomes virtually the only
and need simple, standardized operations way that a brewery can continue to grow.
that can deliver quality brews and keep up Operators can access to brew history and events,
batch reporting and advanced diagnostic data
with complex consumer demand. Once the automated programs are
via the HMI
optimized, operations are executed the
Bigger Flavors same way every time accurately, enabling
While FactoryTalk Craft Brew is designed consistent, repeatable production. Even With a scalable modular system and
to help smaller breweries spur growth, brewers that are new to automation can better utilization of equipment and timing,
the FactoryTalk Brew™ solution can help learn to trust and value its advantages. brewers can increase output by up to
large craft brewers standardize and fully Well-designed systems are highly flexible 50 percent without having to invest in
automate their production, gaining an and allow brewers to make changes when more tanks. So rather than committing
information platform for reporting and necessary and to program new recipes to an expensive new ten-barrel system,
recipe management and tying together easily. automating the existing five-barrel system
will help a brew house produce more, more
consistently, and save money and time.
For brewers who are ready to scale up,
it is time to use innovative technologies
to streamline brewing processes, increase
capacity and operational efficienc y
throughout production. And by reducing
the amount of time spent managing
equipment and processes, brewers can
FactoryTalk Brew is a modular brewery solution for large breweries while FactoryTalk Craft Brew is a focus on what is most important to them –
modular brew house application for equipment used in microbreweries. crafting beer.
SOUTH EAST ASIA 15PRODUCT & SOLUTION FOCUS
Innovation and Information Up To Date
@ROKAutomation
Rockwell Automation shares stories and information that
celebrate innovation, manufacturing, engineers and automation on
Facebook and Instagram. Industry professionals around the globe can
catch real-time coverage and browse helpful content anywhere and
anytime.
Expanding Scalable MES Applications Capabilities
To provide greater context for enterprise analytics and tighten control over processes, new versions of both Rockwell Software
PharmaSuite® manufacturing execution system (MES) software and MES fit-for-purpose application have been developed. The
of continued support of scalable MES capabilities deployed to solve challenges for rapid time to value.
The expansion of computing power is complicating the technology ecosystem for industrial producers, and the latest
MES updates can help simplify the adoption of new features and the communication between systems. The updates are
PharmaSuite v8.4 software and FactoryTalk® Quality v4.0 application.
The latest PharmaSuite v8.4 software improves communication with any distributed control
change the process parameter. All changes are recorded by the MES for quality assurance review.
This avoids wasting time if operators get stuck trying to make exceptions.
By building off user-friendly, intuitive widgets that reduce quality-management effort, the updated FactoryTalk® Quality v4.0
application introduces statistical process control (SPC) capabilities out of the box. Quality management teams can gain a suite of control
charts and graphs that help predict when a process is going outside of acceptable
when and where they are needed.
Free Download: Connect to the Cloud
The Cloud Connectivity guide provides guidance for using
New Network Design Guidance the FactoryTalk® Cloud gateway to establish a more secure
Rockwell Automation and Cisco, a strategic alliance as FactoryTalk Analytics for Machines. The design guide addresses
member of the PartnerNetwork™ program, have released the varying levels of security measures that should be considered
new network design guides and white papers to help for small to large companies.
companies connect mobile devices and deploy end-to-end cloud Fortify Industrial Security
connectivity while maintaining security best practices. The guides The industrial firewalls guide provides several use cases for
are the latest addition to the Converged Plantwide Ethernet industrial firewalls and addresses application requirements,
(CPwE) program and giving companies best practices for wired technologies and design considerations. For example, machine
and wireless network architectures when deploying cloud and
mobile Industrial Internet of Things (IIoT) solutions.
Secure Mobile Connections Additionally, the previously released Industrial Demilitarized
The Identity and Mobility Services guide helps companies Zone (IDMZ) guide has been updated with new applications for
connect mobile devices in a way that manages security risks. using the FactoryTalk® VantagePoint and FactoryTalk ViewPoint
It also helps users establish unified and autonomous WLAN software. These new free resources are available for download on
architectures and manage self-service wireless access. the Rockwell Automation website.
16 SOUTH EAST ASIAPRODUCT & SOLUTION FOCUS
Modern Process Solutions for MES layer. It can also integrate enterprise-level automation and
information to enable The Connected Enterprise and help inform
Building a Connected Brewhouse business decisions. The new offering provides a solution to
brewers struggling to build a software layer on their automation
Rockwell Automation and McRae Integration have platform or building an automation platform from scratch.
collaborated to develop two new brewing production While the FactoryTalk Brew solution helps large brewing
solutions for brewers seeking efficiency and enhancing companies get their brews to market faster, the FactoryTalk
their operations. The new FactoryTalk Brew™ solution can help Craft Brew solution is also ready for small craft brewers to gain a
breweries manage tough challenges in today’s competitive competitive edge in niche market segments.
market.
The Fac tor yTalk Brew This globally supported brewery
solution is based on the solution is customized and delivered
P l a n t PA x ® d i s t r i b u t e d by Rockwell Automation and
control system from Rockwell Automation. It enables large certified partner system integrators
brewers to standardize and fully automate production, gain an or manufacturers with knowledge
information platform for reporting and recipe management of the required products and large
and tie together information from the automation layer to the brewing processes.
Simplifying Analytics
Machine Designs for Industrial Productivity
Two machine builder libraries and automation device Rockwell Automation has expanded the FactoryTalk
objects are the latest application content available to help Analytics por tfolio, a robust advanced analytics
manufacturers and engineers create state-of-the-art environment that empowers users with the ability to
machine designs faster and at a lower cost. quickly and confidently make informed decisions. These latest
The two new machine builder libraries – one for converting, advancements were developed to reduce the complexity of the
print and web (CPW ) machines and one for process skids – operations environment for manufacturers and producers and
provide standardized application-specific code that can help their employees who are driving operations.
engineers design CPW machines and process skids faster while
still achieving best-in-class performance. The libraries also include The FactoryTalk Analytics brings contemporary user experience
capabilities, which are common for consumer experiences, to
The automation device objects are coding that provide a the production environment. Focused on driving ease of use and
productivity, FactoryTalk Analytics features internet-like search
product on a machine. This can drastically reduce programming capabilities of production data, as well as self-serve drill-downs,
rework when replacing a device on a machine. Engineers can allowing the user to make data-driven decisions quickly. It has
simply add the object for a new device instead of rewriting the been developed for scale, discovering and connecting data
machine’s entire engineering cycle to accommodate the device. sources from the edge of the network up through the enterprise,
The Studio 5000® Application Code Manager provides a single, and then intelligently fusing the information to resolve issues close
user-friendly way for engineers to access the content, build their to the source. Empowered
applications and even test applications before they build a cabinet. Analytics with machine learning
The new application content is available for free download from c a p a b i l i t i e s, Fa c to r yTa l k
the Rockwell Automation Product Compatibility Download Analytics learns the process and looks for trends in the data,
Center (PCDC). proactively presenting users with insights before an issue arises.
Key improvements include
faster axis definition and sizing,
with Updated Motion Analyzer redesigned solution search
and configure components
The Allen-Bradley® Motion Analyzer features, additional application
an optimized user experience with intuitive navigation template profile support, and
and in-workflow production selection. This updated the ability to import from a
legacy motion profile with support of more advanced motion
develop complete motion control systems for their machines. segments.
SOUTH EAST ASIA 17PRODUCT & SOLUTION FOCUS
New Large Contactors Updated Visualization Solution
Improve Flexibility for Operators for Standalone Machines
The Allen-Bradley® NEMA contactors and IEC contactors Allen-Bradley PanelView™ 800 Graphic
help machine builders design smaller, energy-efficient Terminals is now available for download. Firmware 5.011 is
panels. These new lines of contactors can be controlled updated for enhancing usability and increasing functional
connectivity with CompactLogix 5370
controllers.
The updated graphic terminals are
As large size contactors are increasingly used in applications to available in 4-10 inch display sizes and
isolate or bypass these loads and resistive loads, the contactors can support up to 50 screens, 400
feature a universal coil for an easier voltage control on multiple external tags and 400 alarms. New
applications with fewer parts and features include supporting email notification over encryption
smaller power supply.
In addition, the new NEMA
contactors and IEC contactors are printing over Ethernet and USB connections. They are ideal for
significantly smaller than previous standalone machines to meet a wide variety of small to midsize
product lines, allowing for a smaller panel and a smaller enclosure. applications.
A Single View of Process As the configuration of the entire system is simplified, users
can gain a common environment for archiving, visualization and
and Electrical Systems reporting when using the library of add-on instructions from
Rockwell Automation. The library provides prebuilt, validated add-
The new IntelliCENTER® Integration Unit integrates the on instructions for third-party devices that are used in typical
intelligent electrical devices from the electrical distribution control strategies for electrical control systems.
system into the process-automation control and software The IntelliCENTER Integration Unit is
environment. Integrating both systems into a single control and key to an integrated power and process
software platform avoids the need for a separate eSCADA and control system and a technology enabler
of the Intelligent Packaged Power offering
data. from Rockwell Automation. The Intelligent
By using the control capabilities of a Logix-based processor, Packaged Power solution helps reduce risk
the integration unit enables intelligent switchgear and other by delivering motor-control devices and
intelligent equipment in the electrical control system to become the electrical distribution system in one
part of a complete automation system. consolidated package.
Making Network Operations More Drives Application
and Maintenance Easier
The new FactoryTalk Network Manager™ software can Heavy-industry operators can now use the Allen-Bradley
PowerFlex® 6000 medium voltage drives to meet a
and maintaining a growing number of Internet of Things broader range of application requirements and lower their
(IoT) devices on their network. It allows them to take control of the total system costs.
health of their Allen-Bradley® Stratix-managed switches,
switches all from one easy-to-use software interface. transformer option for the Asia Pacific market. With a previous
launch for 200-680-amp applications in 2017, SVC is now available
The software automatically discovers assets, their associated for 0-680 amps and 2.3-11 kV voltage
IP addresses, and creates a topology of the connected devices. ratings. The SVC addition provides
Its intuitive interface offers grouping constant torque capability without
of equipment along with dashboard the need for an encoder, helping
information, so users can organize lower the total cost of ownership for
devices into specific areas or analyze applications such as slurry pumps and
them individually. reciprocating compressors.
18 SOUTH EAST ASIAYou can also read
